Journal of Materials Processing Technology 153–154 (2004) 722–728

New method of thread rolling

Z. Pater∗ , A. Gontarz, W. Weroñski
Mechanical Department, Technical University of Lublin, Nadbystrzycka 36, Lubin 20-618, Poland

Abstract

The research and implementation works completed in the framework of new thread rolling technology developed for sleeper fixing
screws have been described in the present study. Described thread rolling method consists in thread forming by means of two flat wedges
provided with special grooves designed for thread forming. The results obtained from numerical simulation of thread rolling process are
presented in the study. The calculations have been completed using finite volumes method (FVM) and finite element method (FEM).
Furthermore experimental tests consisting in thread forming on the bars made of commercial lead in laboratory conditions and results of
industrial tests with simultaneous thread forming on two screws have been described.
© 2004 Elsevier B.V. All rights reserved.

Keywords: Thread rolling; FEM; FVM; Experiment

1. Introduction pany in MINSK (Belorussia) being the manufacturer of

The sleeper fixing screws (Fig. 1) are characterised by
single thread with large pitch and depth values. Therefore
they are formed in hot rolling process by means of three
working rollers (with parallel axes), Fig. 2. Surface material
flow model is forced by kinetics associated with that process
resulting in a vortex cavity in screw face being sometimes
the reason of batch size reduction for sleeper fixing screws
being ordered.
A/m disadvantage has been eliminated in the concept of
new thread rolling technology developed in Metal Forming
Department in Technical University of Lublin. According to
proposed solution, thread rolling is performed by means of
two flat wedge tools provided with additional grooves at an
angle equal to lead angle (Fig. 3). Simultaneous forming of
two screws will be possible due to separating cutter appli-
cation.
Selected results of research- and -implementation works
completed in course of development of thread rolling tech-
nology according to new concept have been described in the
present study. The works encompassed numerical analyses,
experimental tests carried out in laboratory conditions and
industrial tests associated with thread forming. The calcu-
lations have been completed using finite volumes method
(FVM) and finite element method (FEM). Industrial tests
were performed in JSC “BELTECHNOLOGIA & M” com-
∗ Corresponding author. Tel.: +48 81 5381242; fax: +48 81 5381241.
E-mail address: z.pater@pollub.pl (Z. Pater).
flat-wedge rolling machines.
2. Numerical analysis
2.1. Finite volumes method
MSC.Super Forge 2000 program has been applied for
thread rolling process modelling (using FVM). Detailed de-
scription of geometrical process model, parameters assumed
for calculations, simplifying assumptions and obtained re-
sults is included in previous studies [1,2]. We have to em-
phasize that rolling process analysis in mentioned studies
was limited to several leads of thread in order to reduce time
of calculations.
In course of completed calculations, progression of rolled
workpiece was traced, as illustrated in Fig. 4. The data in-
cluded in that Figure indicate that in course of initial pro-
cess stage, the tools are forced into material forming a
wedge–shaped neck with simultaneous material forcing into
the grooves existing on tools surface. Workpiece is rotated
under influence of side walls of the wedges (tools) and its
diameter is reduced (along required width). In course of
rolling process, the component cross-section is subject to
extreme ovalisation to be corrected by means of calibrating
surfaces of the tools (situated between successive grooves).
However the results of calculations using FVM indicate
that mentioned ovalisation is not corrected by means of
calibrating surfaces of the tools. The variations of forging

