Customer magazine for the roll forming and metal bending industry Edition August/2004

Newsletter of the data M Software + Engineering GmbH

Foreword Content: Roll-Kraft goes for COPRA FEA RF ............................P. 10

Sheet Metal Bending 10 years COPRA at Avesta ..........................................P. 10
Sheet Metal Transitions and Ductings for Inventor ........P. 2 /3 Roll design services for Bosal Africa..............................P. 10
COPRA MetalBender for MDT in practical use ............P. 4 Flexible Roll Forming and Slide-Draw-Bending ............P. 10
Dear reader, Laser Sensor for Bending Machines..............................P. 4 Autodesk software products from data M ......................P. 12
This issue of our CMB for AutoCAD ..........................................................P. 4 data M live: exhibitions and seminars ............................P. 12
info-forum has Roll Forming data Ms resellers - worldwide........................................P. 12
taken long in coming. However, I The new generation of the COPRA RollScanner ........P. 5 Response Form - We would like to hear from you ........P. 12
believe waiting was worth while.
data M - a success story in roll forming ........................P. 5
Despite the poor worldwide eco-
COPRA RF software in India and Slowenia ................P. 5 COPRA MetalBender
nomic constraints in the past we
havnt lost our optimism and con- Development&Optimization of Cold Roll Forming Tool Sets P. 6
tinued in our product development Korean Steel supplier goes for COPRA FEA RF..........P. 7 Software for Sheet Metal
and research activities. COPRA RF and AutoCAD ............................................P. 7
This issue of info-Forum covers: FEA RF replicates roll forming dynamics ......................P. 8 Design and Unfolding
Software module simulates tube welding ......................P. 8
COPRA MetalBender software New: COPRA Wire Forming ........................................P. 9 COPRA MetalBender TDi & Metal Bender
(interfaces for TOPS and Cybelec) Analyseri for Autodesks Inventor, Mechanical
Roll Design Services-we are not only offering software ....P. 9
Improved COPRA LaserCheck Desktop and
COPRA FEA RF and Webco, USA ..............................P. 9 AutoCAD
bending angle sensor
Technical Seminar on roll form analysis at data M ........P. 10 see page 2
COPRA Roll Form software pack-
age in a new version with some in- International Tube Association re-elects chairman ........P. 10
teresting new features like the pos- PVG switched their roll design software to COPRA RF ....P. 10
sibility to evaluate even plastic
strain values using COPRA DTM
Flexible Forming COPRA Roll Forming
COPRA RollScanner now avail-
able with an additional 3rd axis
data M is presenting you two
Flexible Forming Development & Optimization of
new flexible forming methods for
longitudinally variable profiles
of Profiles - Roll Forming Tool Sets
COPRA FEA RF - data Ms finite
Usually roll formed sections or tubes For some years now the firm data M chain for the design and validation
element analysis software for the
have a constant longitudinal cross- Software GmbH, based in Bavaria, of roll sets in roll forming producti-
roll forming process has been intro-
section...see page 11 has been offering a virtual process on. The COPRA RF (Roll Forming)
duced successfully to industry. It
software program supports all
makes the user understand the roll steps in the development of open
forming process and helps to devel- or closed profile cross-sections: from
op new and more complex prod- design of the final cross-sections to
ucts. This is important in view of be produced, through definition of
new high strength material and the the various shaping steps (passes
growing demands from industry or flower) to generation of...
data M is also offering consulting see page 6
and design services. A trial order
will convince you
last but not least: data M is offer- COPRA LaserCheck COPRA Wire Forming
ing a totally new software product -
COPRA WF (Wire Forming) for the Laser Sensor for New: Software Solution for
design and manufacture of wire
rolling tools Press Brakes and Rolling of Wire Profiles
I am sure that our developments are
folding machines
Today the production and forming in a highly rationalized manner. As
able to give you some suggestions data Ms Laser Triangulation Probe of wire is an industrial process by with many other forming processes,
for your business since economy is for wide range of application... which large quantities of very diffe- the technology is still primarily based
moving upward. I kindly ask you to see page 4 rent shapes can be manufactured on experience. So in most cases
see for yourself and talk to our data the production of new profile sha-
M team and representatives. pes is not only associated with a
considerable design effort but also
means protracted trials and expe-
Yours sincerely riments during startup. The starting
Albert Sedlmaier, President product for shaped wire is very often
round or rectangular wire...
see page 9

data M info-forum Aug./2004

Newsletter of the data M Software + Engineering GmbH

COPRA MetalBender Tdi and COPRA MetalBender Analyseri

Sheet Metal Transitions

COPRA MetalBender TDi & MetalBender Analyseri for

The sheet metal working tech- Licensed sheet metalworking tech- and COPRA Metal-Bender TDi. from MetalBender Solver are imple-
nology integrated in Inventor comes nology By the way: i stands for Inventor mented, including the machine cor-
from data M Software GmbH in Everything changed for the appli- since we are still offering our appli- rection tables that are important
Valley located south of Munich. cation programmers too, including cations for AutoCAD or MDT tool. for many companies. Here a spe-
The sheet metal working software data M. Early in 1999, Autodesk cial-to-machine correction is deter-
specialist has been offering add- decided to license sheet metal Powerful flat pattern computation mined from the parameters metal
on applications for heating, ven- working technology from data M COPRA MetalBender Analyseri thickness, bending radius and open-
tilation and air-conditioning engi- for Inventor. Today data M is Auto- gives you powerful flat pattern com- ing angle. In addition, the elastic
neering and for extended flat pat- desks preferred provider of sheet puting capability for bent metal parts, recovery function produces the nec-
tern computation, thus closing a metal engineering functionality in
gap in the functionality of Inventor. Inventor. During the past years
of cooperation with Autodesk, data
Theres nothing so good that it M has left its imprint on the sheet
cant be bettered that also holds metal working solution in Inventor.
in the CAD sector. When Autodesk Starting with release 2, Inventor
hit the market some years ago with already offered a good, integrated
an entirely new 3D CAD system, sheet metalworking functionality
dealers and customers tended to that was continuously improved in
be skeptical. the releases that followed.

