3D FEM forming simulation optimization and experiment on bevel thread-forming screw

Abstract This study adopts 3 forming passes and 1 thread rolling process as the multi-pass schedule of bevel thread-forming screw. The finite element simulation software is used to simulate the plastic behaviour of forming and thread rolling processes. The geometry shapes, the part dimensions of each pass, the effective stress, the effective strain, the forming force and the die stress of each pass can be reached via FEM simulation. Moreover, especially Taguchi method for the maximum force pass is conducted to optimize the forming processes. Considering 4 control factors such as A: head arc radius (r H ), B: flange thickness (t), C: corner radius (r), and D: frictional factor(m) and 3 levels to establish the orthogonal array table for optimum forming force, the influence rank and the optimal parameters combination are obtained to carry out the realistic experiment for confirming the feasibility of FEM simulation optimization. In a word, the influence rank of control factors: flange thickness (t) > head arc radius (r H ) > corner radius (r) > frictional factor (m), and the optimal parameters combination is A 3 B 3 C 3 D 1 (r H =42 mm, t=1.3 mm, r=0.7 mm, and m=0.12).