2. data M Software’s high-end Finite Element Analysis Software “COPRA® FEA RF” was introduced first to the tube industry at Tube Düsseldorf 2000 and has been extended since then continuously. 
The non-linear elasto plastic calculation (based on MSC.MARC), the automatically generated model, a process-wizard driven easy definition of process parameters and reduced calculation time are making this solution to a virtual try-out and analysis tool.
At Tube Singapore 2005 data M will be showing COPRA® FEA RF with an integrated simulation of the welding process as well – in addition to the analysis of the forming process before and after the welding unit.
COPRA® FEA RF actually allows for both – the verification of roll tool design as well as the analysis of tube making and roll forming processes (picture 2).

Picture 2: COPRA® FEA RF now also allows the analysis of the welding process
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3. New Product COPRA®  Software solution for Rolling of Wire Profiles

The history of wire goes back many centuries. The first step towards rationalization came in the 13th century when wire drawing was invented, and straight away used for military purposes. The coat of mail, which until then only the more well-to-do could purchase, became affordable for the simple warrior.
Today the production and forming of wire is an industrial process by which large quantities of very different shapes can be manufactured in a highly rationalized manner. As with many other forming processes, the technology is still primarily based on experience. So in most cases the production of new profile shapes is not only associated with a considerable design effort but also means protracted trials and experiments during startup. 

The starting product for shaped wire is very often round or rectangular wire. Proceeding from this geometry, the wire is turned into the required final form in a number of rolling passes. So only the starting and finishing state of the wire is known. Seeing as shaped wires very often have geometries with different radii, calculating the intermediate stages is a complex matter. In addition to the purely geometric aspect, there are other factors that play a by no means negligible role. These include the fact that the material lengthens when it is formed, and can be very difficult to force into the border regions. Large deformations produce local strain hardening, as a result of which the material can become brittle and thus fissured.
The COPRA® Wire Rolling solution for wire rolling pursues three objectives:

               Interactive modeling of the forming steps based on available experience: the designer draws the forming steps and can put the areas into the required percentage ratio with the aid of COPRA® Wire Rolling.

               Automatic layout of the forming steps by specifying the start and end cross-section. Here it is possible to specify the degree of forming and the estimated reduction of the cross-section. 

               Verification of the design by finite element simulation. Forming is computed based on roller geometry and the start cross-section. The actual shape to be expected can be verified in the individual steps and the change in the material examined. 

Picture 3: Example of a wire section with automatic calculated forming steps
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Picture 4: Simulation of wire forming with COPRA® FEA for Wire Rolling
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If you have any question, please do not hesitate to contact:
Mr. Albert Sedlmaier at +49 8024 640-0
Fax: +49 8024 640-300
mailto:datam@datam.de
Reprint free of charge;
Author’s copy kindly requested

Valley, May 2005