Topology Optimization Design and Analysis of an Integrated Aluminum Alloy Mirror
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摘要: 针对口径为300 mm的一体化铝合金反射镜进行了拓扑优化设计，在反射镜光轴方向的自重载荷下，以整体柔度作为约束，反射镜最小体积作为目标进行迭代优化，得到了拓扑优化结果模型，根据其特征建立了实体模型并进行了参数优化，最终得到了总质量为2.08 kg、面形均方根RMS（Root Mean Square）为5.9 nm、轻量化率为70%的一体化反射镜结构。通过参数优化，结合与对比结构的对比验证了拓扑结构特征的有效性，并进行了支撑特性分析。中心六边形的支撑结构和半封闭的结构在自重工况下对面形精度的提升有极大贡献。中心六边形结构存在最佳支撑位置，即正六边形高度与直径比值为0.26。Abstract: Topology optimization design was conducted for an integrated aluminum alloy mirror with a diameter of 300 mm. Under the self-weight load along the optical axis of the mirror, the global flexibility was considered as a constraint, and the minimum volume of the mirror was considered as an objective for iterative optimization to obtain a topology optimization model. According to the results, a solid model was established, and its parameters were optimized. Finally, an integrated mirror structure with a total mass of 2.08 kg, root mean square of 5.9 nm, and lightweight ratio of 70% was obtained. Through comparisons to a contrast structure combined with a parameter optimization process, the validity of the topological structure features was determined, and the support characteristics were analyzed. A support structure consisting of a central hexagon and semi-closed structure contributes significantly to the improvement of surface shape accuracy under the conditions of self-weight. There is an optimal supporting position for the central hexagon structure, where the ratio of height to diameter of the regular hexagon is 0.26.
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图 10 镜体高度对面形的影响
Figure 10. The influence of the height of the mirror body on the surface shape
图 11 中心六边形大小对面形的影响
Figure 11. The influence of the size of the central hexagon on the surface shape
表 1 Al6061的材料属性
Table 1. Material properties of Al6061
Material Density/(g·cm－3) Young's modulus/GPa Thermal conductivity/
(W·m－3·K－1)Coefficient of thermal
expansion/10－6K－1Poisson's ratio Al6061 2.7 71 154.3 22.4 0.25 
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表 2 反射镜结构参数
Table 2. Structural parameters of reflector
External diameter/mm Internal diameter/mm Radius of curvature/mm Height/mm 300 80 610 45
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表 3 其他特征参数的优化
Table 3. Optimization of other characteristic parameters
Features Auxiliary rib plate position
Lf/mmRound hole size
D/mmFlanging size
L1/mmFlanging thickness
H1/mmRib plate thickness
Tj/mmRange 60-70 20-30 2-6 1-8 3-7 Step 1 2 1 1 0.5 Optimum 66 30 6 3 6
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表 4 对比结果
Table 4. Comparison results
Z: RMS/nm Z: PV/nm Y: RMS/nm Y: PV/nm Optimization results 5.888 26.039 5.884 32.884 Center circular support structure 9.235 40.451 4.454 22.964 Structure of open circular hole without flanging 6.232 27.737 7.203 39.019 Structure of triangular rib plate in inner ring 8.297 35.722 5.042 27.561
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