냉장고용 고하중 슬라이드 레일의 롤포밍 공정 해석

Abstract

Roll forming process is one of the most widely used processes in the world for forming metals. It can manufacture goods of the uniform cross section throughout the continuous processing. Roll forming is a very important process used in many industrial fields. It is difficult to predict the plastic deformation in roll forming process because of its inherent complexity. So, many forming roll designers still depend on his or her art, not the science in spite of technical process. This situation raises problems which take a long time and cost a lot of money. Computer analysis methods such as FEM(Finite Element Method) and the FDM(Finite Difference Method) help the forming roll designers to estimate the roll forming process easily. In this thesis, the slide rail composed of inner member, center member and outer member is designed as 3-dimensional model. The heavy load slide rail is used in the refrigerator. Tensile test is performed about SCP-1 to obtain material properties. Heavy load slide rail is simulated by static structural analysis to evaluate the structural defect. Curve fitting is executed by using the least square method to set up the flow stress equation which is the governing equation for rigid plastic FEA. The slide rail is designed using the constant arc length forming method. The inner member and the outer member are designed using the outside lip method, and the center member are designed using the center bead method. The forming roll of the inner member in the slide rail is designed as two types. TYPE A is formed by the upper roll and the lower roll, and TYPE B is added the side roll in last pass. Each types are simulated and compared with the longitudinal strain, width strain and thickness strain using SHAPE-RF software.