Engineering topics
Arnold, William
Publications and source records attributed to Arnold, William.
Advanced Mirror Technology Development (AMTD) Thermal Trade Studies
No abstract available
Advanced Mirror & Modelling Technology Development
The 2020 Decadal technology survey is starting in 2018. Technology on the shelf at that time will help guide selection to future low risk and low cost missions. The Advanced Mirror Technology Development (AMTD) team has identified development priorities based on science goals and engineering requirements for Ultraviolet Optical near‐Infrared (UVOIR) missions in order to contribute to the selection process. One key development identified was lightweight mirror fabrication and testing. A monolithic, stacked, deep core mirror was fused and replicated twice to achieve the desired radius of curvature. It was subsequently successfully polished and tested. A recently awarded second phase to the AMTD project will develop larger mirrors to demonstrate the lateral scaling of the deep core mirror technology. Another key development was rapid modeling for the mirror. One model focused on generating optical and structural model results in minutes instead of months. Many variables could be accounted for regarding the core, face plate and back structure details. A portion of a spacecraft model was also developed. The spacecraft model incorporated direct integration to transform optical path difference to Point Spread Function (PSF) and between PSF to modulation transfer function. The second phase to the project will take the results of the rapid mirror modeler and integrate them into the rapid spacecraft modeler.
Advanced UVOIR Mirror Technology Development (AMTD) for Very Large Space Telescopes
ASTRO2010 Decadal stated that an advanced large-aperture ultraviolet, optical, near-infrared (UVOIR) telescope is required to enable the next generation of compelling astrophysics and exoplanet science; and, that present technology is not mature enough to affordably build and launch any potential UVOIR mission concept. AMTD builds on the state of art (SOA) defined by over 30 years of monolithic & segmented ground & space-telescope mirror technology to mature six key technologies. AMTD is deliberately pursuing multiple design paths to provide the science community with op-tions to enable either large aperture monolithic or segmented mirrors with clear engineering metrics traceable to science requirements.
Engineering Specification for Large-aperture UVO Space Telescopes Derived from Science Requirements
An advanced large aperture UV/optical UVO space telescope is required for the next generation of astrophysics and exoplanet science. The science requirements of proposed exoplanet and astrophysics missions were used to determine the encircled energy, point spread function stability and thermal environment requirements. These requirements then determine the optical wavefront specification for potential telescope assemblies which can fit inside current and planned launch vehicles. The optical wavefront specification becomes the top level of the error budget that is split into various sources that control the structural, thermal and optical design.
Cryogenic Optical Performance of a Light-weight Mirror Assembly for Future Space Astronomical Telescopes: Optical Test Results and Thermal Optical Model
A 40 cm diameter mirror assembly was interferometrically tested at room temperature down to 250 degrees Kelvin for thermal deformation. The 2.5 m radius of curvature spherical mirror assembly was constructed by low temperature fusing three abrasive waterjet core sections between two face sheets. The 93% lightweighted Corning ULE mirror assembly represents the current state of the art for future UV, optical, near IR space telescopes. During the multiple thermal test cycles, test results of interferometric test, thermal IR images of the front face were recorded in order to validate thermal optical model.
Next Generation Lightweight Mirror Modeling Software
The advances in manufacturing techniques for lightweight mirrors, such as EXELSIS deep core low temperature fusion, Corning's continued improvements in the Frit bonding process and the ability to cast large complex designs, combined with water-jet and conventional diamond machining of glasses and ceramics has created the need for more efficient means of generating finite element models of these structures. Traditional methods of assembling 400,000 + element models can take weeks of effort, severely limiting the range of possible optimization variables. This paper will introduce model generation software developed under NASA sponsorship for the design of both terrestrial and space based mirrors. The software deals with any current mirror manufacturing technique, single substrates, multiple arrays of substrates, as well as the ability to merge submodels into a single large model. The modeler generates both mirror and suspension system elements, suspensions can be created either for each individual petal or the whole mirror. A typical model generation of 250,000 nodes and 450,000 elements only takes 5-10 minutes, much of that time being variable input time. The program can create input decks for ANSYS, ABAQUS and NASTRAN. An archive/retrieval system permits creation of complete trade studies, varying cell size, depth, and petal size, suspension geometry with the ability to recall a particular set of parameters and make small or large changes with ease. The input decks created by the modeler are text files which can be modified by any editor, all the key shell thickness parameters are accessible and comments in deck identify which groups of elements are associated with these parameters. This again makes optimization easier. With ANSYS decks, the nodes representing support attachments are grouped into components; in ABAQUS these are SETS and in NASTRAN as GRIDPOINT SETS, this make integration of these models into large telescope or satellite models possible.
