Accurate modeling of threaded connections and evaluation of contact surface distribution errors oriented to accurate digital twins

作     者：Zhang, Min Sheng, Zhichao Xiong, Jian Saren, Qimuge Chen, Xiao Zhang, Zhijing 

作者机构：Beijing Inst Technol Sch Mech Engn Beijing 100081 Peoples R China Genertec Machine Tool Engn Res Inst Co Ltd Beijing 101300 Peoples R China Univ Huddersfield EPSRC Future Metrol Hub Huddersfield HD1 3DH West Yorkshire England 

出 版 物：《MEASUREMENT》 (Meas J Int Meas Confed)

年 卷 期：2025年第247卷

核心收录：

学科分类：08[工学] 080401[工学-精密仪器及机械] 0804[工学-仪器科学与技术] 081102[工学-检测技术与自动化装置] 0811[工学-控制科学与工程] 

基　　金：National Natural Science Founda-tion of China [U22B2088  52205512  52305530] 

主　　题：Threaded connections Distribution errors Accurate geometric error 3D modeling method Geometric digital twin model Non-uniform distribution error evaluation method Simulation calculations 

摘      要：The assembly performance of precision structural threaded connections is significantly influenced by the threads geometric parameters and the geometric form of the thread contact surface (TCS). Due to the complexity involved in the helical structure and surface form of the thread itself, establishing a 3D solid model that conforms to the actual machining conditions presents challenges. This study first proposes an accurate geometric error 3D modeling method for representing the non-uniform distribution error of the TCS. The non-contact optical measurement method obtained the point cloud data containing the actual machining errors of the TCSs. Based on data processing, a 3D distribution error model of the TCS was established using the NURBS surface numerical model. Using CAD modeling, the 3D geometric distribution error was integrated with the ideal 3D solid model to create an accurate geometric digital twin model of the thread. Then, anon- uniform distribution error evaluation method of TCSs was proposed to quantitatively evaluate the non-uniform distribution characteristics of the errors on the TCSs. The feasibility of the proposed method was validated by comparing the modeling and evaluation of normal-precision and high-precision threads. The simulation calculations results of ideal and error bolted joints indicated that the non-uniform distribution errors on the TCS lead to local point contact or non-contact, and the resulting stress distribution is discontinuous and nonuniform. This study provides a practical approach for predicting and optimizing the performance of threaded connections.