Because in the first place a new Consistent follow-on development

system means more work, you During the past 17 years, data
have to rethink your market strat- M concentrated on Autodesk plat-
egy, among other things, and you forms like AutoCAD and Mechanical
have to leave the well-beaten track Desktop for sheet metal working,
that you are used to this is new and won itself a good reputation
ground. in the sector for its consistent
follow-on development of these
A feeling of uncertainty comes sheet metal solutions.
about. After all, you do not yet know Thus the basic version of
Transition with added fastener
if the new product is going to make COPRA Metal Bender, SheetMetal
it on the market. Today nobody any Desktop, was sold in many coun-
longer doubts that Autodesks tries of Europe in the Mechanical enabling you to process rounded, essary overbend angle and radius
strategy was the right one. Desktop package. And data M sharp-edged or combined - round- for each bend by the Oehler-Sachs
focused the same consistency in ed and sharp-edged - bent metal or Bis-was formula. Given the high
its work on the sheet metal en- parts. A clear-view dialog allows -strength materials that are increas-
gineering functionality of Inventor. custom setting of computing meth- ingly being used and processed
Meanwhile data M Software is offer- ods, which can then be saved today, it is important to obtain a good,
Imprint ing its sheet metal applications for retrieval. To compute neutral theoretical estimate of the required
COPRA MetalBender Analyseri fibers, the processes familiar bending angle, because the

Software +
Engineering

data M Software GmbH

data M Engineering GmbH
Am Marschallfeld 17
D-83626 Valley/Oberlaindern
Germany
Phone: +49 80 24 / 6 40 - 0
Fax: +49 80 24 / 6 40 -300
e-mail: [email protected]
http://www.datam.de
data M Corporation
700 Commerce Drive, Suite 500
Oak Brook, IL 60523, USA
Circulation: 10,000 Sheet Metal Lofting - Model and flat pattern of a bearing block
COPRA MetalBender created by COPRA MetalBender Analyseri

data M info-forum Aug./2004 2

 Newsletter of the data M Software + Engineering GmbH

and Ductings for Inventor

Autodesks Inventor - from Autodesks preferred supplier

starting material is costly, and every is comparable to the standard loft-

piece of waste bites into the profit. ing function, but it allows better for
the specific requirements of the
Flat pattern ready for production parts. In every case a foldable and
The number of interpolation points thus bendable model is generated.
of cutting curves can be minimized And, of course, the generated tran-
and, if needed, transformed to tan- sitions can be further processed
gential transition radii, e.g. for laser by standard Inventor functions and
cutting. This produces optimal cut- Analyseri. Flat pattern - CMB Analyser ... and maximum
ting speed because the laser can calculates 3 layers: top, contour for
work at a virtually constant rate and Standard transitions bottem and centre layer... laser cutting
there is no more time-consuming Frequently used standard tran-
slowdown and acceleration. Corners sitions are particularly easy to gen-
and bending zones can be auto- erate. All combinations of circle,
matically reworked in different ways rectangle and rounded rectangles
so that you no longer have to sub- can be freely selected in the ex-
sequently modify the flat pattern. tremely clearly structured dialog
The pattern itself can be saved as box and then automatically cre-
a 2D drawing in a dxf file and trans- ated as bendable parts. Sharp-
ferred to production (nesting, punch- edged transitions can even be com-
ing, lasering). bined with rounded clips. Export of flat pattern in different formats - also for 5 axis laser cutting

SheetMetal Lofting Integrated workflow

In HVAC engineering you need The solutions fit seamlessly in- common systems at your disposal,
a whole variety of transitions, which to the Inventor workflow. It is irrel- e.g. Cybelec, Delem, DXF or TOPS.
can be generated with Inventor as evant whether flat pattern com- Plus, data M Software GmbH offers
a model purely theoretically by what putation from Inventor or COPRA powerful solutions for the simu-
is called lofting. But these models MetalBender is used for instance. lation and planning of bending
present two problems: computing For you, the user, the procedure stages in the process right
the flat pattern is not so straight- remains the same, only the result through to our laser-based angu-
forward and, if it can be generat- can look different because of the lar position measuring systems for
ed by appropriate add-on programs, extra possibilities. Thus the flat pat- bending presses, which are already
the potential for error is very large. tern of Analyseri appears in the win- in use with a whole number of
The reason is the structure of the dow of Inventor and offers the same OEM customers worldwide.
lofted model. data M consequently routine as the standard program.
decided against computing flat pat-
terns for transitions generated in Interfaces with production and bend-
this way. Instead there is a sep- ing simulation Please do not hesitate to get in
arate function for these parts called For data transfer to bending ma- touch with us if you are interest- Tool definition for tool dependent
SheetMetal Lofting. The procedure chines you have interfaces for all ed in more detailed information. correction factors

Model and sheet blank of an exhaust Automatic smoothing of sheet metal Automatic replacement of corners with
manifold using COPRA MetalBender TDi edges for laser cutting predefined punch tools

3 data M info-forum Aug./2004

Newsletter of the data M Software + Engineering GmbH

Sheet Metal Design for Mechanical Desktop MetalBender for AutoCAD

COPRA MetalBender for Mechanical CMB for

Desktop in practical use AutoCAD
in combination with Mechanical COPRA MetalBender is now
Desktop: available also for AutoCAD 2005
For their yearly company festi- and AIS 9.
vity they designed and manu-
factured a barbecue grill which defi-
nitely did its service (see photo-
graph).

