First worldwide presentation of Release COPRA® FEA RF 2009 at Industrie Paris 2008

On 31st March data M Software GmbH and its newly established Center Of Competence in France Samara-Tech & Engineering S.A.R.L will be showing its new products and services at Industrie Paris 2008 (the professional manufacturing technologies exhibition).

We have got news in the sectors of roll forming and simulation technology. data M will present the new version of the Finite Element Simulation solution for the roll form process – COPRA® FEA RF 2009.

When doing the first steps of development in the middle of the Nineties of the last century we had some dreams what Simulation Technology could do one day. Today these dreams have come true. COPRA® FEA RF helps to understand the roll form process, trace for occurring problems and do a target-oriented optimisation.

This new version has come closer to reality than any other simulation- or analysis software ever. However – not only the FE Analysis software but also our known design package COPRA® RF has got enhanced (see below). One example is the handling of cage forming methods and interfaces to 3D CAD/ CAM Systems, Inventor and SolidWorks.



picture 1: FEA_RF_Rotation.tif:
Figure of model with friction / rotating rolls including:
§ driven rolls at specific rotational speed (purple arrowed)
§ idler rotating rolls, driven by speed of the sheet (green striped)
§ welding and deactivating of welding addition
§ drawing die (with friction) for improved forming process

COPRA® RF Software simplifies the fabrication of cold rolled profiles in development and optimization

For some time now the Bavarian company data M Software has been offering a virtual process chain for the design and validation of roll tool sets in roll forming manufacture. The COPRA® RF (Roll Forming) software program supports all work steps in the development of open or closed profile cross-sections. It runs from the design of the profile cross-sections to be manufactured through definition of the individual bending steps to generation of the technical documentation (production drawings, parts lists, CNC programs) and later quality testing of profile cross-sections and roll tools. The latter uses optical tools (COPRA® RollScanner, COPRA® LaserCheck), especially Scanner, developed for this purpose.

Not long ago, the only possible way to arrive at a functioning roll tool set was practical trialing on the machine. Today there is an alternative way of speeding up this time-consuming and costly “breaking in“ of a new roll forming tool set, and entirely avoiding any reworking of the tools – simulation by the finite element method (FEM).



picture 2: FEA_RF_TQM.jpg:
COPRA® FEA RF - Total Quality Management

FEM simulation of roll forming process
As soon as a roll set is ready designed, the data are run by the FEM simulation program. COPRA® FEA RF (Finite Element Analysis for Roll Forming) simulates the roll forming operation by a nonlinear elasto-plastic computing method. The user need not bother about questions like definition of the finite element computing model, discretization and selection of suitable element types or application of the boundary conditions. These points are automatically handled by the software, fully integrated into the COPRA® process chain.



picture 3: FEA_RF_Drawing_Die.tif:
COPRA® RF supports also integrated drawing dies

Producing discontinuous roll formed profiles

data M Software offers you a new method for fabricating load-matching profiles
Cold rolled profiles are used in many engineering branches, especially in the production of automobiles or industrial plant. There are whole numbers of possible fields of application for profiles with cross-sections that alter along their length.

l The question is: Can these profiles be manufactured on roll forming lines? data M has investigated such questions for a number of years as part of R&D projects, and is able to answer “Yes“.



picture 4: Profiles.tif:
Possible target profile geometries in flexible roll forming (CAD and simulation images)

Flexible roll forming from a single source
data M Software offers practical support in developing and introducing this forming process, together with all the necessary mechanical and electronic components.
1) Development of the process and its validation by finite element simulation (feasibility study). This is especially important for determining the tolerances that are later achieved.
2) Planning and implementation of the required mechanical components (e.g. flexible stand).
3) Delivery of the complete CNC control including graphical programming and collision control.