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data M info-forum Aug./2004

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

Newsletter of the data M Software + Engineering GmbH

Foreword

Dear reader,This issue of our

info-forum has

taken long in coming. However, I

believe waiting was worth while.

Despite the poor worldwide eco-

nomic constraints in the past we

havnt lost our optimism and con-

tinued in our product development

and research activities.This issue of info-Forum covers:

COPRA MetalBender software(interfaces for TOPS and Cybelec)

Improved COPRA LaserCheckbending angle sensor

COPRARoll Form software pack-age in a new version with some in-

teresting new features like the pos-

sibility to evaluate even plastic

strain values using COPRA DTM

COPRA RollScanner now avail-able with an additional 3rd axis

data M is presenting you two

new flexible forming methods forlongitudinally variable profiles

COPRAFEA RF - data Ms finiteelement analysis software for the

roll forming process has been intro-

duced successfully to industry. It

makes the user understand the roll

forming process and helps to devel-

op new and more complex prod-

ucts. This is important in view of

new high strength material and the

growing demands from industry

data M is also offering consultingand design services. A trial order

will convince you last but not least: data M is offer-ing a totally new software product -

COPRAWF (Wire Forming) for the

design and manufacture of wire

rolling tools

I am sure that our developments areable to give you some suggestionsfor your business since economy ismoving upward. I kindly ask you tosee for yourself and talk to our dataM team and representatives.

Yours sincerelyAlbert Sedlmaier, President

COPRA MetalBender

COPRA MetalBender TDi & Metal BenderAnalyseri for Autodesks Inventor, MechanicalDesktop andAutoCADsee page 2

COPRA Wire Forming

Software for Sheet Metal

Design and Unfolding

Flexible Forming

Flexible Forming

of Profiles -

COPRA LaserCheck

data Ms Laser Triangulation Probefor wide range of application...see page 4

Laser Sensor forPress Brakes andfolding machines

New: Software Solution for

Rolling of Wire Profiles

Today the production and formingof wire is an industrial process bywhich large quantities of very diffe-rent shapes can be manufactured

in a highly rationalized manner. Aswith many other forming processes,the technology is still primarily basedon experience. So in most casesthe production of new profile sha-pes is not only associated with aconsiderable design effort but alsomeans protracted trials and expe-

riments during startup. The startingproduct for shaped wire is very oftenround or rectangular wire...see page 9

COPRA Roll Forming

Development & Optimization of

Roll Forming Tool SetsFor some years now the firm data MSoftware GmbH, based in Bavaria,has been offering a virtual process

chain for the design and validationof roll sets in roll forming producti-on. The COPRA RF (Roll Forming)software program supports allsteps in the development of openor closed profile cross-sections: fromdesign of the final cross-sections tobe produced, through definition ofthe various shaping steps (passesor flower) to generation of...see page 6

Usually roll formed sections or tubeshave a constant longitudinal cross-section...see page 11

Content:Sheet Metal Bending

Sheet Metal Transitions and Ductings for Inventor ........P. 2 /3

COPRA MetalBender for MDT in practical use ............P. 4

Laser Sensor for Bending Machines..............................P. 4

CMB for AutoCAD ..........................................................P. 4

Roll Forming

The new generation of the COPRA RollScanner ........P. 5

data M - a success story in roll forming ........................P. 5

COPRA RF software in India and Slowenia ................P. 5

Development& Optimization of Cold Roll Forming Tool Sets P. 6

Korean Steel supplier goes for COPRA FEA RF..........P. 7

COPRA

RF and AutoCAD ............................................P. 7FEA RF replicates roll forming dynamics ......................P. 8

Software module simulates tube welding ......................P. 8

New: COPRA Wire Forming ........................................P. 9

Roll DesignServices-we arenot only offeringsoftware....P. 9

COPRA FEA RF and Webco, USA ..............................P. 9

Technical Seminar on roll form analysis at data M ........P. 10

International Tube Association re-elects chairman ........P. 10

PVG switched their roll design software to COPRA RF....P. 10

Roll-Kraft goes for COPRA FEA RF ............................P. 10

10 years COPRA at Avesta ..........................................P. 10

Roll design services for Bosal Africa..............................P. 10

Flexible Roll Forming and Slide-Draw-Bending ............P. 10

Autodesk software products from data M ......................P. 12

data M live: exhibitions and seminars ............................P. 12

data Ms resellers - worldwide........................................P. 12

Response Form - We would like to hear from you ........P. 12


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starting material is costly, and everypiece of waste bites into the profit.

Flat pattern ready for productionThe number of interpolation points

of cutting curves can be minimizedand, if needed, transformed to tan-gential transition radii, e.g. for lasercutting. This produces optimal cut-ting speed because the laser can

work at a virtually constant rate andthere is no more time-consumingslowdown and acceleration. Cornersand bending zones can be auto-matically reworked in different waysso that you no longer have to sub-sequently modify the flat pattern.The pattern itself can be saved asa 2D drawing in a dxf file and trans-ferred to production (nesting, punch-ing, lasering).