Consistent software is our rus-

sian distributor for our sheet
metal software products. Consistent
Software is one of our COPRA
Our russian distributor Consistent Roll Form competence centers not
Software shows a practical exam- only re-selling our software pro-
Barbecue grill which was designed ple of how to use our COPRA ducts but also offering design- and
with COPRA MetalBender
MetalBender software - in this case consulting services.

COPRA LaserCheck - Perfect Bending on the First Try

Laser Sensor for Bending Machines

COPRA LaserCheck for Brakes, Folding Machines or Ring Rolling Machines

Data M is offering a device for ing bending. As the measurement More information on COPRA
press-brakes controlling bending is contact free there is no wear on LaserCheck and its working prin-
angles via laser COPRA Laser the system and it doesnt require ciple can be found on the inter-
Check. Variations in material thick- any maintenance. net at: http://lasercheck.datam.de
ness or tensile strength is affect- Up to four sensors can be linked
ing accuracy of press brake ben- to one COPRA LaserCheck sys-
Source: Weinbrenner, Germany ding drastically. Such kind of vari- tem. This allows producers of large
ations can vary from end to end as sheet metal parts to determine bend
well as from side to side. data M angle for the entire surface. Infor-
is offering a way out of this dilemma. mation like actual / target bend
data Ms COPRA LaserCheck comparison is transferred to the
determines the exact bending angle press brake controller. The bend-
for press brakes by a built-in semi- ing process can even be modified
conductor laser with line optics and required.
1/3CCD-camera-combined with Strain gauge force sensors are
Source: Accurpress, Canada a force detecting sensor. Bend being used with COPRA Laser Gauging Bending Angles on Folding
angle measurement is done by Check in order to determine the Machines
checking the lines projection on spring back. An additional meas- In order to allow an in-process
both sides of the part. The cam- urement amplifier transfers the force measurement also on folding
era which looks down on the parts data signal to the press brake con- machines a modified version of
surface measures the lines posi- troller during the bending process. COPRA LaserCheck with sepa-
tion and a recalculation of the bend The system is delivered fully wired rated laser and optical lens unit has
angle is made accordingly. The and calibrated. There are interfaces been developed. This unit oper-
press brakes control unit auto- for different control units available, ates with an operating disctance
matically corrects deviations dur- e.g. Cybelec, Delem. data M also of 800 mm and is installed on the
Source: Salvagnini, Italy offers customization to different con- front face of the machine. It is able
trollers. The range of use for data to gauge both bending angles
Ms LaserCheck system is a upward as well as downward. The
good more far-reaching than for accuracy achieved is +/- 0.2
press brakes. It has been adapt- degrees. In order to ease the inte-
ed for applications like tube bend- gration into the folding machines
ing, ring rolling or even quality con- control an analog signal is recallable
trol in the ceramic industry. We are in addition to the standard seri-
Source: Vimercati, Italy - Mounted on a looking forward to hearing about al interface (RS232) and network
Source: Finnpower, Finland press with hydraulic crowning your request on special use... connection (Ethernet).

data M info-forum Aug./2004 4

 Newsletter of the data M Software + Engineering GmbH

data M history data M history

A story of success 2002:

First presentation of a commer-
in roll form soft- cial high-end finite element
analysis software solution (non
ware development linear/ elasto plastic) for roll form-
ing: COPRA FEA RF based on
For more than 17 years, data M MARC/Mentat
Software has been focussing on
the analysis and simulation of 2003:
the roll forming process. This COPRA TQM (total quality ma-
started back in 1987 with a nagement) concept for design,
method for computing strip try-out, verification and in-pro-
edge elongation that has been cess quality control of roll tools.
further developed ever since: Large-scale industrial launch of
COPRA FEA RF (finite element
1986: analysis for roll forming). Improve-
First strip edge elongation com- ment of the analytical roll form
putation. analysis COPRA DTM by com-
Development of a descriptive putation of plastic strain values
process for roll formed sections in addition to the known profile
devised by Albert Sedlmaier on stress analysis.
the basis of Bezier curves of the
Loading a roll onto the scanning unit upper order (contribution to a 2004:
research project conducted at Presentation of a new version
the PtU, Darmstadt Institute of of COPRA FEA RF at Tube
COPRA RollScanner Production Engineering and Dsseldorf show with an inte-
Forming Machines). grated thermo mechanical
simulation of the roll forming and
The new generation of 1990:
First strip elongation computa-
welding process.