Integration of Mirror Design with Suspension System using NASA's New Mirror Modeling Software
Advances in mirror fabrication is making very large space based telescopes possible. In the many applications, only monolithic mirrors meet the performance requirements. The existing and near-term planned heavy launch vehicles place a premium on lowest possible mass. Again, available and planned payload shroud size limits near term designs to 4 meter class mirror. Practical 8 meter and beyond designs could encourage planners to include larger shrouds if it can be proven that such mirrors can be manufactured. These two factors lower mass and larger mirrors, presents the classic optimization problem. There is a practical upper limit to how large a mirror can be supported by a purely kinematic mount system and be launched. This paper shows how the design of the suspension system and mirror blank needs to be designed simultaneously. We will also explore the concepts of auxiliary support systems, which act only during launch and disengage on orbit. We will define required characteristics of these systems and show how they can substantially reduce the mirror mass. The AMTD project is developing and maturing the processes for future replacements for HUBBLE, creating the design tools, validating the methods and techniques necessary to manufacture, test and launch extremely large optical missions. This paper will use the AMTD 4 meter "design point" as an illustration of the typical use of the modeler in generating the multiple models of mirror and suspension systems used during the conceptual design phase of most projects. The influence of Hexapod geometry, mirror depth, cell size and construction techniques (Exelsis Deep Core Low Temperature Fusion (c) versus Corning Frit Bonded (c) versus Schott Pocket Milled Zerodur (c) in this particular study) are being evaluated. Due to space and time consideration we will only be able to present snippets of the study in this paper. The advances in manufacturing techniques for lightweight mirrors, such as EXELSIS deep core low temperature fusion, Corning's continued improvements in the Frit bonding process and the ability to cast large complex designs, combined with water-jet and conventional diamond.
Engineering Specifications derived from Science Requirements
Advanced Mirror Technology Development (AMTD) is a multi-year effort to systematically mature to TRL-6 the critical technologies needed to produce 4-m or larger flight-qualified UVOIR mirrors by 2018 so that a viable mission can be considered by the 2020 Decadal Review. This technology must enable missions capable of both general astrophysics & ultra-high contrast observations of exoplanets. To accomplish our objective, we use a science-driven systems engineering approach. We mature technologies required to enable the highest priority science AND result in a high-performance low-cost low-risk system.
Advanced UVOIR Mirror Technology Development (AMTD) for Very Large Space Telescopes
ASTRO2010 Decadal Survey stated that an advanced large-aperture ultraviolet, optical, near-infrared (UVOIR) telescope is required to enable the next generation of compelling astrophysics and exoplanet science; and, that present technology is not mature enough to affordably build and launch any potential UVOIR mission concept. AMTD is the start of a multiyear effort to develop, demonstrate and mature critical technologies to TRL-6 by 2018 so that a viable flight mission can be proposed to the 2020 Decadal Review. AMTD builds on the state of art (SOA) defined by over 30 years of monolithic & segmented ground & space-telescope mirror technology to mature six key technologies: (1) Large-Aperture, Low Areal Density, High Stiffness Mirror Substrates: Both (4 to 8 m) monolithic and (8 to 16 m) segmented primary mirrors require larger, thicker, and stiffer substrates. (2) Support System: Large-aperture mirrors require large support systems to ensure that they survive launch and deploy on orbit in a stress-free and undistorted shape. (3) Mid/High Spatial Frequency Figure Error: Very smooth mirror is critical for producing high-quality point spread function (PSF) for high contrast imaging. (4) Segment Edges: The quality of segment edges impacts PSF for high-contrast imaging applications, contributes to stray light noise, and affects total collecting aperture. (5) Segment to Segment Gap Phasing: Segment phasing is critical for producing high-quality temporally-stable PSF. (6) Integrated Model Validation: On-orbit performance is driven by mechanical & thermal stability. Compliance cannot be 100% tested, but relies on modeling. AMTD is pursuing multiple design paths to provide the science community with options to enable either large aperture monolithic or segmented mirrors with clear engineering metrics traceable to science requirements.