SheetMetal LoftingIn HVAC engineering you need

a whole variety of transitions, which

can be generated with Inventor asa model purely theoretically by whatis called lofting. But these modelspresent two problems: computingthe flat pattern is not so straight-forward and, if it can be generat-ed by appropriate add-on programs,the potential for error is very large.The reason is the structure of thelofted model. data M consequentlydecided against computing flat pat-terns for transitions generated inthis way. Instead there is a sep-arate function for these parts calledSheetMetal Lofting. The procedure

is comparable to the standard loft-ing function, but it allows better forthe specific requirements of theparts. In every case a foldable andthus bendable model is generated.And, of course, the generated tran-sitions can be further processedby standard Inventor functions andAnalyseri.

Standard transitionsFrequently used standard tran-sitions are particularly easy to gen-erate. All combinations of circle,rectangle and rounded rectanglescan be freely selected in the ex-tremely clearly structured dialogbox and then automatically cre-ated as bendable parts. Sharp-edged transitions can even be com-bined with rounded clips.

Integrated workflowThe solutions fit seamlessly in-

to the Inventor workflow. It is irrel-

evant whether flat pattern com-putation from Inventor or COPRA

MetalBender is used for instance.For you, the user, the procedureremains the same, only the resultcan look different because of theextra possibilities. Thus the flat pat-tern of Analyseri appears in the win-dowof Inventor and offers the sameroutine as the standard program.

Interfaces with production and bend-ing simulation

For data transfer to bending ma-chines you have interfaces for all


and Ductings for InventorAutodesks Inventor - from Autodesks preferred supplier

Tool definition for tool dependent

correction factors

Model and sheet blank of an exhaust

manifold using COPRA MetalBender TDi

Export of flat pattern in different formats - also for 5 axis laser cutting

Automatic replacement of corners with

predefined punch tools

Flat pattern - CMB Analyser

calculates 3 layers: top,

bottem and centre layer...

Automatic smoothing of sheet metal

edges for laser cutting

common systems at your disposal,e.g. Cybelec, Delem, DXF or TOPS.

Plus, data M Software GmbH offerspowerful solutions for the simu-lation and planning of bendingstages in the process rightthrough to our laser-based angu-lar position measuring systems forbending presses, which are alreadyin use with a whole number ofOEM customers worldwide.

Please do not hesitate to get intouch with us if you are interest-ed in more detailed information.

... and maximum

contour for

laser cutting


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in combination with MechanicalDesktop:

For their yearly company festi-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 sheetmetal software products. ConsistentSoftware is one of our COPRA

Roll Form competence centers not

only re-selling our software pro-ducts but also offering design- andconsulting services.

Sheet Metal Design for Mechanical Desktop MetalBender for AutoCAD

COPRA MetalBender is nowavailable also for AutoCAD 2005and AIS 9.

CMB for

AutoCAD


Laser Sensor for Bending MachinesCOPRA LaserCheck for Brakes, Folding Machines or Ring Rolling Machines

Data M is offering a device for

press-brakes controlling bendingangles via laser COPRA LaserCheck. Variations in material thick-ness or tensile strength is affect-ing accuracy of press brake ben-ding drastically. Such kind of vari-ations can vary from end to end aswell as from side to side. data Mis offering a way out of this dilemma.

data Ms COPRA LaserCheckdetermines the exact bending anglefor press brakes by a built-in semi-conductor laser with line optics and1/3CCD-camera-combined witha force detecting sensor. Bend

angle measurement is done bychecking the lines projection onboth sides of the part. The cam-era which looks down on the partssurface measures the lines posi-tion and a recalculation of the bendangle is made accordingly. Thepress brakes control unit auto-matically corrects deviations dur-

ing bending. As the measurement

is contact free there is no wear onthe system and it doesnt requireany maintenance.

Up to four sensors can be linkedto one COPRA LaserCheck sys-tem. This allows producers of largesheet metal parts to determine bendangle for the entire surface. Infor-mation like actual/ target bendcomparison is transferred to thepress brake controller. The bend-ing process can even be modifiedrequired.

Strain gauge force sensors arebeing used with COPRA Laser

Check in order to determine thespring back. An additional meas-urement amplifier transfers the forcedata signal to the press brake con-troller during the bending process.The system is delivered fully wiredand calibrated. There are interfacesfor different control units available,e.g. Cybelec, Delem. data M alsooffers customization to different con-trollers. The range of use for dataMs LaserCheck system is agood more far-reaching than forpress brakes. It has been adapt-ed for applications like tube bend-

ing, ring rolling or even quality con-trol in the ceramic industry. We arelooking forward to hearing aboutyour request on special use...