tion based on a wire-frame model

the COPRA RollScanner (Profile Strain Analysis - PSA). Opinions
1992:
...a new design concept of a roll tool scanning device - First presentation of a FEA (Finite Black Art?
solid built and highest accuracy Element Analysis) based roll form
analysis at Tube 2000 show in COPRA Roll Forming Software
COPRA RollScanner is an auto- production facilities. The COPRA Dsseldorf. data M internal re- has initiated deep interest amongst
matically working optical scanning RollScanner is able to scan all kind search project with an explicit all of us and has enabled us to
device for roll tooling. There is a of roll contours irrespective of its FEA approach (LS-Dyna 3D). learn more about the strategies
variety of possible applications in shape (corners, smallest or large Commencement of research and involved in roll forming.
the roll forming industry. It enables radii, jogs etc.) quickly, accurately development work with MARC/
the trouble shooting in roll form and automatically. Results are Mentat in coperation with PtU. Through the COPRA Roll For-
production (e.g. by scanning the stored in the data base and writ- Darmstadt. data M invests both ming Software, we have learnt
current roll tooling and using respec- ten to DXF- and MS Excel files . personnel and financial support that roll designing which was con-
tive geometric data in order to do The COPRA RollScanner is de- in this work in the following years. sidered as Black Arttill now is
a finite element analysis of the cur- signed for operation in rough indus- now made simple through the
rent production process), contin- trial environment. The rolls can be 1993: scientific approach. We would
uous quality control, rework of rolls handled either manually, by fork First introduction of an automatical love to know future developments
and also archiving of existing rolls lifter or crane. optical roll inspection system: in the COPRA Roll Forming
(e.g. in order to develop your own The Rollscanner reaches meas- COPRA RollScanner Software.
roll data base for retrieval during ured values of 1/100 mm (0.0004 Dr. P. Shanmugam
design or re-use existing rolls inches) accuracy and an optical 1995: Manager Corporate R&D
as blanks for turning new ones). resolution of 4 m. New is a hor- First presentation of an analyt- Tube Products of India
COPRA RollScanner can also izontal moveable (third) camera axis ical simulation model for the roll
digitise profile cross sections in (COPRA RollScanner Type 200-3) forming process - COPRA DTM
order to compare them with the which enables the Scanner to auto- (Deformation Dechnology Module)
Opinions
original CAD drawings. matically re-focus contour lines run- -taking into account parameters
Practical experience has shown ning out of the center plane. like roll diameter and material
that there is actually no alterna- Being a closed system the thickness. Tooling Costs
tive to COPRA RollScanner in the COPRA RollScanner is protected
application area of roll forming or against external influence of 2000: Since we have been optimis-
tube production. Meanwhile it has ambient light. It operates completely First Presentation of a commercial ing our rolls with COPRA DTM
been installed at a grown number free of vibration and is thanks finite element analysis roll form- (Deformation Tecnology Module)
of locations wordlwide some of to its solid granite block most- ing simulation solution (with a sim- we were able to reduce our tool-
our roll forming customers have ly resistant to thermal deforma- plified rigid plastic calculation ing costs drastically
even installed more than one of tion. Interested? model) at the Tube 2000 show Matjas Knez,
these inspection systems in order Visit our web site: in Dsseldorf. Alpos, Slowenia
to have access to at every of their http://rollscanner.datam.de

5 data M info-forum Aug./2004

Newsletter of the data M Software + Engineering GmbH

Quality Management in the Design of Roll Form Tooling

Development & Optimization of

How to get roll forming up and
deformation of the end-product due the shaping stations. Within a mat-
to, e.g. internal material strains. ter of seconds, this software pro-
Which takes us straight to the sub- gram computes the theoretical
ject of analysis and optimization (elastic as well as plastic) strains
software, presenting a whole lot on the material during forming as
of potential for remedying this sit- a function of influencing variables
uation. like profile cross-section geom-
To get cold roll forming up and etry, material gauge, roll config-
going with all its efficiency, you need uration and roll diameter (an essen-
to apply methods as early as the tial parameter in the forming
profile and tool design phase that process). In this way it is able to
can play a major role in improv- indicate where the material might
ing the quality of the rolled sec- be overstressed. This fast simu-
tion. lation program enables you to run
For some years now the firm data through a whole series of differ-
M Software GmbH, based in ent shaping variants, and to cor-
Bavaria, has been offering a vir- rect the drafted flower or number
tual process chain for the design of shaping stations and tool
To get roll forming up: and validation of roll sets in roll form- dimensions, as necessary, before
2) Design optimisation by COPRA Deformation Technology Module ing production. The COPRA RF starting the actual detailed work
3) Process verification by COPRA FEA RF (Roll Forming) software program or even production of the roll tools.
4) Analysis of current roll tooling by COPRA RollScanner
supports all steps in the devel-
opment of open or closed profile This is very time-saving, and it
Because of their large variety of driven rolls. Particular advan- cross-sections: from design of the reduces the risk of having to rework
applications, cold roll formed tages of this process are the vir- final cross-sections to be produced, the roll tools later at startup, or
parts have become increasingly tually unlimited variety of profile through definition of the various even having to make them afresh.
important in recent years, and made cross-sections, and the strain shaping steps (passes or flower) In many cases, the major cause
their way into whole new sectors hardening of the material that results to generation of technical docu- of poor profile quality is residual,
like automotive industry. The rea- from the shaping, which can be mentation (production drawings, local deformation of the sheet metal
sons for this include the introduction turned to good advantage - in many parts lists, CNC programs, etc), (internal strain) produced by
of new types of materials and cases. These are the benefits. But and later quality control of profile (mostly longitudinal) elongation dur-
improved forming capabilities like there are also drawbacks like, in cross-sections and
shaping on flexible roll forming lines. some instances, the time-con- roll tools.
Cold roll forming is seen as a high- suming design and production of The latter works
ly productive process for manu- roll tools, difficulties during instal- with optical instru-
facturing steel sections through con- lation of a new tool set and get- ments specially devel-
tinuous shaping of sheet steel by ting it into operation or unexpected oped for the appli-
cation (COPRA Roll
Scanner and COPRA
Laser Check). A multi-
stage concept speeds
up both the design
and the analytical
process, allowing for
the needs of the designer who COPRA DTM (Deformation Technology
wants to create a tool set fast, as Module) shows theoretical strain values
well as those of the production man- on the material during forming as a func-
ager interested in checking out the tion of influencing variables like profile
cross-section geometry, material gauge,
later roll forming process as early
roll configuration and roll diameter
as possible.

