Reliability-based design optimization of the spiral water jacket for motorized spindle

Abstract

Spiral water jackets are essential refrigeration units in motorized spindles. The design of spiral water jackets directly affects the machining accuracy and reliability of motorized spindles. In this regard, a reliability-based design optimization (RBDO) method is presented to obtain the optimal configuration of the spiral water jacket. The proposed RBDO algorithm aims to minimize the volume of the spiral water jacket and power loss of the cooling equipment while ensuring machining reliability. The geometric correlation and machining reliability are selected as constraints. The Kriging surrogate model is established to approximate the time-consuming finite element model for improving computational efficiency. An efficient metaheuristic algorithm is introduced to perform optimal exploration for the proposed RBDO problem. The risk speed of the motorized spindle is investigated by the experiment and finite element analysis. Subsequently, the effects of various cooling configurations on thermal error are investigated thoroughly. Eventually, the proposed RBDO is conducted on a motorized spindle. Through probabilistic evaluation, machining reliability is guaranteed by the proposed RBDO compared to deterministic design optimization. This paper provides a new design paradigm for cooling configurations in motorized spindles from the perspective of machining reliability.