COPRA LaserCheck - Perfect Bending on the First Try

Source: Accurpress, Canada

Our russian distributor Consistent

Software shows a practical exam-ple of how to use our COPRA

MetalBender software - in this case

Barbecue grill which was designed

with COPRA MetalBender

Source: Weinbrenner, Germany

More information on COPRA

LaserCheck and its working prin-ciple can be found on the inter-net at: http://lasercheck.datam.de

Gauging Bending Angles on Folding

MachinesIn order to allow an in-process

measurement also on foldingmachines a modified version ofCOPRA LaserCheck with sepa-rated laser and optical lens unit hasbeen developed. This unit oper-ates with an operating disctanceof 800 mm and is installed on thefront face of the machine. It is ableto gauge both bending angles upward as well as downward. Theaccuracy achieved is +/- 0.2degrees. In order to ease the inte-gration into the folding machines

control an analog signal is recallable in addition to the standard seri-al interface (RS232) and networkconnection (Ethernet).

data M info-forum Aug./2004 4

Source: Salvagnini, Italy

Source: Finnpower, Finland

Source: Vimercati, Italy - Mounted on a

press with hydraulic crowning

COPRAMetalBender for Mechanical

Desktop in practical use


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data M history

For more than 17 years, data MSoftware has been focussing onthe analysis and simulation ofthe roll forming process. Thisstarted back in 1987 with amethod for computing stripedge elongation that has beenfurther developed ever since:

1986:First strip edge elongation com-putation.Development of a descriptiveprocess for roll formed sections

devised by Albert Sedlmaier onthe basis of Bezier curves of theupper order (contribution to aresearch project conducted atthe PtU, Darmstadt Institute ofProduction Engineering andForming Machines).

1990:First strip elongation computa-tion based on a wire-frame model(Profile Strain Analysis - PSA).

1992:First presentation of a FEA(Finite

Element Analysis) based roll formanalysis at Tube 2000 show inDsseldorf. data M internal re-search project with an explicitFEA approach (LS-Dyna 3D).Commencement of research anddevelopment work with MARC/Mentat in coperation with PtU.Darmstadt. data M invests bothpersonnel and financial supportin this work in the following years.

1993:First introduction of an automaticaloptical roll inspection system:

COPRA

RollScanner

1995:First presentation of an analyt-ical simulation model for the rollforming process - COPRA DTM(Deformation Dechnology Module)-taking into account parameterslike roll diameter and materialthickness.

2000:First Presentation of a commercialfinite element analysis roll form-ing simulation solution (with a sim-

plified rigid plastic calculationmodel) at the Tube 2000 showin Dsseldorf.

data M history

A story of success

in roll form soft-

ware development



production facilities. The COPRA

RollScanner is able to scan all kindof roll contours irrespective of itsshape (corners, smallest or largeradii, jogs etc.) quickly, accuratelyand automatically. Results arestored in the data base and writ-ten to DXF- and MS Excel files .

The COPRA RollScanner is de-signed for operation in rough indus-trial environment. The rolls can behandled either manually, by forklifter or crane.

The Rollscanner reaches meas-ured values of 1/100 mm (0.0004inches) accuracy and an opticalresolution of 4 m. New is a hor-izontal moveable (third) camera axis(COPRA RollScanner Type 200-3)which enables the Scanner to auto-matically re-focus contour lines run-ning out of the center plane.

Being a closed system theCOPRA RollScanner is protectedagainst external influence ofambient light. It operates completelyfree of vibration and is thanksto its solid granite block most-

ly resistant to thermal deforma-tion. Interested?Visit our web site:http://rollscanner.datam.de

COPRA RollScanner

COPRA RollScanner is an auto-maticallyworking optical scanningdevice for roll tooling. There is avariety of possible applications inthe roll forming industry. It enablesthe trouble shooting in roll formproduction (e.g. by scanning thecurrent roll tooling and using respec-tive geometric data in order to doa finite element analysis of the cur-rent production process), contin-uousquality control, rework of rollsand also archiving of existing rolls

(e.g. in order to develop your ownroll data base for retrieval duringdesign or re-use existing rollsas blanks for turning new ones).COPRA RollScanner can alsodigitise profile cross sections inorder to compare them with theoriginal CAD drawings.

Practical experience has shownthat there is actually no alterna-tive to COPRA RollScanner in theapplication area of roll forming ortube production. Meanwhile it hasbeen installed at a grown numberof locations wordlwide some of

our roll forming customers haveeven installed more than one ofthese inspection systems in orderto have access to at every of their

The new generation of

the COPRARollScanner...a new design concept of a roll tool scanning device -

solid built and highest accuracy

Opinions

Black Art?COPRA Roll Forming Software

has initiated deep interest amongstall of us and has enabled us tolearn more about the strategiesinvolved in roll forming.

Through the COPRA Roll For-ming Software, we have learntthat roll designing which was con-sidered as Black Arttill now isnow made simple through thescientific approach. We wouldlove to know future developmentsin the COPRA Roll Forming

Software.Dr. P. Shanmugam

Manager Corporate R&D

Tube Products of India

Opinions

Tooling CostsSince we have been optimis-

ing our rolls with COPRA DTM(Deformation Tecnology Module)we were able to reduce our tool-

ing costs drasticallyMatjas Knez,

Alpos, Slowenia

Loading a roll onto the scanning unit

2002:First presentation of a commer-cial high-end finite elementanalysis software solution (nonlinear/ elasto plastic) for roll form-ing: COPRA FEARF based onMARC/Mentat

2003:COPRA TQM (total quality ma-nagement) concept for design,try-out, verification and in-pro-cess quality control of roll tools.Large-scale industrial launch ofCOPRA FEARF (finite elementanalysis for roll forming). Improve-ment of the analytical roll formanalysis COPRADTM by com-putation of plastic strain valuesin addition to the known profile

stress analysis.