Fast simulation by deformation ing roll forming. In addition to the

analysis theoretical figures for such elon-
Taking the end-user's idea, a pro- gation on the top and/or under side
file flower is created by a draft pro- of the metal, COPRA DTM pre-
gram COPRAs profile design dicts how the figures are distrib-
COPRA DTM (Deformation Technology Module) is now able to show even theoret-
module. The resulting CAD data uted over the cross-section. Why
ical plastic strain values (permanent deformation added up over all forming steps)
on the material during forming as a function of influencing variables like profile goes into an analytical program this is so important is that there
cross-section geometry, material gauge, roll configuration and roll diameter. The COPRA DTM (Deformation is still much talk about so called
picture shows the plastic strain distribution on the top surface of the metal strip. Technology Module) to design strip edge elongation, even

data M info-forum Aug./2004 6

 Newsletter of the data M Software + Engineering GmbH

Cold Roll Forming Tool Sets

going with all its efficiency?
though the majority of profile cross- functions predict for the user the
sections that are produced are in ex-pected profile quality or mate-
fact stressed over their entire cross- rial properties. Both the ready pro-
section during roll forming. You file and the individual shaping steps
can see this effect very clearly in are pre-sented in three-dimen-
prepunched material. The holes sional, colour images.
punched before the material Visualization of defects means
goes onto the line are deformed that the empirical trials needed to
by the plastic elongations caused date and adjustments to the
by the roll stations. forming mill can be dispensed with
a new tool set is ready optimised
Once the design of the shaping in the design phase.
flower and details of the roll set
are firm, it is possible to gener- An entire finite element com-
ate the complete documentation putation cannot be performed with-
for making the rolls, i.e. sawing in a matter of minutes, even on
lists, production drawings and CNC today's high-speed computer
data, and to produce the roll tools. systems, so the dual-step solu-
After this, the tool is set up on the tion described here, i.e. advance
forming plant. Without the kind of optimisation by a fast computing
optimization of the shaping flower approach followed by validation COPRA FEA RF provides the roll tooling engineer with a lot of information allowing
described above, extensive set- of the complete tool set by the FE him to better understand to forming process.
tings and adjustments will usually method, has proven extremely suc-
be necessary on the plant, some- cessful in actual practice. COPRA
times even elementary modification FEA RF, however, provides the
of the tools, before a new section roll tooling engineer with a lot of
of the required quality comes off additional information allowing him
the line. Not so long ago, the only to better understand to forming
way to create a properly functioning process.
roll set was through practical tri- The practical benefits in the roll
als on the machine. forming of profiles go beyond
reduced running in times for a new
Today there is an alternative - tool set and enhanced process
a possibility of speeding up this control. The producer now derives
time-consuming and costly process significant expertise and experi-
getting a new roll forming tool set ence in the roll forming process,
into operation, and of avoiding putting him in a position to elim-
reworking of the tools altogeth- inate faults and problems in the
er - namely simulation by the finite leadup phase to new products. Virtual Roll Forming - Tryout Mill: COPRA FEA RF
element method (FEM).

FEM simulation of the roll FEA in Korea COPRA RF and AutoCAD

forming process
Once a roll set has been ready
designed, the data go into the FEM Korean Steel Roll Design and CAD
simulation program. COPRA
FEA RF (Finite Element Analysis supplier goes for seamlessly integrated
for Roll Forming) simulates the roll
forming process by a nonlinear, COPRA FEA RF Due to the complete integration All required data like drawings
elastoplastic form of computation. of COPRA RF in AutoCAD the or dxf-files for CNC programming
The user can forget questions like Korean steel supplier POSCO roll form designer gets a powerful are available at the press of a but-
definition of the finite element com- has recently purchased the sim- and effective tool for his job. There ton just for a single roll or the
puting model, discrete data for- ulation software COPRA FEA is actually no need to switch complete tool set. There is no need
mulation, selection of suitable ele- RF (Finite Element Analysis for between different applications like any more to grapple with both-
ment types or application of Roll Forming) in order to learn CAD program and calculation ersome repeating functions. An
boundary conditions. The software about roll forming process and modules. Flower- and roll tool lay- immense time saving for the tool
program fully integrated into the its influence on the material out are seamlessly integrated engineer.
COPRA process chain auto- behaviour. you can work on them just by Mike Stenbrock, roll form engineer,
matically considers these factors. mouse click. Wickede, Germany
A number of effective analytical

7 data M info-forum Aug./2004

Newsletter of the data M Software + Engineering GmbH

This article was published in

By J. Neiland Pennington, Executive Editor, Modern Metals Modern Metals August 2003.
Printed with permission of Modern Metals.

FEA RF replicates roll forming dynamics

New finite element analysis module for roll design software pinpoints potential forming problems,
and predicts actual strip shape at each roll stand. A virtual tooling tryout mill.

