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<p>Precision deep-hole grinding is essential for machining high-accuracy internal surfaces of aerospace components with a large depth-to-diameter ratio. For electric spindles with a length-to-diameter ratio exceeding 10, the increased bending deformation of the core shaft leads to significant vibration and degraded machining precision. Conventional single-parameter optimization methods fail to systematically balance the stiffness-mass trade-off and lack a profound analysis of parameter coupling mechanisms. This study proposes a multi-parameter collaborative optimization approach, which involves a coupled analysis of the interactions among the core shaft diameter, bearing span, and overhang. An optimization model is established to simultaneously minimize shaft end deformation and mass. The proposed method is validated through fully coupled finite element simulations and experiments. The results demonstrate that the optimized electric spindle achieves an 18.946% increase in stiffness, a 9.68% reduction in mass, and a first-order critical speed of 4816.14 r/min. Within the operational speed range of 2000–3500 r/min, the shaft end runout is consistently maintained below 0.96&#xa0;μm. These findings underscore the effectiveness of multi-parameter collaboration in resolving the stiffness-lightweight conflict in large length-to-diameter ratio electric spindles. This work provides a practical design framework and experimental validation for developing high-performance electric spindles for precision deep-hole grinding.</p>

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A multi-parameter collaborative optimization approach for the stiffness-lightness trade-off in a large length-diameter ratio electric spindle

  • 期刊论文

  • 发表日期：

    2025年11月6日

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  • Zijun Zhu,
  • Xianglong Zhu,
  • Renke Kang,
  • Zhigang Dong,
  • Qiusong Xu,
  • Zhiyuan Zhang

摘要

Precision deep-hole grinding is essential for machining high-accuracy internal surfaces of aerospace components with a large depth-to-diameter ratio. For electric spindles with a length-to-diameter ratio exceeding 10, the increased bending deformation of the core shaft leads to significant vibration and degraded machining precision. Conventional single-parameter optimization methods fail to systematically balance the stiffness-mass trade-off and lack a profound analysis of parameter coupling mechanisms. This study proposes a multi-parameter collaborative optimization approach, which involves a coupled analysis of the interactions among the core shaft diameter, bearing span, and overhang. An optimization model is established to simultaneously minimize shaft end deformation and mass. The proposed method is validated through fully coupled finite element simulations and experiments. The results demonstrate that the optimized electric spindle achieves an 18.946% increase in stiffness, a 9.68% reduction in mass, and a first-order critical speed of 4816.14 r/min. Within the operational speed range of 2000–3500 r/min, the shaft end runout is consistently maintained below 0.96 μm. These findings underscore the effectiveness of multi-parameter collaboration in resolving the stiffness-lightweight conflict in large length-to-diameter ratio electric spindles. This work provides a practical design framework and experimental validation for developing high-performance electric spindles for precision deep-hole grinding.