Topology Optimization and Stiffener Reconstruction of a Ram-Boring Spindle Assembly in a Floor-Type Milling and Boring Machine for Deformation Control Under Large Extension

To reduce ram deflection and positional deviation at the boring spindle front end of a floor-type milling and boring machine under large extension, a ram-boring spindle assembly was investigated. A finite element model was established based on the actual structure, guideway support, and spindle assembly. Gravity-induced deformation and vertical displacement at the boring spindle front end under different extension conditions were analyzed to identify weak regions. The Solid Isotropic Material with Penalization method was then used to optimize the adjustable internal region of the ram with the objective of reducing structural compliance. The topology–density distribution and the deformation characteristics under different extension conditions were then used to guide an engineering reconstruction of the internal stiffeners, considering casting, assembly, internal space constraints, and engineering experience. Static analysis, displacement testing, and modal analysis were performed to verify the optimized structure. Results show that the maximum total deformation under simultaneous maximum extension decreased from 0.10268 mm to 0.097325 mm, while the mass decreased from 2424 kg to 2363 kg. The measured vertical displacement decreased from 0.114 mm to 0.108 mm. The first six natural frequencies increased by 1.48–5.91%. The proposed reconstruction improves deformation control and dynamic performance while reducing mass.