Finite element analysis is the lat- director of data M, ,,it took a month
est capability of COPRA design or two to produce a single result.
software for roll forming tools. The But the development of FEA RF
German firm, data M Software + has paralleled the progress in PCs.
Engineering GmbH, Valley/Ober- Todays computers provide analy-
laindern, Bavaria, is the origina- sis in a matter of hours or days,
tor of COPRA, the Computer Orien- depending on the complexity of
ted Profiling Assistant. That pro- the Job. The development of FEA
gram has a new module called RE included three years of in-house
FEA RF, which is a virtual tooling testing, using the software to ver-
tryout mill that tests roll designs ify the design of customer proj-
before any metal is turned. ects. But there was no end-user
The first generation of COPRA involvement during development
was introduced 16 years ago, about and no beta site testing, which
the time that IBM released its 286 could lead to convoluted software
series of personal computers. data that only the creators com-pre-
M began experiments with finite hended. data M dodged this pit-
element analysis programs in 1992, fall by enlisting an associate who
but the speed and capacity limita- was not a software engineer...
tions oft the earlier PCs put commer- (...continued)
cial FEA software ahead of its time. The article in its full length is avail-
FEA RF illustrates roll formed profiles as solid models and the forming rolls as wire frame ,,In the beginning, recalled able on our website:
projections so that the action of the rolls at the point of contact on the strip can be visualized. Albert Sedlmaier, co-managing http://www.datam.de/go/FEA1

This article was published in

By J. Neiland Pennington, Executive Editor, Modern Metals Modern Metals May 2004.
Printed with permission of Modern Metals.

Software module simulates tube welding

Roll form tooling design program is enhanced by an addition to its finite element analysis capability.

In August 2003, Modern Metals In the previous article we asked In data Ms welding simulation and analysis module, solid modeling illustrates the
introduced a finite element analy- Albert Sedlmaier, co-managing tube shape, and wire mesh drawings depict the weld pressure rolls.
The yellow dot on the tube seam is the point of heat application far laser welding.
sis upgrade for COPRA (Com- director of the Bavarian firm, if finite
puter-Oriented Profiling Assistant) element analysis was the final
roll form tooling design software. stage in the softwares develop-
Called COPRA FEA RF, the optio- ment. Sedlmaier assured us that
nal module models the dynamics it was not, that there were a num-
of roll forming, comparing the shape ber of avenues for expansion and
being produced to the original augmentation. He concluded with
flower pattern. With COPRA FEA this tantalizing comment: ,,Also writ-
RF, we said, a COPRA-equipped ten bold on our list (of enhanced
Computer becomes a virtual try- capabilities) is simulating the in-
out mill for testing and validating line welding of profiles.
roll designs. It is now a tool for The future is edging closer, as
modeling the. welding of tube, pipe visitors to the trade show Tube
and other closed profiles with a 2004 discovered at the end of
module that adds thermal analy- March in Dsseldorf. data Ms dis-
sis to the FEA RF capabilities. play featured the welding module
Welding simulation is the latest for COPRA, which adds ther-
development of software introduced modynamic prediction to COPRA
in l987 by data M Software + FEA RFs mechanical analysis.
Engineering GmbH, Valley/Oberlain- Sedlmaier stressed that the of our ongoing research and devel-
dem, Germany. COPRA began Tube 2004 demonstration did not opment, he said...
with an elementary strain analy- officially introduce the product, the (...continued)
sis capability for the strip edge and unnamed welding module has yet The article in its full length is avail-
has added sophistication over the to be released commercially. able on our website:
ensuing 17 years. ,,We presented it strictly as a view http://www.datam.de/go/FEA2

data M info-forum Aug./2004 8

 Newsletter of the data M Software + Engineering GmbH

New: COPRA Wire Forming

NEW - COPRA Wire Forming

Software Solution for Rolling of Wire Profiles

The history of wire goes back ting product for shaped wire is very The COPRA WF solution for wire rol- be expected can be verified in the
many centuries. The first step often round or rectangular wire. ling pursues three objectives: individual steps and the change
towards rationalization came in the Pro-ceeding from this geometry, in the material examined.
13th century when wire drawing the wire is turned into the re-qui- Interactive modeling of the form-
was invented, and straight away red final form in a number of rol- ing steps based on available expe-
used for military purposes. The coat ling passes. rience: the designer draws the form-
of mail, which until then only the ing steps and can put the areas
more well-to-do could purchase, So only the starting and finis- into the required percentage
became affordable for the simp- hing state of the wire is known. ratio with the aid of COPRA WF.
le warrior. Seeing as shaped wires very often Automatic layout of the form-
Today the production and forming have geometries with different radii, ing steps by specifying the start
of wire is an industrial process by calculating the intermediate sta- and end cross-section. Here it is
which large quantities of very dif- ges is a complex matter. In addi- possible to specify the degree of
ferent shapes can be manu- tion to the purely geometric forming and the estimated reduc- Example of a wire section
factured in a highly rationalized aspect, there are other factors that tion of the cross-section. with automatic calculated forming steps
manner. As with many other for- play a by no means negligible role. Verification of the
ming processes, the technology These include the fact that the design by finite ele-
is still primarily based on experi- material lengthens when it is for- ment simulation.
ence. So in most cases the pro- med, and can be very difficult to Forming is comput-
duction of new profile shapes is force into the border regions. Large ed based on roller
not only associated with a consi- deformations produce local strain geometry and the
derable design effort but also hardening, as a result of which start cross-section.
means protracted trials and expe- the material can become brittle The actual shape to
riments during startup. The star- and thus fissured.

We are not only offering software...

