Research and Optimization of Process Parameters for Internal Thread Forming Based on Numerical Simulation and Experimental Analysis

In order to improve the forming quality of extruded thread, finite element analysis and experimental research are combined to reduce the two keys that affect thread quality in the machining process—extrusion torque and extrusion temperature. The effects of different processing parameters on the extrusion torque and temperature are obtained by numerical simulation, including the bottom hole diameter of the workpiece, the machine tool speed, and the lubrication medium. For the purpose of reducing extrusion torque and temperature, the process parameters for internal thread forming are further optimized by orthogonal design. It is determined that when machining the M22 × 2 internal thread on the connecting rod of the marine diesel engine made of 42CrMo4 steel, the bottom hole diameter of the workpiece should be ∅21.20 mm, the speed of the machine tool should be 40 RPM, and the lubricating medium should be PDMS polydimethylsiloxane coolant. Compared to before optimization, the maximum extrusion torque and the maximum extrusion temperature are reduced by 19.27% and 15.07%, respectively. On the premise of ensuring the thread connection strength, the height of the thread tooth is reduced by 0.052 mm, and the surface condition of the thread is improved. The surface microhardness at the root, top, and side of the thread increases by about 5 HV(0.2), and the depth of the hardened layer increases by 0.05 mm. The results show that the quality of the optimized thread is higher.