Roll-Forming Design of Eco-Friendly Stud using Finite Element Analysis

Abstract

Recently, the eco-friendly stud obtained by expanding the sheared pattern of the web and by roll-forming the flange is going to prevail because of the scrapless manufacturing process. In order to design the shearing pattern for the eco-friendly stud, the finite element analysis and Taguchi method are employed. For the design of expanding process of sheared patterns, the whole roll-forming processes are simulated by finite element method. Six geometries are considered to see the durability and fire resistance of the dry wall, for which structural and thermal analyses are performed. For determining the best, the orthogonal array and smaller-the-better characteristics of the Taguchi method are utilized. As the roll gap of the upper-and-lower roll type causes flange buckling, the side roll type is adopted. The stress and strain distributions as well as the formed shape obtained from the finite element simulation are used for the successful design of the roll-forming processes. The material cost of the eco-friendly stud can be reduced, compared to the conventional stud. Moreover, the expanding process by side rolls shortens the length of the roll-forming process and minimizes the die cost.