2004:Presentation of a new versionof COPRA FEA RF at TubeDsseldorf show with an inte-grated thermo mechanicalsimulation of the roll forming andwelding process.


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the shaping stations. Within a mat-ter of seconds, this software pro-gram computes the theoretical(elastic as well as plastic) strainson the material during forming asa function of influencing variableslike profile cross-section geom-etry, material gauge, roll config-uration and roll diameter (an essen-tial parameter in the formingprocess). In this way it is able to

indicate where the material mightbe overstressed. This fast simu-lation program enables you to runthrough a whole series of differ-ent shaping variants, and to cor-rect the drafted flower or numberof shaping stations and tooldimensions, as necessary, beforestarting the actual detailed workor even production of the roll tools.

This is very time-saving, and itreduces the risk of having to reworkthe roll tools later at startup, oreven having to make them afresh.

In many cases, the major causeof poor profile quality is residual,local deformation of the sheet metal(internal strain) produced by(mostly longitudinal) elongation dur-

ing roll forming. In addition to thetheoretical figures for such elon-gation on the top and/or under sideof the metal, COPRA DTM pre-dicts how the figures are distrib-

uted over the cross-section. Whythis is so important is that thereis still much talk about so calledstrip edge elongation, even

driven rolls. Particular advan-tages of this process are the vir-tually unlimited variety of profile

cross-sections, and the strainhardening of the material that resultsfrom the shaping, which can beturned to good advantage - in manycases. These are the benefits. Butthere are also drawbacks like, insome instances, the time-con-suming design and production ofroll tools, difficulties during instal-lation of a new tool set and get-ting it into operation or unexpected


Because of their large variety ofapplications, cold roll formedparts have become increasingly

important in recent years, and madetheir way into whole new sectorslike automotive industry. The rea-sons for this include the introductionof new types of materials andimproved forming capabilities likeshaping on flexible roll forming lines.Cold roll forming is seen as a high-ly productive process for manu-facturing steel sections through con-tinuous shaping of sheet steel by

deformation of the end-product dueto, e.g. internal material strains.Which takes us straight to the sub-ject of analysis and optimizationsoftware, presenting a whole lotof potential for remedying this sit-uation.

To get cold roll forming up andgoing with all its efficiency, you needto apply methods as early as theprofile and tool design phase that

can play a major role in improv-ing the quality of the rolled sec-tion.

For some years now the firm dataM Software GmbH, based inBavaria, has been offering a vir-tual process chain for the designand validation of roll sets in roll form-ing production. The COPRA RF(Roll Forming) software programsupports all steps in the devel-opment of open or closed profilecross-sections: from design of thefinal cross-sections to be produced,through definition of the various

shaping steps (passes or flower)to generation of technical docu-mentation (production drawings,parts lists, CNC programs, etc),and later quality control of profilecross-sections androll tools.

The latter workswith optical instru-ments specially devel-oped for the appli-cation (COPRA RollScanner and COPRA

Laser Check). Amulti-stage concept speeds

up both the designand the analyticalprocess, allowing forthe needs of the designer whowants to create a tool set fast, aswell as those of the production man-ager interested in checking out thelater roll forming process as earlyas possible.

Fast simulation by deformationanalysis

Taking the end-user's idea, a pro-file flower is created by a draft pro-gram COPRAs profile design

module. The resulting CAD datagoes into an analytical program COPRA DTM (DeformationTechnology Module) to design

To get roll forming up:

2) Design optimisation by COPRA Deformation Technology Module

3) Process verification by COPRA FEA RF

4)Analysis of current roll tooling by COPRA RollScanner

COPRA DTM (Deformation Technology

Module) shows theoretical strain values

on the material during forming as a func-

tion of influencing variables like profile

cross-section geometry, material gauge,

roll configuration and roll diameter

Quality Management in the Design of Roll Form Tooling

Development & Optimization ofHow to get roll forming up and

COPRA

DTM (Deformation Technology Module) is now able to show even theoret-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

cross-section geometry, material gauge, roll configuration and roll diameter. The

picture shows the plastic strain distribution on the top surface of the metal strip.



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Cold Roll Forming Tool Setsgoing with all its efficiency?

though the majority of profile cross-sections that are produced are infact stressed over their entire cross-section during roll forming. Youcan see this effect very clearly inprepunched material. The holespunched before the materialgoes onto the line are deformedby the plastic elongations causedby the roll stations.

Once the design of the shapingflower and details of the roll setare firm, it is possible to gener-ate the complete documentationfor making the rolls, i.e. sawinglists, production drawings and CNCdata, and to produce the roll tools.After this, the tool is set up on theforming plant. Without the kind ofoptimization of the shaping flowerdescribed above, extensive set-tings and adjustments will usuallybe necessary on the plant, some-times even elementary modificationof the tools, before a new section

of the required quality comes offthe line. Not so long ago, the onlyway to create a properly functioningroll set was through practical tri-als on the machine.

