Steve C. West

Practical design and performance of the stressed-lap polishing tool

We present an overview of the engineering design and empirical performance of four stressed-lap polishing tools developed at the University of Arizona. Descriptions of the electromechanical actuators, servo systems, computer interfacing, and attachment of the lap to the polishing machine are provided. The empirical performance of a representative tool is discussed in terms of accuracy, repeatability, and hysteresis. Finally, we estimate the statistical likelihood of aluminum lap-plate failure through a metal-fatigue analysis for a worst-case stress-cycling situation.

Active supports and force optimization for the MMT primary mirror

We describe the active support system and optimization of support forces for the 6.5 m primary mirror for the Multiple Mirror Telescope Conversion. The mirror was figured to an accuracy of 26 nm rms surface error, excluding certain flexible bending modes that will be controlled by support forces in the telescope. On installation of the mirror into its telescope support cell, an initial optimization of support forces is needed because of minor differences between the support used during fabrication and that in the telescope cell. The optimization is based on figure measurements made interferometrically in the vibration- isolated test tower of the Steward Observatory Mirror Lab. Actuator influence functions were determined by finite- element analysis and verified by measurement. The optimization is performed by singular value decomposition of the influence functions into normal modes. Preliminary results give a wavefront accuracy better than that of the atmosphere in 0.11 arcsecond seeing.

Progress in the stressed-lap polishing of a 1.8-m f/1 mirror

We are in the process of polishing a 1.8-rn f/i ellipsoid with an actively stressed lap. As a preliminary exercise, we have polished the mirror as a sphere using a rigid subdiameter lap. The overall surface error was 25 nm rms, and the surface met a specification corresponding to i/8-arcsec image quality. A stressed lap 600 mm in diameter was designed and built to polish the mirror as an f/i ellipsoid. It consists of an aluminum disk which changes shape continuously under the influence of 12 moment-generating actuators. These actuators are programmed to produce the shape changes necessary to make the lap fit the mirror surface as it moves across that surface and rotates. In this paper we describe the principles and design of the lap, test results, and progress to date in polishing the 1.8-rn mirror.

Production of 8.4m segments for the Giant Magellan Telescope

Production of segments for the Giant Magellan Telescope is well underway at the Steward Observatory Mirror Lab. We report on the completion of the first 8.4 m off-axis segment, the casting of the second segment, and preparations for manufacture of the remaining segments. The complete set of infrastructure for serial production is in place, including the casting furnace, two 8.4 m capacity grinding and polishing machines, and a 28 m test tower that incorporates four independent measurement systems. The first segment, with 14 mm p-v aspheric departure, is by some measures the most challenging astronomical mirror ever made. Its manufacture took longer than expected, but the result is an excellent figure and demonstration of valuable new systems that will support both fabrication and measurement of the remaining segments. Polishing was done with a 1.2 m stressed lap for smoothing and large-scale figuring, and a series of smaller passive rigid-conformal laps for deterministic figuring on smaller scales. The interferometric measurement produces a null wavefront with a 3-element asymmetric null corrector including a 3.8 m spherical mirror and a computer-generated hologram. In addition to this test, we relied heavily on the new SCOTS slope test with its high accuracy and dynamic range. Evaluation of the measured figure includes simulated active correction using both the 160-actuator mirror support and the alignment degrees of freedom for the off-axis segment.

Toward first light for the 6.5-m MMT Telescope

Operated by the Multiple Mirror Telescope Observatory (MMTO), the multiple mirror telescope (MMT) is funded jointly by the Smithsonian Institution (SAO) and the University of Arizona (UA). The two organizations equally share observing time on the telescope. The MMT was dedicated in May 1979, and is located on the summit of Mt. Hopkins (at an altitude of 2.6 km), 64 km south of Tucson, Arizona, at the Smithsonian Institutions Fred Lawrence Whipple Observatory (FLWO). As a result of advances in the technology at the Steward Observatory Mirror Laboratory for the casting of large and fast borosilicate honeycomb astronomical primary mirrors, in 1987 it was decided to convert the MMT from its six 1.8 m mirror array (effective aperture of 4.5 m) to a single 6.5 m diameter primary mirror telescope. This conversion will more than double the light gathering capacity, and will by design, increase the angular field of view by a factor of 15. Because the site is already developed and the existing building and mount will be used with some modification, the conversion will be accomplished for only about

Null test optics for the MMT and Magellan 6.5-m f/1.25 primary mirrors

20 million. During 1995, several major technical milestones were reached: (1) the existing building was modified, (2) the major steel telescope structures were fabricated, and (3) the mirror blank was diamond wheel ground (generated). All major mechanical hardware required to affect the conversion is now nearly in hand. Once the primary mirror is polished and lab-tested on its support system, the six-mirror MMT will be taken out of service and the conversion process begun. We anticipate that a 6 - 12 month period will be required to rebuild the telescope, install its optics and achieve f/9 first light, now projected to occur in early 1998. The f/5.4 and f/15 implementation will then follow. We provide a qualitative and brief update of project progress.

Fabrication and measured quality of the MMT primary mirror

The instruments used to interferometrically measure the optical surfaces of the 6.5-m f/1.25 primary mirrors for the MMT conversion and Magellan Telescopes must compensate over 800 micrometers surface departure from the best fitting sphere. The errors in the optical test must not contribute more than 0.04 arc seconds FWHM to the final image and the conic constant must be held to 0.01%. This paper presents the design, analysis, fabrication, and certification of the instruments used to measure these giant mirrors to such high accuracy.

Rapid fabrication strategies for primary and secondary mirrors at Steward Observatory Mirror Laboratory

The primary mirror for the Multiple Mirror Telescope Conversion is the first 6.5 m honeycomb sandwich mirror cast and polished by the Steward Observatory Mirror Lab. We describe the optical fabrication and testing of the f/1.25 paraboloid, and present the final measurements of figure accuracy and inferred image quality. Figuring was performed with a 1.2 m stressed lap--which bends under active control to match the local curvature of the optical surface--and a variety of small passive tools. The mirror was pressurized to compensate for polishing loads and thereby eliminate print-through of the honeycomb structure. The net result is a smoother surface on scales of 5 - 20 cm than has been achieved on previous honeycomb sandwich mirrors. The figure was measured with IR and visible interferometers, using refractive null correctors to compensate 810 microns of aspheric departure. The final measurements were used to calculate synthetic stellar images in a variety of seeing conditions.

Fabrication of the 6.5-m primary mirror for the Multiple Mirror Telescope Conversion

The pursuit of economical fabrication of large (8 m) fast (< f/2), astronomical optics has led to the development of efficient fabrication and testing methods at the Mirror Lab. These methods rely on a mix of advanced technology blended with some traditional practices. Two fabrication strategies have been developed, one for primary mirrors and one for secondary mirrors. Both of these plans rely heavily on the use of the stressed lap both as a grinder as well as for polishing. For secondary fabrication novel methods of testing the convex, severely aspheric mirrors are used.

Optical metrology for two large highly aspheric telescope mirrors

The Steward Observatory Mirror Lab is in the process of fabricating the 6.5 m mirror for the conversion of the multiple mirror telescope (MMT) to a single primary mirror. For this purpose the lab has developed a versatile polishing system built around the stressed lap polishing tool. The system must produce an f/1.25 parabolic surface with an accuracy corresponding to 0.09 arcsecond FWHM seeing and 1.5% scattering loss at 500 nm wavelength.