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Re: [ATM] How much cell induced deformation is too much?



Nils Olof Carlin wrote:

>So, if we would let the cell lower by say 1% (to 0.99 for a perfect mirror,
>or from 0.95 to 0.94 for a more realistic one), how much RMS wavefront
>error - assuming a reference wavelength of 550 nm, near the peak of photopic
>vision? I get some 8.7 nm, or a little more than 4 nm on the surface. This,
>4 nm RMS, I think could be a practical upper design limit for PLOP, allowing
>some realistic margin for less than perfect implementation. But then again,
>this is quite arbitrary.
>
Plop is frequently run with 4.25e-6 mm (4.25 nm) RMS as an acceptable 
threshold.  This however does not take into account construction errors.

In my study on 18 point cells I found that construction errors on the 
order on 1 mm to 2 mm could seemingly result in varying amounts of 
performance changes, depending on the cell design.  For non-refocus 
optimized cells, the Monte Carlo error simulation resulted in about a 2x 
degradation on average performance and a 4x-5x performance degradation 
in the worst case.  For the refocused cell design, the average 
degradation was over 3x and the worst case was over 8x.

1000 run Monte Carlo on refined models with refocusing

            DesignRMS  AvgRMS    MaxRMS    Avg/Des   Max/Des
Straw-man   2.67E-06   4.84E-06  1.05E-05   1.81     3.95
Even force  2.65E-06   4.82E-06  1.05E-05   1.82     3.96
No refocus  2.36E-06   4.87E-06  1.09E-05   2.06     4.62
0.8 force_  2.37E-06   5.29E-06  1.20E-05   2.23     5.07
Refocused   1.59E-06   5.45E-06  1.34E-05   3.43     8.43

Thus construction imprecision can significantly affect the cell 
performance.  The study also concluded that part balance errors are more 
critical than part placement errors, so it is very important to 
construct the parts carefully. 

Hence I would probably recommend a limit of 2 nm (2.0e-6 mm) for 
non-refocused cell designs and 1.0 nm to 1.5 nm (1.03-6 to 1.5e-6 mm) 
for refocused cell designs, unless precise machining is used to generate 
the parts.

Jeff Anderson-Lee

http://elib.cs.berkeley.edu/~jonah/18plus/p18.html
    A Study of 18-point Mirror Cell Optimization Using Varying Forces




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