Today there is an alternative -a possibility of speeding up thistime-consuming and costly processgetting a new roll forming tool setinto operation, and of avoidingreworking of the tools altogeth-er - namely simulation by the finiteelement method (FEM).

FEM simulation of the rollforming process

Once a roll set has been readydesigned, the data go into the FEMsimulation program. COPRA

FEARF (Finite Element Analysisfor Roll Forming) simulates the rollforming process by a nonlinear,elastoplastic form of computation.The user can forget questions likedefinition of the finite element com-puting model, discrete data for-mulation, selection of suitable ele-ment types or application ofboundary conditions. The software

program fully integrated into theCOPRA process chain auto-matically considers these factors.

A number of effective analytical

functions predict for the user theex-pected profile quality or mate-rial properties. Both the ready pro-file and the individual shaping stepsare pre-sented in three-dimen-sional, colour images.

Visualization of defects meansthat the empirical trials needed todate and adjustments to theforming mill can be dispensed with a new tool set is ready optimised

in the design phase.

An entire finite element com-putation cannot be performed with-in a matter of minutes, even ontoday's high-speed computersystems, so the dual-step solu-tion described here, i.e. advanceoptimisation by a fast computingapproach followed by validationof the complete tool set by the FEmethod, has proven extremely suc-cessful in actual practice. COPRA

FEA RF, however, provides theroll tooling engineer with a lot of

additional information allowing himto better understand to formingprocess.

The practical benefits in the rollforming of profiles go beyondreduced running in times for a newtool set and enhanced processcontrol. The producer now derivessignificant expertise and experi-ence in the roll forming process,putting him in a position to elim-inate faults and problems in theleadup phase to new products.

FEA in Korea

Korean Steel

supplier goes for

COPRA FEA RFKorean steel supplier POSCO

has recently purchased the sim-ulation software COPRA FEARF (Finite Element Analysis forRoll Forming) in order to learnabout roll forming process and

its influence on the materialbehaviour.

COPRA FEA RF provides the roll tooling engineer with a lot of information allowing

him to better understand to forming process.

Virtual Roll Forming - Tryout Mill: COPRA FEA RF



COPRA RF and AutoCAD

Roll Design and CAD

seamlessly integratedDue to the complete integration

of COPRA RF in AutoCAD theroll form designer gets a powerfuland effective tool for his job. Thereis actually no need to switchbetween different applications likeCAD program and calculationmodules. Flower- and roll tool lay-

out are seamlessly integrated you can work on them just bymouse click.

All required data like drawingsor dxf-files for CNC programmingare available at the press of a but-ton just for a single roll or thecomplete tool set. There is no needany more to grapple with both-ersome repeating functions. Animmense time saving for the tool

engineer.Mike Stenbrock, roll form engineer,

Wickede, Germany


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of our ongoing research and devel-opment, he said...

(...continued)The article in its full length is avail-able on our website:http://www.datam.de/go/FEA2



FEA RF replicates roll forming dynamicsNew 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.

director of data M, ,,it took a monthor two to produce a single result.But the development of FEARFhas paralleled the progress in PCs.Todays computers provide analy-sis in a matter of hours or days,depending on the complexity ofthe Job. The development of FEARE included three years of in-housetesting, using the software to ver-ify the design of customer proj-ects. But there was no end-user

involvement during developmentand no beta site testing, whichcould lead to convoluted softwarethat only the creators com-pre-hended. data M dodged this pit-fall by enlisting an associate whowas not a software engineer...(...continued)The article in its full length is avail-able on our website:http://www.datam.de/go/FEA1

By J. Neiland Pennington, Executive Editor, Modern Metals

Finite element analysis is the lat-est capability of COPRA designsoftware for roll forming tools. TheGerman firm, data M Software +Engineering GmbH, Valley/Ober-laindern, Bavaria, is the origina-tor of COPRA, the Computer Orien-ted Profiling Assistant. That pro-gram has a new module calledFEARF, which is a virtual toolingtryout mill that tests roll designsbefore any metal is turned.

The first generation of COPRA

was introduced 16 years ago, aboutthe time that IBM released its 286series of personal computers. dataM began experiments with finiteelement analysis programs in 1992,but the speed and capacity limita-tions oft the earlier PCs put commer-cial FEAsoftware ahead of its time.

,,In the beginning, recalledAlbert Sedlmaier, co-managing

8

This article was published in

Modern Metals August 2003.

Printed with permission of Modern Metals.

FEA RF illustrates roll formed profiles as solid models and the forming rolls as wire frame

projections so that the action of the rolls at the point of contact on the strip can be visualized.

Software module simulates tube weldingRoll form tooling design program is enhanced by an addition to its finite element analysis capability.

In the previous article we askedAlbert Sedlmaier, co-managingdirector of the Bavarian firm, if finiteelement analysis was the finalstage in the softwares develop-ment. Sedlmaier assured us thatit was not, that there were a num-ber of avenues for expansion and

augmentation. He concluded withthis tantalizing comment: ,,Also writ-ten bold on our list (of enhancedcapabilities) is simulating the in-line welding of profiles.

