Micro-screws can be defined by their outer diameter of generally less than 1 mm. They are manufactured by head forging and thread rolling processes. In this study, the thread rolling process was numerically analyzed for a micro-screw with a diameter and pitch of 0.8 and 0.2 mm, respectively. Through finite element (FE) analysis, the effects of two design parameters (die gap and chamfer height) on the dimensional accuracy were investigated. Three combinations of chamfer heights were chosen first and the corresponding die gap candidates selected by geometric calculation. FE analyses were performed for each combination and their results indicated that the concave chamfer height should be less than 0.3 mm, while a 10 ?m difference in the die gap might cause degeneration in dimensional accuracy. These results conclude that ultra-high accuracy is required in die fabrication and assemblies to ensure dimensional accuracy in micro-screw manufacturing.
