Thermo-mechanical Coupled Finite Element Simulation Analysis of Warm Thread Rolling Forming for GH4169 Bolts

ZHANG Hui; LI Xiangfeng; LIU Junkang; KE Shuzhong; WANG Lijun; SUN Xiaojun

doi:10.3969/j.issn.1674-6457.2026.05.020

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Journal of Netshape Forming Engineering ›› 2026, Vol. 18 ›› Issue (5) : 216-225. DOI: 10.3969/j.issn.1674-6457.2026.05.020

Superalloy Forming

Thermo-mechanical Coupled Finite Element Simulation Analysis of Warm Thread Rolling Forming for GH4169 Bolts

ZHANG Hui¹, LI Xiangfeng^1,*, LIU Junkang¹, KE Shuzhong^2,3, WANG Lijun^2,3, SUN Xiaojun^2,3

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Abstract

The work aims to investigate the thermo-mechanical coupling mechanism and the evolution of multi-physical fields during the warm thread rolling of GH4169 bolts, so as to provide theoretical guidance and modeling support for subsequent process optimization and thread quality improvement. A thermo-mechanically coupled finite element model incorporating both the heat transfer stage and the warm thread rolling stage was established in DEFORM, and the temperature, stress, and velocity fields as well as the forming force during thread formation were numerically simulated and theoretically analyzed. Infrared thermometry and rolling experiments were conducted to validate the simulated temperature and forming force. The deviations between experiment and simulation were controlled within 0.9% for temperature during cooling, 7.7% for temperature during forming, and 11.3% for forming force, indicating that the developed model could effectively reproduce the warm thread rolling process. A “three-zone” temperature field was formed inside the workpiece due to the combined effects of deformation-induced heating and spray cooling: the core region exhibited a uniform temperature (range <5 ℃), the surface rolling zone showed a temperature difference of about 100 ℃, and the end faces was cooled to approximately 230 ℃. The thread root experienced a triaxial compressive stress state (peak of about 1 560 MPa), the flanks were dominated by high shear stress, and the crest alternated between radial compression and axial tension, representing a potential tensile instability zone. The velocity field within the rolling contact region displayed a pattern of “low-speed turbulence-localized high speed-contour-aligned uniformity”, and asymmetry in the plastic flow velocity on the two flanks was identified as a major contributor to crest folding. The forming force varied markedly with the deformation rate, reaching a peak of about 83.5 kN in the later feeding stage due to work hardening and decreasing during stable rolling as stress was released. The developed finite element model accurately captures the thermo-mechanical behavior of GH4169 warm thread rolling, reveals the formation mechanism of crest folding, and provides guidance for the design and optimization of warm thread rolling processes.

Key words

GH4169 / thermo-mechanical coupling / plastic deformation / crest folding / finite element model

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ZHANG Hui, LI Xiangfeng, LIU Junkang, KE Shuzhong, WANG Lijun, SUN Xiaojun. Thermo-mechanical Coupled Finite Element Simulation Analysis of Warm Thread Rolling Forming for GH4169 Bolts[J]. Journal of Netshape Forming Engineering. 2026, 18(5): 216-225 https://doi.org/10.3969/j.issn.1674-6457.2026.05.020

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Funding

Henan Key Laboratory Project of Fastening and Joining Technology (XM2024-HK17); Suzhou Science and Technology Achievement Transformation Project (SZC202317)