The future is edging closer, asvisitors to the trade show Tube2004 discovered at the end ofMarch in Dsseldorf. data Ms dis-play featured the welding modulefor COPRA, which adds ther-modynamic prediction to COPRA

FEA RFs mechanical analysis.Sedlmaier stressed that the

Tube 2004 demonstration did not

officially introduce the product, theunnamed welding module has yetto be released commercially.,,We presented it strictly as a view

By J. Neiland Pennington, Executive Editor, Modern Metals

In August 2003, Modern Metalsintroduced a finite element analy-sis upgrade for COPRA (Com-puter-Oriented Profiling Assistant)roll form tooling design software.Called COPRA FEARF, the optio-nal module models the dynamicsof roll forming, comparing the shape

being produced to the originalflower pattern. With COPRA FEARF, we said, a COPRA-equippedComputer becomes a virtual try-out mill for testing and validatingroll designs. It is now a tool formodeling the. welding of tube, pipeand other closed profiles with amodule that adds thermal analy-sis to the FEA RF capabilities.Welding simulation is the latestdevelopment of software introducedin l987 by data M Software +Engineering GmbH, Valley/Oberlain-dem, Germany. COPRA began

with an elementary strain analy-sis capability for the strip edge andhas added sophistication over theensuing 17 years.

This article was published in

Modern Metals May 2004.

Printed with permission of Modern Metals.

In data Ms welding simulation and analysis module, solid modeling illustrates the

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.


9/12

The COPRAWF solution for wire rol-ling pursues three objectives:

Interactive modeling of the form-ing steps based on available expe-rience: the designer draws the form-ing steps and can put the areasinto the required percentageratio with the aid of COPRA WF.

Automatic layout of the form-ing steps by specifying the startand end cross-section. Here it is

possible to specify the degree offorming and the estimated reduc-tion of the cross-section.

Verification of thedesign by finite ele-ment simulation.Forming is comput-ed based on rollergeometry and thestart cross-section.The actual shape to

be expected can be verified in theindividual steps and the changein the material examined.

The history of wire goes backmany centuries. The first steptowards rationalization came in the13th century when wire drawingwas invented, and straight awayused for military purposes. The coatof mail, which until then only themore well-to-do could purchase,became affordable for the simp-le warrior.

Today the production and formingof wire is an industrial process by

which large quantities of very dif-ferent shapes can be manu-factured in a highly rationalizedmanner. As with many other for-ming processes, the technologyis still primarily based on experi-ence. So in most cases the pro-duction of new profile shapes isnot only associated with a consi-derable design effort but alsomeans protracted trials and expe-riments during startup. The star-


New: COPRA Wire Forming


ting product for shaped wire is veryoften round or rectangular wire.Pro-ceeding from this geometry,the wire is turned into the re-qui-red final form in a number of rol-ling passes.

So only the starting and finis-hing state of the wire is known.Seeing as shaped wires very oftenhave geometries with different radii,calculating the intermediate sta-

ges is a complex matter. In addi-tion to the purely geometricaspect, there are other factors thatplay a by no means negligible role.These include the fact that thematerial lengthens when it is for-med, and can be very difficult toforce into the border regions. Largedeformations produce local strainhardening, as a result of whichthe material can become brittleand thus fissured.

We are not only offering software...

No experience in roll design?No in-house capacity for roll toolengineering? Want to minimizemachine down time during set up?You want to get a bit moreindependent from your machinevendor? You want to profit fromour expertise?

We design roll sets on request- optimised and verified by our

design- and simulation softwarepackages COPRA DTM/ COPRA

FEA RF.

We are analysing your exist-ing roll tool sets in order to im-prove your production process.Starting from your existing draw-ings or (even better) from your actu-al tooling by scanning the real rolltooling by means of our COPRA

Roll Scanner, an optical rollinspection device developed andbeing distributed also by data M.

We are happy to assist you introubleshooting in existing form-

ing problems. And last but not least: we areoffering you the complete service

up to reworking your existingor supplying you with new setsof roll tooling.

As the leading engineering- andsoftware company for roll form too-ling our engineers have got thebest tools for their business- COPRA RF software.

COPRA Roll Design Service

We design rolls for all kinds oftubes and open sections:

Design and conception of theflower Longitudinal strain check

Check of material thicknessduring the roll forming process(for subsequent processes likehydro forming) Roll Design

Generation of drawings (dimen-sioned single rolls & assemblyplans)

Parts list, spacer lists, CNC pro-gramming, COPRA archive files etc.

COPRARoll Analysis ServiceWe do not fight the symptoms but

we are analysing the formingprocess in order to find out andtheir causes:

Analysis of existing forming andshaping passes

Analysis Report with sugges-tions how to solve a problem

Get the actual geometry ofexisting rolls by using our COPRA

RollScanner

Compare the designed roll withthe scanned roll (generating aso-called fingerprint diagram)

What you get is:

A re-design of your flower pat-tern (if we have to derive the form-ing process from an existing tool set)

An optimization of the flowerwith COPRA DTM (DeformationTechnology Module) Analysis.Of course, your data are treatedconfidentially. You will receive rollsoptimally designed for perfect pro-duction of your sections and tubes.

