Modeling and numerical analysis of the thread rolling process

The paper presents the physical and mathematical models of deformations (displacements and strains) and the stress in the cold process of the thread rolling. The process is considered as a geometrical and physical nonlinear, initial as well as a boundary value problem. The phenomena of a typical incremental step were described using a step-by-step incremental procedure, in the updated Lagrangian formulation. The state of strains was described by Green-Lagrange's tensor, while the state of stress was described by the second symmetrical Pioli-Kirchhoff's tensor. The object was treated as an elastic (in the reversible zone) and visco-plastic body (in the non-reversible zone) with mixed hardening. The variational equation of the motion in three dimensions for this case was proposed. Then, the finite elements methods (FEM) and dynamic explicit method (DEM) were used to obtain the solution. In a numerical analysis, boundary condition for a displacement increment, was determined in the model investigation. The results of a numerical analysis were compared and verified in an experimental investigation. Examples of calculations of the influence of a friction coefficient on the state of the deformation and stress, and an example application for this method of thread rolling were presented. (© 2006 WILEY-VCH Verlag GmbH & Co. KGaA, Weinheim)