Roll Design Services Roll Tooling Analysis

Troubleshooting - Roll Tool Manufacturing and Set-Up
No experience in roll design? up to reworking your existing we are analysing the forming Simulation of wire forming with
No in-house capacity for roll tool or supplying you with new sets process in order to find out and COPRA FEA WF
engineering? Want to minimize of roll tooling. their causes:
machine down time during set up? As the leading engineering- and Analysis of existing forming and
You want to get a bit more software company for roll form too- shaping passes
independent from your machine ling our engineers have got the Analysis Report with sugges-
vendor? You want to profit from best tools for their business tions how to solve a problem FEA in Tubemaking
our expertise? - COPRA RF software. Get the actual geometry of
We design roll sets on request existing rolls by using our COPRA
- optimised and verified by our COPRA Roll Design Service RollScanner Process Problems
design- and simulation software We design rolls for all kinds of Compare the designed roll with
packages COPRA DTM/ COPRA tubes and open sections: the scanned roll (generating a The FEA analysis that data M
FEA RF. Design and conception of the so-called fingerprint diagram) performed for us allowed us to
We are analysing your exist- flower see a visual representation of
ing roll tool sets in order to im- Longitudinal strain check What you get is: the process problem we were
prove your production process. Check of material thickness A re-design of your flower pat- having, as well as providing a
Starting from your existing draw- during the roll forming process tern (if we have to derive the form- quantitative value to the stress-
ings or (even better) from your actu- (for subsequent processes like ing process from an existing tool set) es we were imparting to the prod-
al tooling by scanning the real roll hydro forming) An optimization of the flower uct. The visual representation
tooling by means of our COPRA Roll Design with COPRA DTM (Deformation was described by the machine
Roll Scanner, an optical roll Generation of drawings (dimen- Technology Module) Analysis. operator as exactly what Im
inspection device developed and sioned single rolls & assembly Of course, your data are treated seeing coming out of the mill.
being distributed also by data M. plans) confidentially. You will receive rolls This analysis showed us exactly
We are happy to assist you in Parts list, spacer lists, CNC pro- optimally designed for perfect pro- where in the process our prob-
troubleshooting in existing form- gramming, COPRA archive files etc. duction of your sections and tubes. lems were occurring.
ing problems. You will also get the full history
And last but not least: we are COPRA Roll Analysis Service of your designs for your files and Duffy Armstrong,
offering you the complete service We do not fight the symptoms but later reference. Webco Industries, USA

9 data M info-forum Aug./2004

Newsletter of the data M Software + Engineering GmbH

Seminar References Flexible Roll Forming

Flexible Roll
Technical Seminar Change to COPRA
A workshop on design and finite PVG, a german major custom
element analysis application in roll forming company has recent-
roll forming took place at data ly switched their roll design soft-
Ms office in Oberlaindern from ware to COPRA RF. - A future industrial production
March 3 to 5, 2004. There were Main reason for this decision
39 customers from Europe, Asia to change the software supplier
and Africa joining this 3 day event. was data Ms continious software
For dates and venues of simi- developement as well as data Ms
lar events look at: TQM philosophy (total quality
www.datam.de/go/events management in the design of roll
tooling) consisting of design
(COPRA roll design software),
optimisation (COPRA DTM -
Deformation Technology Module),
verification (COPRA FEA RF)
and quality control (COPRA flexible roll forming 1st experimental
RollScanner). setup (source PtU)

Usually roll formed sections or

Chairmanship References tubes have a constant longitudi-
nal cross-section.
Certain areas of application like
International Roll-Kraft goes for the automotive industry have shown
a demand on profiles with vari-
Tube Association COPRA FEA RF able cross-sections. However, the Computer control unit for flexible roll
use of roll forming for varying cross- forming (source: data M Engineering)
re-elects chairman Roll-Kraft, USA, has continued sections has not (yet) led to an
to develop new products and industrial application. Since a typ- design- and engineering tools
At ITAs 24th annual general methods to strengthen its posi- ical car chassis has only a few respectively.
meeting during Tube Dsseldorf tion over the years. The latest straight cross-sections with con- One project undertaken is the
exhibition in April 2004, Albert innovation to be added is stant shape throughout this situ- development of a flexible roll form-
Sedlmaier, managing director at COPRA FEA RF - data Ms soft- ation is disappointing for the auto- ing process which data M Software
data M Software + Engineering, ware for finite element simula- motive industry. and Engineering GmbH has been
was re-elected as chairman of tion of the roll forming process. The current production- and supporting actively as well as finan-
the association. In 2003 he suc- This technology allows tooling assembly methods (e.g. deep cially. The project was performed
ceeded Professor Manabu Kiuchi designs to be tested on the com- drawing or composite construc- at the Institute for Production
(Japan) who was elected as new puter before they are manu- tions) for such kind of components Engineering and Forming Machines
president of ITA. factured - a major step forward are comparatively costly. Profiles PtU of Technical University of
The International Tube Associa- for the industry. or longitudinal components with Darmstadt. Longitudinally variable
tion has got the worlds largest variable cross-sections would profiles can be produced by
membership of tube&pipe engi- Roll-Kraft Press Release be able to substitute such com- means of a flexible forming sta-
neers. Tube & Pipe Technology 7/8 04. posite constructions. Thus it will tion with movable motor-driven roll
be really interesting to see what tools.
Tube Russia 2004 in Moscow kind of future applications for roll The complete control unit (soft-
ITA Chairman Albert Sedlmaier References formed sections with longitudinally ware and motor drives) of the flex-
had the honour of officiating at variable cross-sections will result ible forming station was developed
the opening ceremony alongside 10 years COPRA - if there was a way to produce and supplied by data M Engineering
Sergey Mitin, Russian Minister them in an economic way by while data M Software simulated
for Industry and Energy. Thanks for 10 years of coop- means of roll forming. the forming process using an
Mr Sedlmaier also made a short eration with data M and usage data M has been joining research- enhanced version of its COPRA
speech before the tape ceremony. of the excellent COPRA Roll and development projects for flex- FEA RF software package.
Forming program. ible forming in order to develop Currently data M is developing a
Please refer to our web site at:
http://www.datam.de/go/tube-russia Lars-Gunnar Sderlind, Avesta Polarot open profiles
Stainless Tube, Sweden

How Roll Designs hat-type profiles

should be... closed profiles

The roll design supplied by data

M is as a roll design should be!