Advanced UVOIR Mirror Technology Development (AMTD) for Very Large Space Telescopes
AMTD partner Exelis developed & demonstrated a technique to manufacture a 400 mm thick substrate via stacking and fusing core structural elements to front and back faceplates; making a 40 cm cut-out of a 4 meter diameter 60 kilograms per square meter mirror. This new process offers a lower cost approach for manufacturing large-diameter high-stiffness mirrors.
Design Considerations of Polishing Lap for Computer-Controlled Cylindrical Polishing Process
This paper establishes a relationship between the polishing process parameters and the generation of mid spatial-frequency error. The consideration of the polishing lap design to optimize the process in order to keep residual errors to a minimum and optimization of the process (speeds, stroke, etc.) and to keep the residual mid spatial-frequency error to a minimum, is also presented.
Development of a Computer-Controlled Polishing Process for X-Ray Optics
The future X-ray observatory missions require grazing-incidence x-ray optics with angular resolution of < 5 arcsec half-power diameter. The achievable resolution depends ultimately on the quality of polished mandrels from which the shells are replicated. With an aim to fabricate better shells, and reduce the cost/time of mandrel production, a computer-controlled polishing machine is developed for deterministic and localized polishing of mandrels. Cylindrical polishing software is also developed that predicts the surface residual errors under a given set of operating parameters and lap configuration. Design considerations of the polishing lap are discussed and the effects of nonconformance of the lap and the mandrel are presented.
Alignment System for Full-Shell Replicated X-Ray Mirrors
We are developing grazing-incidence x-ray optics for high-energy astrophysical applications using the electroformnickel replication process. For space-based applications these optics must be light-weight yet stable, which dictates the use of very-thin-walled full-shell mirrors. Such shells have been fabricated with resolution as good as 11 arcsec for hard x-rays, and technology enhancements under development at MSFC are aimed at producing mirrors with resolution better than 10 arcsec. The challenge, however, is to preserve this resolution during mounting and assembly. We present here a status report on a mounting and alignment system currently under development at Marshall Space Flight Center designed to meet this challenge.
Mounting and Alignment of Full-Shell Replicated X-Ray Optics
We are developing grazing-incidence x-ray optics for astronomy. The optics are full-cylinder mirror shells fabricated using electroformed-nickel replication off super-polished mandrels. For space-based applications where weight is at a premium, very-thin-walled, light-weight mirrors are required. Such shells have been fabricated at MSFC with greater than 15 arcsec resolution. The challenge, however, is to preserve this resolution during mounting and assembly. We present here a status report on a mounting and alignment system currently under development at Marshall Space Flight Center to meet this challenge.
Cockpit Ocular Recording System (CORS)
The overall goal was the development of a Cockpit Ocular Recording System (CORS). Four tasks were used: (1) the development of the system; (2) the experimentation and improvement of the system; (3) demonstrations of the working system; and (4) system documentation. Overall, the prototype represents a workable and flexibly designed CORS system. For the most part, the hardware use for the prototype system is off-the-shelf. All of the following software was developed specifically: (1) setup software that the user specifies the cockpit configuration and identifies possible areas in which the pilot will look; (2) sensing software which integrates the 60 Hz data from the oculometer and heat orientation sensing unit; (3) processing software which applies a spatiotemporal filter to the lookpoint data to determine fixation/dwell positions; (4) data recording output routines; and (5) playback software which allows the user to retrieve and analyze the data. Several experiments were performed to verify the system accuracy and quantify system deficiencies. These tests resulted in recommendations for any future system that might be constructed.