The malformation of sheet metal tapping screw threads in the screw threading process increases the cost of screw threading dies and their maintenance. Die factories do not reveal their screw threading die design techniques, so production and maintenance processes are established by trial-and-error or worker experience and passing down such techniques and documenting quality control is difficult. In this study, screw thread forming design and process analysis were carried out by combining computer-aided design software with computer-aided metal forming analysis software. Simulation results were verified in an actual forming process. The sheet metal tapping screw forging size error was less than 0.90%, except at a sharp angle, which was associated with an error of 3.075%, thereby demonstrating the accuracy of the simulated forming process. The numerical analysis process can be utilized to shorten forming development time; to reduce the number of die tests, and to improve product quality and die service life, reducing the cost of development and promoting the overall competitiveness of the company.