Pictured at the tape cutting ceremony Johann Breytenbach,

are Mr Sedlmaier (far left)
Bosal Afrika The production of a complete part family with a single tool system:
and Mr Mitin (far right)
Flexible Roll Forming (source: PtU)

data M info-forum Aug./2004 10

 Newsletter of the data M Software + Engineering GmbH

Forming and Slide-Draw-Bending

method for profiles with variable cross sections.
6-axis flexible roll forming stand order to form a variable cross sec- idea
- based on its extensive know-how tion (see photograph).
height
in parallel kinematics (COPRA Interested in more information? height and width
variation variation
Hexapod Robot). Or interested in developing an width variation
industrial application for such a
Another project is the develop- flexible forming processes?
ment of a totally new slide- In cooperation with our partners
draw-bending process for pro- we are able to develop and sup-
files with longitudinally vari- ply flexible manufacturing com- realisation
able cross-sections, per- ponents starting with theoreti-
formed at the Institute of cal analysis (finite element sim-
Forming Technology ulation of the forming processes load-matching profiles
IFUM (University of and evaluation of material prop-
longitudinely
Hannover) where erties) , computerized control equip- variable
data M is also part ment (flexible forming stands and cross-section

Finite Element Analysis of the industrial motor drives) and tool design.
slide-draw-bending concept (source: IFUM)
of the flexible roll forming process consortium. The
slide-draw-bend- We would be pleased if you get
ing process uses in touch with us.
a split flexible
motor driven die in

fixed dies
work piece

draw-bending Flexible slide-draw-bending die divided in

(according Neubauer, Bogojawlenskij, Ris) a left and right section; (source: IFUM)

Die moveable dies:

(second forming step) left section
right section
Die
(first forming step)
drawing direction
work piece

drive motor
hydraulic cylinder bed plate
Flexible slide-draw-bending die experimental setup; (source: IFUM)

11 data M info-forum Aug./2004

 Newsletter of the data M Software + Engineering GmbH

data M offers all kinds of Autodesks CAD software products bundled with COPRA software Exhibitions and seminars

next shows...
data M Software GmbH
your single source supplier for Autodesk software products! Tube China 2004
China International Tube & Pipe Trade Fair
22th - 25th September Shanghai, China
Unique Solutions from tribution channel if the end COPRA RF (Roll Forming) Please ask us for more
one supplier! data M is user needs specific tech- software or COPRA Metal details.
EuroBLECH 2004
offering all Autodesk nical support.In many Bender is being offered Intern. Sheet Metal Working Techn. Exhibition
CAD products bundled cases a typical Autodesk in a bundle with AutoCAD, Autodesk appoints data 26th - 30th October Hanover, Germany
with its COPRA software dealer doesnt have the AutoCAD Mechanical, Me- M as MAI Partner world-
solutions worldwide. specific know how on sub- chanical Desktop or Inventor. wide. Metalex 2004
international machine tools exhibition
jects like metal bending
18th - 21st November Bangkok, Thailand
And even more: in addi- or roll forming. In addition to this UAR Since 2003 data M has been
tion to data Ms direct sup- programme we are con- appointed as a new mem- More information about data Ms activities can
port you are still having As an UAR Partner data tinuing to offer as a very ber of Auto-desks MAI be found on the internet at:
access to Autodesks M Software GmbH is now attractive alternative for (Mechanical Applications
support and sales chan- able to bundle its software our roll forming and tub- Initiative) partner program http://www.datam.de/en/shows-press
nels. products with respective ing software COPRA RF in the area of sheet metal
basic software platform in combination with a application.
data M Software GmbH from Autodesk and offer standalone option which
resellers and solution providers
is one of Autodesks UAR you a complete solution. is nothing else than an This is a further credit Au-
Partner. UAR stands for If you wish we are able AutoCAD OEM version todesk gives to the quality find a reseller
Unique Application Resel- to provide you with sup- (the COPRA RF software of data Ms software pro-
ler and allows Autodesks port from one single comes with AutoCAD ducts as already 4 years or solution
strategic developers to source. already included). This ago data M Software GmbH
bundle their applications option is tailored to end- was selected as Autodesks provider...
with any Autdesk software This is especially of impor- users who do not need to preferred supplier of sheet at
product. This partner pro- tance if the application is do extensive CAD designs metal technology and http://www.datam.de/go/dealer
gram is a real alternative an essential component beyond the typical COPRA validation in Inventor.
to Autodesks normal dis- of the complete solution. roll design operations.

Contact

We would like to hear from you!

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Engineering
Name
I would like to know more about the COPRA RollForm software
COPRA RollForm Software
COPRA Finite Element Analysis Company

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COPRA Roll Design and Analysis Service

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COPRA MetalBender

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data M Academy Training Center

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COPRA RollScanner
data M Engineering design of special-purpose machines e-mail

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data M info-forum Aug./2004