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An axisymmetric model for thread forming in polycarbonate and polypropylene screw and boss fasteners
Author(s) -
Ellwood Kevin R. J.,
Fesko Don,
Bauer David R.
Publication year - 2004
Publication title -
polymer engineering and science
Language(s) - English
Resource type - Journals
SCImago Journal Rank - 0.503
H-Index - 111
eISSN - 1548-2634
pISSN - 0032-3888
DOI - 10.1002/pen.20146
Subject(s) - boss , thread (computing) , materials science , composite material , finite element method , polycarbonate , screw thread , mechanical engineering , shim (computing) , forming processes , structural engineering , engineering , metallurgy , medicine , erectile dysfunction
Plastic boss and screw fasteners are an economical means of securing automotive components, such as instrument or body panels. However, new materials and/or suboptimal design present challenges to the boss/screw effectiveness. Failure of a boss/screw can result is loss of functional performance or increased squeak and rattle. Failure is often controlled by what occurs during the initial thread‐forming process. Thus, the goal of this paper is to develop an FEA model to elucidate the thread‐forming process so that we can facilitate subsequent design and/or process optimization, and understand potential failure modes. The FEA must accommodate nonlinear couplings, such as large strain and heat transfer. Heat generation is present in the forms of interfacial shear heating and plastic work associated with the large deformation of the interface between the boss and screw. Strain rate‐dependent materials are included using the Eyring theory for plastic flow of polymeric materials. Results of the model are presented and compared to experimentally determined torque curves and temperatures. Polym. Eng. Sci. 44:1498–1508, 2004. © 2004 Society of Plastics Engineers.