Numerical Modeling of the External Thread Rolling Process

External threaded fasteners manufactured by the thread rolling process are applied in many commercial and military applications due to their superior properties. However, the process design for thread rolling is still primarily based on empiricism and experience. This approach is very inefficient and expensive. A more scientifically based methodology to predict the process response and product properties prior to thread rolling is desired. Numerical simulation and modeling of the thread rolling process, based on knowledge of underlying process physics and validated by experimental results, is a powerful tool for optimizing process parameters. At this time, few studies related to numerical simulation of the thread rolling process have been published in the literature. In this thesis, a numerically based 2D model for the thread rolling process will be established and validated. The relationships between process parameters and effective strain, load and thread profile obtained from the results of the 2D numerical simulation for the thread rolling process will be presented. In addition, a preliminary 3D model for flat-die thread rolling will also be presented. The 2D process model and validation results are presented in Chapter 3. The effect of the thread rolling process parameters on metal flow, effective strain and rolling load from the 2D numerical simulation results are discussed in Chapter 4. The 3D modeling of the process is described in Chapter 5. Suggestions for future work and a summary of the results are presented in Chapter 6