Condenser mirrors with the ellipsoidal surface type are widely used in laser illuminating systems. Nonetheless, thermal absorption in optical components is unavoidable because of high-energy lasers, leading to a decline in surface shape accuracy. In extreme instances, this can shorten the operational longevity or impair the system’s focusing capabilities. Currently, water cooling is a major technical approach for controlling the thermal deformation of condenser mirrors. This paper proposes an efficient cooling flow channel based on topology optimization methods for high-gradient ellipsoidal optical mirrors. Firstly, topology optimization of the cooling flow channel was performed with the objective function of minimizing average temperature and entransy dissipation. Next, the influence of different design parameters on the optimization results was investigated, and the optimal topological structure was obtained. Then, a thermal–fluid–solid coupled simulation was carried out for a three-dimensional model of the water-cooled condenser mirror to verify the topology optimization design. The results show that when the inlet flow rate is 2.82×10−4m3/s, the surface shape accuracy of the water-cooled condenser mirror (RMS 213.79 nm) equipped with the topology optimization cooling flow channel is reduced by 22.96% compared to that of the water-cooled condenser mirror (RMS 277.66 nm) with the traditional spiral cooling flow channel. Finally, the manufacturability of the optimized model was verified by selective laser melting technology and x-ray detection.
Read full abstract