Cooling water jacket design of motorized spindle system using multi-objective topology optimization

The heat dissipation performance is the main factor affecting the dynamic accuracy of the motorized spindle system. Currently, the cooling water jacket with the traditional spiral and serpentine channels is usually used for the heat dissipation of the motorized spindle system. However, the traditional channels of the cooling water jacket cannot meet the increasing demand on its heat dissipation performance, and have the disadvantages of a large flow resistance and uneven cooling temperature. In view of the above challenges, a high-efficiency and strong-convergence structure design method is proposed for the cooling water jacket based on the multi-objective topology optimization to improve the heat dissipation performance and reduce the pressure drop loss. A lightweight conjugate heat transfer equivalent model, which can significantly reduce the computation time and improve the convergence performance, is constructed for the cooling water jacket based on the Darcy model. Then the topology structure of the cooling water jacket is optimized with the equivalent model, and the topology optimization channel is verified by the Reynolds-averaged Navier-Stokes model. The results show that the Darcy equivalent model and the Reynolds-averaged Navier-Stokes model are in a reasonable agreement. Finally, the cooling water jackets with the topology optimization and traditional cooling channels are embedded into the motorized spindle system, and the multi-physical field simulation is conducted for the motorized spindle system to validate the heat dissipation performance of the cooling water jacket. The results indicate that the cooling water jacket with the topology optimization channel has a much more outstanding heat dissipation performance and lower pressure loss than the cooling water jacket with the traditional spiral and serpentine channels. The high-efficiency and strong-convergence structure design method is feasible to get the effective topology structure of the cooling water jacket, and provides a reference for the thermal design of the motorized spindle system.