Design and Dynamic Characteristics Analysis of Carbon Fiber-Reinforced Metal Composite Spindles with High Length-to-Diameter Ratio

This paper investigates deflection deformation and premature bearing failure in deep-hole machining spindles with high length-to-diameter ratios under eccentric loading. A contact stiffness model for angular contact ball bearings was developed based on Hertz contact theory. Combined with the finite element method (FEM), a comprehensive mechanical analysis model of the spindle was established. The results show that spindles with high length-to-diameter ratios exhibit significant cantilever behavior, leading to considerable front-end deflection under eccentric loading. This deflection causes the inner and outer rings to incline, resulting in localized stress concentrations, which are the primary contributors to spindle fatigue failure. To improve the spindle’s stress distribution and dynamic performance, an optimized design replacing the metal housing with carbon fiber composite material is proposed. Static and modal analyses were performed using Abaqus and Romax. The analysis results demonstrate that the carbon fiber shell reduces self-weight deformation by 35.8%, decreases coupled deformation under self-weight and grinding loads by 28.6%, and increases modal fundamental frequencies by 20.88% to 47.41%. These improvements significantly enhance structural stiffness and dynamic stability. Experimental vibration monitoring during machine testing validated the accuracy of the modeling and simulation.