Thermo-Structural and Dynamic Performance Analysis of a 42CrMo4 Steel Ball Screw Assembly

This study presents a comprehensive thermo-structural and modal analysis of a ball screw assembly. Thermal analysis revealed a maximum temperature of 29.1 °C at the ball nut, corresponding to a total rise of 7.1 °C above ambient. The resulting thermal deformation reached 77.81 μm, while the von Mises stress peaked at 53.9 MPa, both within acceptable limits. Modal simulation of 360 modes showed a sharp increase in frequency with mode number and larger deformation patterns at the higher modes. The first two modes dominate the effective mass with the first 8 modes capturing over 90% of the cumulative effective mass. Overall, the results demonstrate stable thermal performance, limited deformation, low stress, and controlled vibrations, confirming the modeling approach and the suitability of 42CrMo4 steel for high-precision ball screw assemblies.