Entwicklung einer effizienten Simulationsmethode für einen Gewindewalzprozess

Plastic forming is characterized by a high degree of design freedom, short production times, high process reliability and improved mechanical properties. In order to understand the influence of a complex forming process on a workpiece as well as on the tools the use of finite element simulation is necessary. In this master thesis, a thread rolling process is simulated using a finite element software and subsequently compared with the real thread rolling processes. By varying several parameters, the computational stability of the simulation is tested and the time of the simulation is optimized. The aim of this optimization is to develop an efficient simulation method, with the highest possible accuracy and short a calculation time. Subsequently the simulation results are analyzed and graphically visualized. This evaluation of the simulated loads is in good correspondence with the areas of highest wear in the real process. Finally, various possible improvements in tool design are presented in order to evaluate their influence on tool loads ans to subsequently optimze the thread rolling process.