0924-0136/$ – see front matter © 2004 Elsevier B.V. All rights reserved.
doi:10.1016/j.jmatprotec.2004.04.154
 Z. Pater et al. / Journal of Materials Processing Technology 153–154 (2004) 722–728
Fig. 1. P49A sleeper fixing screw (according to standard PN).
Fig. 2. Diagram of thread forming by means of three rollers-industrial
method.
geometry cross-section (in course of rolling) which can be
monitored in Fig. 5 are the best illustration of such condi-
tions. That fact constitutes significant limitation associated
with finite volumes method application for modelling of
cross-rolling processes (particularly in case of thread form-
ing processes).
Fig. 4. Progression of shape in thread section of screw at process progress (in %) specified in drawing.
723
Fig. 3. Thread forming by means of new technology.
Therefore any information confirming potential applica-
tion of new cross-rolling concept was not obtained from an
analysis of thread rolling process by means of FVM.
2.2. Finite elements method
Owing to complex character of the problem, thread rolling
process modelling shall be performed in three–dimensional
strain state (3D). MSC.Super Form 2002 commercial soft-
ware package using FEM displacement representation has
been used for metal flowing analysis in forming process un-
der test. In order to minimize the time of calculations, the
following simplifying assumptions have been made: con-
stant friction factor on material-tool contact surface, rigid
model for tools material, constant forming temperature and
tools edges radii have been neglected.
The geometrical model of thread rolling process has
been illustrated in Fig. 6 representing essential geometrical
parameters. The model consists of: charge and tools (flat
wedges) moving with linear velocity of 0.065 m/s each. For
724 Z. Pater et al. / Journal of Materials Processing Technology 153–154 (2004) 722–728
Fig. 5. Calculated distribution of strains in forging cross-section, at process progress (in %) specified in drawing.
the charge modelling, eight-node brick elements shaped as
rectangular prism have been used. The option associated
with updating of elements network i.e. so called remeshing
was applied during calculations.
Numerical simulation of thread rolling has been per-
formed for commercial pure lead forming at ambient
temperature, with flow curves determined with following
Equation [3]:
σp = 24.803ε̇0.088 ,
where ␴p is flow stress, ε̇ is strain rate.
Remaining material parameters assumed for calcula-
tions: longitudinal modulus of elasticity E = 18,000 MPa,
Poisson’s ratio ν = 0.42 density ρ = 11,200 kg/m3 .
Owing to possible change of friction forces direction on
material-tool contact surface, constant friction model has
been applied-depending on slip velocity of metal in relation
to tool, according to the following equation:


2 vp vp
τ = −m k arctan , (2)
π ap |vp |
where τ is tangent stress, k the shear yield stress, m the
friction factor (assumed value m = 1), vp is slip velocity
vector, ap is coefficient (assumed value ap = 0.0001).
Fig. 6. Geometrical model of thread rolling process assumed in FEM.
Calculated shape variations for rolled workpiece have
been illustrated in Fig. 7. Owing to complex character of
the problem, forming analysis has been limited to mod-
elling of rolling process for two complete thread leads
only. Despite of such limitation, the data obtained from
calculation indicated that ovalization of cross-section will
be eliminated under influence of calibrating surfaces of the
tool. Therefore, the greatest strains are concentrated in sub-
surface zones of thread core. Assumed geometry of thread
(1) cross-section to be achieved (triangular with sharp cor-
ner) differs from calculated geometry (rounded corner with
large radius) in result of frequent remeshing (associated
with adaptation of finite elements mesh to forging shape
variations) being characterized by sharp edges blunting
trend.
During FEM, results analysis it was take into considera-
tion that the workpiece moves axially. This remark is verified
by longitudinal billet section obtained in advanced phase of
process presented on Fig. 8. The tool-wedges are cutting
into rolled material directly in the middle of the billet but
the longer of obtained perform is different in a both side
of workpiece. It shows that perform moves axially during
the process. Estimation of value of this movement will be
necessary in correct process of thread forming in double ar-
rangement. In this case we must to know the positions of
 Z. Pater et al. / Journal of Materials Processing Technology 153–154 (2004) 722–728 725

Fig. 7. Progression of shape and strain distribution, calculated by means of FEM for time specified in the drawing.

cutting knives mounted on the tools (respecting equal longer
condition).
3. Laboratory research
Experimental research for thread rolling have been per-
formed in laboratory conditions in Metal Forming De-
partment in Technical University of Lublin. The research
works have been carried out on the basis of LUW-1 flat
wedge rolling machine specially designed and built for
that purpose-see Fig. 9. The rolling machine is equipped
with hydraulic drive in order to enable forming with tools
(wedges) drive in forces up to 39 kN and with measurement
system recording tangent and radial components of rolling
force in course of rolling process.
Tool segments with the following parameters have been
applied for thread rolling: forming angle α = 25◦ , spreading
angle β = 10.12◦ , thread forming grooves angle (10.12◦ ),
tool length of 388 mm, width of tool = 120 mm (Fig. 10).
The sections of bars ∅, 22 mm × 250 mm made of pure
lead were used during experiments. Forming was carried out
at room temperature (process parameters were identical as
those assumed for FEM calculations).
Possibility of thread forming in cross-wedge rolling pro-
cess according to new concept has been confirmed on the
basis of completed tests, because the test pieces with the
thread rolled in their central part have been obtained (such
result is impossible in case of technology being actually
used-rolling by means of three rolls). Refer to Fig. 11 for
example of such test piece with the thread.
Analysis of radial and tangent forming forces distribu-
tions (Fig. 12) indicate that those distributions are con-
sistent with those obtained in typical cross-wedge rolling
processes, see reference [4]. Any differences, particularly
those visible in radial force distribution refer to more ir-

Fig. 8. Effective strain distribution in axial cross-section of the forging, calculated by means of FEM for time value t = 1.86 s.
726 Z. Pater et al. / Journal of Materials Processing Technology 153–154 (2004) 722–728

Fig. 9. Laboratory stand LUW-1 for thread rolling by means of flat wedges.

