Design and Experimental Validation of a Novel Sector-Shaped Thread Rolling Machine with Multi-Piece Forming Capability

This study presents the design, simulation, and experimental validation of a novel sector-shaped thread rolling machine aimed at improving forming efficiency, structural compactness, and process controllability compared with conventional linear thread rolling systems. A systematic engineering framework integrating mechanism design, curved-die implementation, motion control, finite-element simulation, and experimental verification is established. DEFORM-3D simulations are performed to investigate the effects of friction coefficient and die spacing on material flow and thread profile formation, and the results are used to guide machine construction and parameter optimization. Experimental results demonstrate that the proposed mechanism can simultaneously form four screws within a single rotation cycle, significantly enhancing production efficiency. Under optimized parameters, the relative errors of pitch diameter and helix angle are maintained within 5%, showing good agreement with simulation predictions. The findings confirm the feasibility, controllability, and stable forming capability of the proposed system, providing a practical and efficient solution for next-generation compact and high-productivity thread rolling equipment.