Fundamental finite element evaluation of a three dimensional rolled thread form: Modelling and experimental results

This paper presents an evaluation of residual stresses generated by a cold rolled thread forming process. Major factors associated with the forming process which affect the residual stress state and are addressed include: stress-strain relations, effects of friction and contact on plastic deformation, and the influence of manufacturing parameters. MARC finite element software is used to determine the stresses and deformation that occur in a multipass cold rolled flat plate with a modified ACME thread form. Variations in friction, contact, and manufacturing parameters are assessed based on relative comparison of results. Stress results for selected parameters are compared to experimentally measured data generated using X-ray diffraction and hole drilling techniques.