Education, Science, Technology, Innovation and Life
Open Access
Sign In
  1. Home
  2. Journals
  3. Journal of Engineering Mechanics and Machinery
  4. Vol 11, Issue 1, 2026

Defect Evolution Mechanism and Quantitative Criteria in Thread Rolling of Ti-6Al-4V Bolts

Download as PDF

DOI: 10.23977/jemm.2026.110116 | Downloads: 3 | Views: 160

Author(s)

Xiangwei Zhang 1, Ni Zhen 1, Rui Ye 2, Liangliang Wei 2

Affiliation(s)

1 School of Mechanical Engineering, Tianjin University of Science and Technology, Tianjin, 300222, China
2 Key Laboratory of Fastening and Connecting Technology Enterprises of Tianjin, Aerospace Precision Industry Co., Ltd, Tianjin, 300300, China

Corresponding Author

Liangliang Wei

ABSTRACT

Thread rolling of titanium alloys is an important process for improving the fatigue resistance of aerospace fasteners. However, under high-speed processing conditions, unstable material flow may lead to severe surface burr defects. This study investigates the influence of rolling speed on thread forming quality and defect evolution in Ti-6Al-4V bolts using DEFORM-3D simulations and experiments. The results show that increasing rolling speed gradually drives the forming process into an unstable state, where burr distribution evolves from localized defects on the thread flank to continuous material overflow at the thread root. To quantitatively characterize this failure process, a multi-dimensional evaluation criterion is proposed based on the speed fluctuation standard deviation (δv) and cumulative slip index (Ds). The results indicate that (δv) determines the frequency and intensity of burr formation, whereas Ds governs the physical depth of burr growth. This study provides a quantitative basis for defect prediction and process optimization in titanium alloy thread rolling.

KEYWORDS

Ti-6Al-4V, Thread Rolling, Forming Instability, Burr Defects, Quantification Criteria

CITE THIS PAPER

Xiangwei Zhang, Ni Zhen, Rui Ye, Liangliang Wei. Defect Evolution Mechanism and Quantitative Criteria in Thread Rolling of Ti-6Al-4V Bolts. Journal of Engineering Mechanics and Machinery (2026). Vol. 11, No. 1, 167-179. DOI: http://dx.doi.org/10.23977/jemm.2026.110116.

REFERENCES

[1] Mei, M., Zhao, Y. and Chen, C., Extrusion internal thread of titanium alloy plate: Multi-objective optimization of material flow-induced defects. Proceedings of the Institution of Mechanical Engineers, Part E: Journal of Process Mechanical Engineering, 2025, 09544089251343974.
[2] Maciel, D. T., Filho, S. L. M. R., Lauro, C. H. and Brandão, L. C., Characteristics of machined and formed external threads in titanium alloy. The International Journal of Advanced Manufacturing Technology, 2015, 79, 779–792.
[3] Tschaetsch, H., Metal forming practise: processes—machines—tools. Springer, 2006.
[4] Song, J., Liu, Z. and Li, Y., Cold rolling precision forming of shaft parts. Springer, 2017.
[5] Zhou, Q., & Zhang, J. (2024). Numerical simulation study on the cold thread rolling forming of Ti-6Al-4V alloy fasteners with external threads and their defects. In Journal of Physics: Conference Series (Vol. 2815, No. 1, p. 012028). IOP Publishing.
[6] Furukawa, A., & Hagiwara, M. (2015). Estimation of the residual stress on the thread root generated by thread rolling process. Mechanical Engineering Journal, 2(4), 14-00293.
[7] Martin, J. A. (1998). Fundamental finite element evaluation of a three dimensional rolled thread form: Modelling and experimental results (No. KAPL-P--000058; K--98003; CONF-980708--). Knolls Atomic Power Lab., Schenectady, NY (United States).
[8] Du Maire, P., Hoffmeister, J., Johlitz, M. and Öchsner, A., Influence of the manufacturing process on the fatigue strength of threads. Materialwissenschaft und Werkstofftechnik, 2025, 56, 638–645.
[9] Maurya, A., Hwang, J.-W., Yeom, J.-T., Kim, J. H., Yang, J., Kim, J. H., Lim, J., Lee, S. W., Park, C. H. and Hong, J. K., Optimized Process Design for Uniform Microstructure and High-Strength Ti-6Al-4 V Alloy Fasteners in Aerospace Applications. Metals and Materials International, 2025, 1–13.
[10] Oberg, E., Jones, F. D., Horton, H. L., Ryffel, H. H. and McCauley, C. J., Machinery's handbook. Industrial press New York, 2004.
[11] Kim, W., Kawai, K., Koyama, H. and Miyazaki, D., Fatigue strength and residual stress of groove-rolled products. Journal of Materials Processing Technology, 2007, 194, 46–51.
[12] Zhang, D.-W., Zhao, S.-D. and Ou, H., Analysis of motion between rolling die and workpiece in thread rolling process with round dies. Mechanism and Machine Theory, 2016, 105, 471–494.
[13] Chen, C. H., Wang, S. T. and Lee, R. S., 3-D finite element simulation for flat-die thread rolling of stainless steel. Journal of the Chinese Society of Mechanical Engineers, Transactions of the Chinese Institute of Engineers, Series C/Chung-Kuo Chi Hsueh Kung Ch'eng Hsuebo Pao, 2005, 26, 617–622.
[14] Hsia, S. Y., Pan, S. K., & Chou, Y. T. (2015). Computer simulation for flat-die thread rolling of screw. In International Conference on Innovation, Communication and Engineering.
[15] Zhang, D.-W., Zhang, C., Tian, C. and Zhao, S.-D., Forming characteristic of thread cold rolling process with round dies. The International Journal of Advanced Manufacturing Technology, 2022, 120, 2503–2515.
[16] Domblesky, J. P. and Feng, F., A parametric study of process parameters in external thread rolling. Journal of Materials Processing Technology, 2002, 121, 341–349.
[17] Giorleo, L. and Cartapani, M., Influence of die threading and finishing length in the thread-rolling process using flat dies: a numerical analysis. Journal of The Institution of Engineers (India): Series C, 2022, 103, 403–411.
[18] Nitu, E., Tabacu, S., Iordache, M. and Iacomi, D., Finite element analysis and experimental validation of the wedge rolling process. Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture, 2013, 227, 1325–1339.
[19] Volz, S. and Groche, P., Experimental investigation on slip conditions during thread rolling with flat dies. Friction, 2024, 12, 136–143.
[20] Groche, P. and Kramer, P., Numerical investigation of the influence of frictional conditions in thread rolling operations with flat dies. International Journal of Material Forming, 2018, 11, 687–703.
[21] Kramer, P. and Groche, P., Defect detection in thread rolling processes–experimental study and numerical investigation of driving parameters. International Journal of Machine Tools and Manufacture, 2018, 129, 27–36.
[22] Zhang, Q., Arentoft, M., Bruschi, S., Dubar, L. and Felder, E., Measurement of friction in a cold extrusion operation: Study by numerical simulation of four friction tests. International Journal of Material Forming, 2008, 1, 1267–1270.
[23] Müller, C., Schmierung von Werkzeugen der Kaltmassivumformung mit Einschichtschmierstoffsystemen. Shaker, 2015.

All published work is licensed under a Creative Commons Attribution 4.0 International License.

Copyright © 2016 - 2031 Clausius Scientific Press Inc. All Rights Reserved.