Thread forming is a crucial process in many industries where a joint is needed to connect different structural components, e.g., a flow drill screw to join different materials such as aluminum to steel in automobile industry; an implant (screw) for installation of dental crown in biomedical industry; a concrete screw to join concrete and other structural elements in civil engineering; a wood screw for connection of wood components in wood industry. A common feature of these joining process is material failure and new threads to be formed in the components to be connected.To study the responses of both the tool (screw) and the component structures, successful numerical analysis would be very helpful not only in design optimization and cost saving (time and experiment), but also in better understanding material responses. &nbsp;Unfortunately, traditional finite element method, discrete element method, or smoothed particle hydrodynamics has not demonstrated their capability in modeling the thread forming process in this type of applications.&nbsp; This talk presents a Galerkin meshfree method, namely, the smoothed particle Galerkin (SPG) method [1, 2], for the analysis of thread forming processes in various industries.The SPG method was developed for physically modelling ductile material failure and a momentum consistent (MCSPG) formulation [3, 4] was developed recently to further improve efficiency and accuracy. Application of the SPG / MCSPG method has been extended from ductile failure to semi-brittle (even brittle) failure in various industrial problems such aerospace, automobile, civil, defense and manufacturing processes. Analysis of metal, wood, concrete, and biomaterial screwing processes will be demonstrated using the SPG / MCSPG method in this presentation. The extreme deformation material failure and threading processes are reasonably simulated by the SPG / MCSPG method. In addition, the strength (e.g., pullout)&nbsp;of the joint can be analyzed by the SPG / MCSPG method as well.&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp; &nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;Reference:1&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp; Wu CT, Koishi M, Hu W. A displacement smoothing induced strain gradient stabilization for the meshfree Galerkin nodal integration method. Comput. Mech. 2015: 56, 19-37.2&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp; Wu CT, Chi SW, Koishi M, Wu Y. Strain gradient stabilization with dual stress points for the meshfree nodal integration method in inelastic analysis. Int. J. Numer. Methods Engrg. 2016:107, 3-30.3&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp; Pan X, Wu CT, Hu W, Wu Y. A momentum-consistent stabilization algorithm for Lagrangian particle methods in the thermo-mechanical friction drilling analysis. Comput. Mech. 2019:64, 625-644.4&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp; Wu CT, Wu Y, Lyu D, Pan X, Hu W.&nbsp; The momentum-consistent smoothed particle Galerkin (MC-SPG) method for simulating the extreme thread forming in the flow drill screw driving process. Comp. Part. Mech. 2020:7,177–191. https://doi.org/10.1007/s40571-019-00235-2

Analysis of Various Industrial Thread Forming Processes Using a Galerkin Meshfree Method

Paper Proceedings: https://asmedigitalcollection.asme.org/IMECE/IMECE2021/volume/85543

ASME 2021 International Mechanical Engineering Congress and Exposition (IMECE2021)

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