Stress polishing demonstrator for ELT M1 segments and industrialisation

After two years of research and development under ESO support, LAM and Thales SESO present the results of their experiment for the fast and accurate polishing under stress of ELT 1.5 meter segments as well as the industrialisation approach for mass production. Based on stress polishing, this manufacturing method requires the conception of a warping harness able to generate extremely accurate bending of the optical surface of the segments during the polishing. The conception of the warping harness is based on finite element analysis and allowed a fine tuning of each geometrical parameter of the system in order to fit an error budget of 25nm RMS over 300 m of bending peak to valley. The optimisation approach uses the simulated influence functions to extract the system eigenmodes and characterise the performance. The same approach is used for the full characterisation of the systemitself. The warping harness has been manufactured, integrated and assembled with the Zerodur 1.5 meter segment on the LAM 2.5meter POLARIS polishing facility. The experiment consists in a cross check of optical and mechanical measurements of the mirrors bending in order to develop a blind process, ie to bypass the optical measurement during the final industrial process. This article describes the optical and mechanical measurements, the influence functions and eigenmodes of the system and the full performance characterisation of the warping harness.