You will also get the full historyof your designs for your files andlater reference.

NEW - COPRAWire FormingSoftware Solution for Rolling of Wire Profiles

FEA in Tubemaking

Process ProblemsThe FEAanalysis that data M

performed for us allowed us tosee a visual representation ofthe process problem we werehaving, as well as providing aquantitative value to the stress-es we were imparting to the prod-uct. The visual representationwas described by the machineoperator as exactly what Imseeing coming out of the mill.This analysis showed us exactlywhere in the process our prob-lems were occurring.

Duffy Armstrong,

Webco Industries, USA

Roll Design Services Roll Tooling Analysis

Troubleshooting - Roll Tool Manufacturing and Set-Up

Example of a wire section

with automatic calculated forming steps

Simulation of wire forming with

COPRA FEA WF


10/12

Flexible Roll- A future industrial production

Usually roll formed sections ortubes have a constant longitudi-nal cross-section.

Certain areas of application likethe automotive industry have showna demand on profiles with vari-able cross-sections. However, theuse of roll forming for varying cross-sections has not (yet) led to anindustrial application. Since a typ-ical car chassis has only a fewstraight cross-sections with con-stant shape throughout this situ-ation is disappointing for the auto-

motive industry.The current production- andassembly methods (e.g. deepdrawing or composite construc-tions) for such kind of componentsare comparatively costly. Profilesor longitudinal components withvariable cross-sections wouldbe able to substitute such com-posite constructions. Thus it willbe really interesting to see whatkind of future applications for rollformed sections with longitudinallyvariable cross-sections will result- if there was a way to produce

them in an economic way bymeans of roll forming.

data M has been joining research-and development projects for flex-ible forming in order to develop



Seminar

Technical Seminar

Chairmanship

International

Tube Association

re-elects chairman

At ITAs 24th annual generalmeeting during Tube Dsseldorfexhibition in April 2004, AlbertSedlmaier, managing director at

data M Software + Engineering,was re-elected as chairman ofthe association. In 2003 he suc-ceeded Professor Manabu Kiuchi(Japan) who was elected as newpresident of ITA.

The International Tube Associa-tion has got the worlds largestmembership of tube&pipe engi-neers.

Tube Russia 2004 in MoscowITAChairman Albert Sedlmaier

had the honour of officiating atthe opening ceremony alongside

Sergey Mitin, Russian Ministerfor Industry and Energy.

Mr Sedlmaier also made a shortspeech before the tape ceremony.

Please refer to our web site at:

http://www.datam.de/go/tube-russia

Pictured at the tape cutting ceremony

are Mr Sedlmaier (far left)

and Mr Mitin (far right)

References

Change toCOPRA

PVG, a german major customroll forming company has recent-ly switched their roll design soft-ware to COPRA RF.

Main reason for this decisionto change the software supplierwas data Ms continious softwaredevelopement as well as data MsTQM philosophy (total qualitymanagement in the design of rolltooling) consisting of design(COPRA roll design software),optimisation (COPRA DTM -Deformation Technology Module),verification (COPRA FEARF)and quality control (COPRA

RollScanner).

Flexible Roll Forming

flexible roll forming 1st experimental

setup (source PtU)

design- and engineering toolsrespectively.

One project undertaken is thedevelopment of a flexible roll form-ing process which data M Software

and Engineering GmbH has beensupporting actively as well as finan-cially. The project was performedat the Institute for ProductionEngineering and Forming MachinesPtU of Technical University ofDarmstadt. Longitudinally variableprofiles can be produced bymeans of a flexible forming sta-tion with movable motor-driven rolltools.

The complete control unit (soft-ware and motor drives) of the flex-ible forming station was developedand supplied by data M Engineering

whiledata M Software simulatedthe forming process using anenhanced version of its COPRA

FEA RF software package.Currently data M is developing a

Computer control unit for flexible roll

forming (source: data M Engineering)

The production of a complete part family with a single tool system:

Flexible Roll Forming (source: PtU)

References

10 years COPRA

Thanks for 10 years of coop-eration with data M and usageof the excellent COPRA RollForming program.

Lars-Gunnar Sderlind, Avesta Polarot

Stainless Tube, Sweden

References

Roll-Kraft goes for

COPRA FEA RFRoll-Kraft, USA, has continued

to develop new products andmethods to strengthen its posi-tion over the years. The latestinnovation to be added isCOPRA FEARF - data Ms soft-

ware for finite element simula-tion of the roll forming process.This technology allows tooling

designs to be tested on the com-puter before they are manu-factured - a major step forwardfor the industry.

Roll-Kraft Press Release

Tube & Pipe Technology 7/8 04.

How Roll Designs

should be...The roll design supplied by data

M is as a roll design should be!

