Analysis of thread rolling process using an analytical single tooth rolling model based on the slip line field theory and slab method

A thread rolling process is one of manufacturing techniques for producing high performance thread parts. Despite the importance of the process, its design has been dependent on mostly experience of experts, and the parameters of the thread rolling process may not have been systematically optimized. In this study, a new analytical model is proposed for the thread rolling process simplified as a single tooth rolling. The modeling with the slip line field (SLF) theory is used to calculate the protrusion height of workpiece, and the force and torque of the thread rolling are analytically calculated from the classical slab method. Then, the proposed model is used to analyze the effects of lubrication and plastic deformation on the performance of formed part. Moreover, experiments on the single tooth rolling process are carried out to validate the proposed modeling approach. The parametric study shows that the model can predict the force and torque of the thread rolling process with certain accuracy. The viscosity of lubricant has a significant effect on the lubrication pressure, and the friction factor determines the stress during plastic deformation. Also, it is found that the radial feed of the roller has more dominant effect on the lubrication pressure than the tangential speed by squeezing the lubrication during process.

Automated summary

This study proposes a new analytical model for the thread rolling process simplified as a single tooth rolling. The protrusion height of the workpiece is calculated using the slip line field theory, and the force and torque of the thread rolling are analytically calculated. Experimental validation demonstrates that the model can accurately predict the force and torque of the thread rolling process, and analyze the effects of lubrication and plastic deformation on the performance of formed parts.