Fasteners are widely used in all industrial sectors and the auto industry alone consumes 2 800 to 3 100 fasteners for assembly of a vehicle. Externally threaded fasteners comprise the bulk of fasteners used in these applications with over 90% of being produced by thread rolling.
Thread rolling is a cold forming or chipless machining operation where a matched set of dies with reverse form of thread displaces material to produce external threads on cylindrical or conical blanks with no material loss. It ensures specialization of production and increased production.
Hence, it is very important to determine reasonable process parameters by simulating a thread rolling process and analyzing the influence of process parameters, for the improvement of product accuracy and lengthening of a roll’s life. Actually, it is very difficult to survey the change of force acting on the roll and blank fitting apparatus. Therefore, the influence of parameters on thread rolling process cannot be correctly determined by real experiments. Thus, prior researchers simulated the thread rolling process by computer modeling. However, their simulations were restricted to 2D simulation due to the difficulties arising in 3D simulation of metric thread rolling process.
Pae Ung Chol, a researcher at the Faculty of Materials Science and Technology, has conducted a 3D simulation of thread rolling process to find influence factors and predict their tendency.
He analyzed the influence of process parameters such as blank diameter, roll diameter and fitting height of blank using a finite element code DEFORM.
The results of the study showed that the blank diameter has a little influence on product accuracy and the life of thread rolling die (roll) while roll diameter has a significant impact on its life, and that fitting height of blank has a remarkable influence on wear of roll screw thread and product accuracy.
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