Johann Breytenbach,

Bosal Afrika

open profiles

hat-type profiles

closed profiles

Aworkshop on design and finiteelement analysis application inroll forming took place at dataMs office in Oberlaindern fromMarch 3 to 5, 2004. There were39 customers from Europe, Asiaand Africa joining this 3 day event.For dates and venues of simi-lar events look at:www.datam.de/go/events


11/12



Forming and Slide-Draw-Bendingmethod for profiles with variable cross sections.

6-axis flexible roll forming stand- based on its extensive know-howin parallel kinematics (COPRAHexapod Robot).

Another project is the develop-ment of a totally new slide-

draw-bending process for pro-files with longitudinally vari-

able cross-sections, per-formed at the Institute of

Forming TechnologyIFUM (University ofHannover) wheredata M is also partof the industrialconsortium. Theslide-draw-bend-ing process uses

a split flexiblemotor driven die in

11

order to form a variable cross sec-tion (see photograph).

Interested in more information?Or interested in developing anindustrial application for such aflexible forming processes?

In cooperation with our partnerswe are able to develop and sup-ply flexible manufacturing com-ponents starting with theoreti-cal analysis (finite element sim-

ulation of the forming processesand evaluation of material prop-erties) , computerized control equip-ment (flexible forming stands andmotor drives) and tool design.

We would be pleased if you getin touch with us.

slide-draw-bending concept (source: IFUM)

Flexible slide-draw-bending die divided in

a left and right section; (source: IFUM)draw-bending

(according Neubauer, Bogojawlenskij, Ris)

Flexible slide-draw-bending die experimental setup; (source: IFUM)

fixed dies

Finite Element Analysis

of the flexible roll forming process

work piece

Die

Die

(second forming step)

(first forming step)

work piece

hydraulic cylinderdrive motor

bed plate

drawing direction

left sectionright section

moveable dies:

idea

height

variation

widthvariation

height

and width

variation

realisation

load-matching profileslongitudinely

variable

cross-section


12/12


Contact


We would like to hear from you!

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

Name

Company

Street

Postal code/ City/Country

Phone

Fax

e-mail

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

I would like to get design support COPRA Roll Design and Analysis Service

I would like to know more about the COPRA MetalBender software COPRA MetalBender

I am interested in software training data M Academy Training Center

I am interested in hardware solutions COPRA RollScanner data M Engineering design of special-purpose machines

www.datam.de

visit our

website

Fax ++ 49 80 24 /640 - 300

Unique Solutions fromone supplier! data M isoffering all AutodeskCAD products bundledwith its COPRAsoftwaresolutions worldwide.

And even more: in addi-tion to data Ms direct sup-port you are still havingaccess to Autodeskssupport and sales chan-nels.

data M Software GmbHis one of Autodesks UARPartner. UAR stands forUnique Application Resel-ler and allows Autodesksstrategic developers tobundle their applicationswith any Autdesk softwareproduct. This partner pro-gram is a real alternativeto Autodesks normal dis-

tribution channel if the enduser needs specific tech-nical support.In manycases a typical Autodeskdealer doesnt have thespecific know how on sub-jects like metal bendingor roll forming.

As an UAR Partner dataM Software GmbH is nowable to bundle its softwareproducts with respectivebasic software platformfrom Autodesk and offeryou a complete solution.If you wish we are ableto provide you with sup-port from one singlesource.

This is especiallyof impor-tance if the application isan essential componentof the complete solution.

COPRA RF (Roll Forming)software or COPRA MetalBender is being offeredin a bundle with AutoCAD,AutoCAD Mechanical, Me-chanical Desktop or Inventor.

In addition to this UARprogramme we are con-tinuing to offer as a veryattractive alternative forour roll forming and tub-ing software COPRA RFin combination with astandaloneoption whichis nothing else than anAutoCAD OEM version(the COPRA RF softwarecomes with AutoCADalready included). Thisoption is tailored to end-users who do not need todo extensive CAD designsbeyond the typical COPRA

roll design operations.

Please ask us for moredetails.

Autodesk appoints dataM as MAI Partner world-wide.

Since 2003 dataM has beenappointed as a newmem-ber of Auto-desks MAI(Mechanical ApplicationsInitiative) partner programin the area of sheet metalapplication.

This is a further credit Au-todesk gives to the qualityof data Ms software pro-ducts as already 4 yearsago data M Software GmbHwas selected as Autodeskspreferred supplier of sheetmetal technology andvalidation in Inventor.

data M Software GmbHyour single source supplier for Autodesk software products!

resellers and solution providers

find a reseller

or solution

provider...at

http://www.datam.de/go/dealer

dataM

08

/04E

Exhibitions and seminars

next shows...

Tube China 2004China International Tube & Pipe Trade Fair

22th

- 25th

September Shanghai, China

EuroBLECH 2004

Intern. Sheet Metal Working Techn. Exhibition

26th - 30th October Hanover, Germany

Metalex 2004

international machine tools exhibition

18th - 21st November Bangkok, Thailand

More information about data Ms activities can

be found on the internet at:

http://www.datam.de/en/shows-press

Software +Engineering

datam aug 04 eng

Documents