Research on synergistic suppression of thermal deformation in electric spindles based on flow channel optimization and carbon fiber composite materials

Abstract To control temperature, rise, and thermal deformation caused by bearing friction and motor losses during high-speed electric spindle operation, this paper proposes a novel structure featuring a cooling-water jacket with integrated protrusions and carbon fiber sleeves at both ends of the spindle. This solution enhances coolant turbulence and heat transfer efficiency by systematically optimizing the dimensions and layout of the protrusions. Simultaneously, carbon fiber composite materials are introduced into critical spindle sections to provide axial thermal resistance through their low thermal conductivity, thereby synergistically suppressing thermal deformation. Thermal–fluid–solid coupled simulations and experimental validation were conducted on an A02 electric spindle operating at 10 000 r min −1 . Results indicate that the protrusion structure reduces maximum spindle temperature by 2.4 °C and thermal displacement by 18.9 μm. Combining this with the carbon fiber sleeve further decreases axial thermal deformation by approximately 20.78% while achieving a more uniform temperature distribution. The proposed structure provides a practical approach to achieving low thermal deformation in high-precision electric spindles, demonstrating significant engineering value.