Faculty Advisor

Brown, Christopher A.


Six thread rolling die specimens were compared based on surface characteristics and material properties. This research is important in providing insights into why some tools may perform better than others. Surface characteristics were quantified by measuring five locations on new and used die regions. Measurements were compared using F-tests of height parameters, relative area, and complexity. Material characteristics were compared by examining the alloy, microstructure, microhardness profiles, and failure mode. The larger dies appeared to have failed from spalling, while the smaller dies by abrasive wear. Hardness vs. depth profiles were different for each die. At scales between 1 and 10 µm2, relative area appears to correlate well to lifetime.


Worcester Polytechnic Institute

Date Accepted

April 2012


Mechanical Engineering

Project Type

Major Qualifying Project



Advisor Department

Mechanical Engineering