## 3 Results and Discussion  
### Stress Results  
The stress simulation condition diagram, shown in Figure 6, offers a comprehensive overview of the outcomes obtained from rigorous testing on the designated rig. This diagram serves as a critical tool in assessing the structural integrity and performance of the system under varying stress conditions. Table 5 illustrates the stress simulation results while Tables 6-8 offer a detailed breakdown of the SolidWorks simulation sample sizes, organized by pitch size, followed by thread size and material choice. A total of 36 simulations were meticulously conducted, providing a broad range of insights into the simulation behavior under stress and torque. Among the pitch variations tested (0.25 mm, 0.30 mm, 0.35 mm, and 0.40 mm), maximum von Mises stress exceeded the upper limit of the yield strength (310 MPa) for annealed Stainless Steel Austenitic AISI 316L, indicating that deformation and failure are likely during consolidation. The simulation results indicated that maximum stress for Titanium Commercial Purity Grade 4 (annealed) with a pitch of 0.25 mm indicates a potential risk, falling within the limits of its yield strengths. Under the given consolidation conditions, this titanium alloy may experience deformation, highlighting a risky scenario for deformation. Conversely, for Titanium Alpha-Beta Alloy Ti-6 Al-4V (annealed), maximum von Mises stress for all pitches remained below the lower limit of its material yield strengths, indicating a favorable scenario and suggesting it is less susceptible to deformation under the given consolidation conditions. These findings underscore the significant influence of pitch size on the mechanical behavior of materials during the consolidation process. Figures 7 and 8 depict the graphical representations of stress on the thread corresponding to different pitches: 0.25 mm, 0.30 mm, 0.35 mm, and 0.40 mm, respectively. These figures visually demonstrate how stress levels vary along the thread under various pitch conditions, offering insight into the material's performance and behavior in response to pitch size and engagement threads. Analyzing these graphs provides valuable information about stress distribution along the thread, aiding in the identification of potential failure points or areas requiring reinforcement. This visual representation serves as a powerful tool for understanding the impact of pitch variation on material mechanical characteristics, facilitating informed decision making in design and optimization. Figure 7a indicates that Stainless Steel Austenitic AISI 316L (annealed), specifically with 10 and 15 engagement thread faces, experiences significantly higher stress levels compared to Titanium alloy counterparts. Additionally, stress on Stainless Steel Austenitic AISI 316L (annealed) material exceeds the upper limit of 310 MPa for all thread engagements, possibly due to the 0.25 mm pitch being too fine to withstand the applied load of 1200 N and 1 N.m torque. Figure 6: (**a**) Stress simulation condition; and (**b**) Stress concentration location. Concerning Titanium Commercial Purity Grade 4 (annealed) with 10-thread engagement, there is a potential risk of deformation as stress falls within the material's yield strength range. However, physical testing is necessary to confirm this risk conclusively. In Figure 7b, stress outcomes for a 0.30 mm pitch indicate that stainless steel austenitic AISI 316L (annealed), particularly with 10-, 15-, and 20-thread engagements, exceed the upper limit of the material yield strength, suggesting susceptibility to plastic deformation under these conditions. Nonetheless, all other simulated results can withstand the conditions. In Figure 8a, the results for both titanium alloys exhibit a similar result. The trend line for titanium alpha beta alloy Ti-6 Al-4V (annealed) essentially overlays that of titanium commercial purity grade 4 (annealed), giving the appearance of only two distinct trends in Figure 8a.