Fig. 10. Forming wedge tools, applied in laboratory tests associated with thread rolling.

regular force variation in case of thread rolling than in

conventional cross-wedge rolling. Disturbances of rolling
process stability occurring in starting phase of successive
thread leads forming are considered as the reason of such
irregularities.

4. Industrial tests

Considering the results obtained from numerical anal-

yses and preliminary laboratory research, wedge tools
enabling thread rolling of sleeper fixing screws in dual
Fig. 11. Part with rolled thread made of bar with diameter of 22 mm. arrangement have been designed. One of designed tools
 Z. Pater et al. / Journal of Materials Processing Technology 153–154 (2004) 722–728 727

14 • forming zone-ensuring thread forming along its whole

Radial length and being characterized by increased width of
12
10
working part of the tool in order to enable forming of
Load [kN]

successive thread leads;

8
• sizing zone-enabling elimination of previously created
6
shape irregularities during about 1 revolution of work-
4 Tangential piece;
2 • cutting zone-dividing of rolled forging into two pieces
0 takes place in that zone.
0 100 200 300 400
On the basis of prepared design of tools, tool kits have
Rolling pitch [mm]
been completed and installed on flat wedge rolling ma-
Fig. 12. Distributions of tangent and radial load measured in course of chine SP2000–manufactured by JSC “Beltechnologia &
laboratory tests. M”. Then the test of thread rolling of sleeper fixing screws
in dual arrangement have been carried out in industrial
has been illustrated in Fig. 13. The tool consists of the conditions with the test pieces made of carbon steel shown
following zones corresponding to individual phases of the in Fig. 14a have been used as forming stock. The shapes of
process: test pieces reflected overall dimensions of preforms to be
used for intended production of screws. The tests were fully
• knifing and guiding zone-the purpose of that zone of the successful. Refer to Fig. 14b for rolled test pieces. This
tool is to form V-shaped groove on whole circumference way the possibility of thread rolling in dual arrangement by
of the workpiece to protect against forging displacement means of cross-wedge rolling ensuring required quality has
in axial direction; been confirmed.

Cutting zone
Sizing zone

Forming zone

Knifing and
guiding zone

Fig. 13. Tooling set designed for simultaneous thread forming on two sleeper fixing screws.

Fig. 14. Preform (drawing a) and corresponding thread components made of that preform (drawing b) in course of industrial tests.
728 Z. Pater et al. / Journal of Materials Processing Technology 153–154 (2004) 722–728
5. Summary
The research- and -implementation works completed in
the framework of new thread rolling technology developed
for sleeper fixing screws have been described in the present
study. The works encompassed numerical analyses, experi-
mental tests performed in laboratory conditions and indus-
trial tests. The following conclusions have been obtained on
grounds of results of calculations and experimental tests:
• Thread forming is possible by means of cross-wedge
rolling with tools incorporating forming surfaces with
special grooves. The shapes of grooves in cross-section
correspond to thread cross-section contour. The advan-
tage of the new technology consists in possibility of
thread forming in any part of shaft.
• In course of rolling process, the workpiece is displaced in
axial direction in result of unbalanced axial forces. Pre-
cise determination of that displacement or its neutraliza-
tion using technological provisions is required for correct
completion of rolling process.
• Higher irregularity of radial force distribution than in
case of typical cross-wedge rolling processes is another
feature of thread rolling carried out according to new
concept.
• Industrial tools enabling simultaneous thread rolling of
two sleeper fixing screws have been designed and com-
pleted.
References
[1] Z. Pater, Three dimensional simulation of flat-die thread rolling, in.
J.M. Torallba (Ed.), Proceedings of the AMPT’01, Madrit, 2001,
pp. 867–873.
[2] Z. Pater, Modelling of Flat-wedge Thread Rolling Process, Obróbka
Plastyczna Metali No. 5, 2002, pp. 29–37 (in Polish).
[3] Z. Pater, A. Gontarz, W. Weroñski, Metal Forming, Calculations of
Forming Loads, Technical University of Lublin, Lublin, 2002 (in
Polish).
[4] Z. Pater, A. Gontarz, W. Weroñski, Selected problems of theory and
technology of cross wedge rolling, Technical University of Lublin,
Lublin, 2002 (in Polish).