FEM simulation on forming vacuum hexagon socket screws using tube workpiece

Abstract

This study proposes a new forming design concept to produce vacuum hexagon socket screws using tube workpiece, and uses the finite element simulation software DEFORM-3D to simulate the multi-pass forming process of vacuum hexagon socket screws. The simulated material is SUS-304 stainless steel, and the frictional conditions are assumed to be constant shear friction, the die is assumed to be a rigid body. In the past, the traditional vacuum hexagon socket screw manufacturing process used a multi-pass process to manufacture a standard screw using a solid workpiece (wire rod), and then drilling an air channel in the core of the screw. This process not only wastes time, but also needs to increase the processing cost. In this study, the time and cost of drilling the air channel can be reduced by forming the vacuum hexagon socket head screw through the hollow tube. The finite element simulation results confirm that this design is a feasible method. The pass schedule can be reduced from 6 stages to 3 stages, the maximum effective stress decreased by 28.13%, and the total forming force decreased by 57.66%. The research results can be provided to relevant industry as the reference.