COPRA® Deformation Technology Module - DTM Simulation (H2)

Increasing competition in the roll forming business and growing customer demands have resulted in a huge variety of complex roll formed shapes. Trends to even more complex roll formed products are challenging the design engineer. However, the decision whether to do or not to do any special new roll formed shape is sometimes a quite risky (and costly) decision. Not just the final product quality but also the company's success is depending on the designer's judgment. A quick and reliable simulation of the forming process is contributing essentially to an increased product quality If you are planning to make a new roll set you never should do it without respective simulation software tools COPRA® DTM is avoiding long computing times COPRA® FEA RF/ DTM can be used without extensive training and experience in FEA technology COPRA® FEA RF/ DTM is state-of-the-art COPRA® FEA RF/ DTM offers you highest accuracy and reliability It can be treated as a virtual try out mill: critical situations and mistakes in roll design will be detected even before the first roll has to be manufactured COPRA® offers you a two-step concept for roll form simulation: COPRA® DTM and COPRA® FEA RF. Already in the design stage you will realize if your tool set has got weak points and thus you'll avoid costly setup periods and reworks. A decisive step toward better product quality! COPRA® Deformation Technology Module (DTM) is a software program for the simulation of the roll forming process. It enables the design engineer to verify and optimize the chosen forming/calibration method with regard to machine parameters and quality requirements. COPRA® DTM is taking into account parameters like material, forming length, geometry of forming zone and tooling diameter. COPRA® DTM is particularly no longer working according to the known but unreliable "strip edge stress" method (triangle calculation method). This approach is already bound to fail when calculating simple C-shaped sections. COPRA® DTM is based on extensive FEA calculations and research results (data M Software has been working using high end FEA solvers since 1992...) COPRA® DTM is a software program of the "third generation" data M Software GmbH has been cooperating with a number of research institutes around the world and is continuously integrating respective experiences in its own research and development activities. How accurate is COPRA® DTM working? A practical example of how to use COPRA® DTM COPRA DTM has always been (and still is) continuously improved by our developers.

COPRA® for Drawing Rings

COPRA® Drawn Tube Technology - Calculating the shaping process for drawn tubes For the manufacturing of drawn tubes round tubes are pulled through one or more drawing rings depending on the complexity of the final shape. The drawing rings are approximately between 40 and 100 mm thick. The incoming side needs to be large enough to cover the round tube. The outgoing side has the final shape of the tube or a defined pre-shape. The faces between the incoming side and the outgoing side build a curve. Of course it would be easier if the two contours (round tube and final shape) would be connected with straight lines. But in this case the friction between tube and drawing ring gets too high and causes other problems. Especially the design of the outgoing shape of the drawing ring is not trivial because the straight legs of the final shape needs to be converted into arcs. It has been nearly impossible to do a true design keeping the circumference of the tube only with the help of a drawing board. Design as well as manufacturing of drawing rings has been quite difficult up to now. The design of drawing rings has been characterized by following difficulties. The layout of the drawing ring was mostly made free hand. The length of the individual lines was very hard to estimate. The manufacturing of drawing rings has been making difficulties as well. The shape of the incoming tube, for example, was made with a machining tool which had mostly the same contour. The manufacturing process itself was very long and winded A negative had to be made from the outgoing contour and the shape of the machining tool. The negative had to be casted to get an original part. This part was manufactured with a copy mill. It also had to be reworked in order to remove intersections with the incoming tube. Therefore a CAD/CAM system for the design and manufacture of drawing rings should allow an easy design of the drawing ring shape, a high accuracy material flow, an easy machining of the drawing ring. It should avoid additional intermediate steps like the need to machine a negative and it should provide the possibility to design and manufacture additional tools required, like cores etc.

COPRA® Roll Analysis Service

You need to improve your roll set? We analyze and redesign your rolls! We do not fight symptoms but... We analyze existing forming and shaping passes We give analysis reports and suggestions how to solve a problem You get the actual geometry of existing rolls with the COPRA® RollScanner We compare the designed roll with the scanned roll (fingerprint diagram)

COPRA® Roll Design and Analysis Service

You need a rollformed profile? We do the roll design for you! You have a problem somewhere in your roll set? We find the solution for it! Design We design rolls for all kinds of tubes and open sections: Design and conception of the flower Longitudinal strain check Check material thickness during the forming process (Hydroforming) Roll Design Service Create dimensioned single roll drawings and dxf contours Create dimensioned assembly plans Analysis We do not fight symptoms. We detect errors and avoid their causes: Analysis of existing forming and shaping passes Check material thickness during the forming process (Hydroforming) Analysis Report with suggestions how to solve a problem Get the actual geometry of existing rolls with the COPRA® RollScanner Compare the designed roll with the scanned roll (fingerprint)

COPRA® Roll Design Service

You produce open, closed or shaped tubes - or you are planning to do so? We do the roll design for you! We are designing rolls for tubes and open sections: Design and conception of the flower Longitudinal strain check Checking material thickness during the forming process Roll Design Dimensioning of single rolls and assembly plans