High-efficiency topology optimization method for thermal-fluid problems in cooling jacket of high-speed motorized spindle

The heat dissipation condition of high-speed motorized spindle is poor, leading to significant temperature and thermal error. To reduce temperature and thermal error, the cooling jacket with serpentine and spiral channels are designed. But for these traditional cooling water jacket, the heat transfer capability is weak and pressure drop loss is significant. It is shown that the cooling jacket designed by the thermal-fluid topology optimization method can overcome the above disadvantages. But the computational efficiency of the thermal-fluid topology optimization method is low. To address this issue, a refined thermal-fluid topology optimization method that combines the finite volume method with adaptive mesh refinement and parallel computing is proposed, sharpening the fluid-solid boundary definition and accelerating computational processes. Then a thermal-fluid topology optimization program is developed and embedded into the open-source platform OpenFOAM for practical application. The improvement rate for the computational efficiency and reduction rate for the memory usage are 82.6 % and 93.89 % are achieved compared to the Darcy model implemented with the commercial software. Compared with high-speed spindle with spiral water jacket, the high-speed spindle with topology optimization water jacket shows a 7.6 % enhancement in heat dissipation performance and a 25.5 % reduction in thermal error.