To address the problem that bonding can lead to a reduction in the surface shape precision of a space-bound mirror, relationships between mirror deformation, thermal stress, and curing shrinkage stress were studied, and a bonding microstress design route was proposed. The thermal stress and thermal deformation introduced by thermal expansion mismatch were eliminated through an athermal adhesive layer thickness design. The relationship between mirror deformation and the curing shrinkage of the adhesive layer was derived completely, and structural optimization measures for releasing the curing stress of the adhesive layer are given. Bonding stress analysis was conducted based on the equivalent thermal deformation method, and an optimal structure meeting the design requirements was obtained. Finally, bonding of the mirror assembly was completed via this route, and the measured surface shape precision was stable at 0.0225λ. The theoretical analysis and experimental study demonstrate that this bonding design method can predict the bonding stress in the assembly process, making the follow-up bonding result controllable. These results should provide an excellent reference for the design and high-precision integration of large-aperture mirrors.
In order to solve the problems of long manufacturing cycle and high processing cost of mirrors in reflective optical systems of space cameras, a method for manufacturing metal mirrors based on additive manufacturing process is proposed. This paper designs an open honeycomb structure on the mirror backplane, mirror blank is prepared by additive manufacturing technology. Preliminary improvement of surface quality with rough machining and diamond turning. Then, a high-precision mirror surface is obtained through surface modification and secondary diamond turning. The diameter of the prepared mirror is 110mm, mass reduction rate of 70% and surface shape accuracy is better than λ /15 RMS( λ =632.8nm).The results show that the metal mirror prepared by this process can meet the requirements of high-precision reflective optical systems. The research work in this article can provide technical reference for the application of additive manufacturing technology in the field of optics. It has important reference and guiding significance for the research and application of related fields.
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