Analysis of Micro-Machining Process for External Thread of Micro Round Tube.

Area of Science:

• Materials Science and Engineering
• Manufacturing Processes
• Mechanical Engineering

Background:

• Micro-scale manufacturing presents unique challenges due to size-dependent material behavior.
• Accurate simulation of micro-machining processes like threading requires consideration of size effects.
• Understanding the influence of process parameters on stainless steel micro tube threading is crucial for quality control.

Purpose of the Study:

• To analyze the external threading process of stainless steel (SUS304) micro round tubes.
• To investigate the impact of varying outer threading pitches, outer diameters, friction factors, and tube thicknesses.
• To evaluate the significance of size effects on material parameters and the threading process using finite element analysis.

Main Methods:

• Finite element analysis (FEA) using DEFORM-3D software.
• Incorporation of corrected material parameters to account for size effects in micro-tubes.
• Comparison of simulation results with experimental data for validation.

Main Results:

• The modified model, incorporating size effects, yielded lower torque, stress, and strain compared to the standard Swift model.
• Increased outer diameter generally led to higher maximum torque for larger pitches (M2 × 0.4), but not for smaller pitches (M2 × 0.25).
• Higher threading pitch significantly increased torque, stress, and strain; increased friction factor reduced stress and strain; tube thickness had minimal impact.

Conclusions:

• Accounting for size effects is essential for accurate simulation and proper torque prediction in stainless steel micro round tube threading.
• Threading pitch and outer diameter are key parameters influencing the threading torque and material deformation.
• The developed simulation method provides a reliable basis for optimizing micro round tube threading processes, enhancing product quality and reducing costs.