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The production of high-precision micro-sized screws, used to fasten parts of micro devices, generally utilizes a cold thread-rolling process and two flat dies to create the teeth. The process is fairly complex, involving parameters such as die shape, die alignment, and other process variables. Thus, up-front finite-element(FE) simulation is often used in the system design procedure. The final goal of this paper is to produce high-precision screw with a diameter of 800μm and a thread pitch of 200μm (M0.8×P0.2) by a cold thread rolling process. Part I is a first-stage effort, in which FE simulation is used to establish process parameters for thread rolling to produce micro-sized screws with M1.4xP0.3, which is larger than the ultimate target screw. The material hardening model was first determined through mechanical testing. Numerical simulations were then performed to find the effects of such process parameters as friction between work piece and dies, alignment between dies and material. The final shape and dimensions predicted by simulation were compared with experimental observation. Key Words : Micro-sized Screw, Flat Type Thread Rolling, Finite Element Analysis, Shear Friction Factor, Parametric Study

Analysis and Experiments on the Thread Rolling Process for Micro-Sized Screws Part I: Process Parameter Analysis by Finite-Element Simulation