deutsche Version

Content of this 2 hour demo of the workflow in COPRAŽ RF 2005:
Profile Flower Design
COPRAŽ Browser and Project Manager
Design of a (fully parametric) flower pattern using COPRAŽ Spread Sheet (change of calibration method after having done the flower design; compresing material, calibration adition, changing table views layout; import flower designs from COPRAŽ graphics package or DXF files)
Deformation Technology Module for strain analysis 
(definition of roll diameters for the analysis; calculation of forming length; using bottom- and/or side rolls for the analysis; theoretical analysis of longitudinal elongations; influences of changing roll diameters on the maximum strain values; calculation of theoretical plastic strain values; values on top- center- and bottom plane of coil material; showing maximum elongation values (bar diagrams); influences of down-hil forming on maximum strain values; how to improve the roll forming quality?)
Spring back / Overbending Calculation
(high tensile material; insert overbent step into flower pattern)
Using COPRAŽ RF Browser for flower- and roll tool navigation
Roll Design
(definition of roll forming line parameters; automatic roll design for open profiles; relief angles; strip guides; basic roll design with AutoCAD / CRF funtions; editing roll geometries; definition of rolls and roll groups; accessory rolls - in addition to the known top/bottom and left/right side rolls the user can now define as many auxiliary rolls as he needs; will be taken into account even in the finite element analysis - and roll axis; modifying accessory rolls; info parts for roll designs allow to assign AutoCAD drawings to single roll form stations or rolls (attributes) for e.g. bearings, mechanical supplements etc.; doing roll design in the context of a complete roll forming mill)
Project- and Document Manager
(automatic creation of single roll drawings; drawing templates and title block with company- and project information; using data M's CADFinder document management software for generating drawings; revision management in COPRAŽ RF/ CADFinder for changing roll geometry and roll drawings; automatic creation of asembly plans in combination with CADFinder; automatic printing and Plotting of drawings generated)
Creating material lists, spacer lists, cutting lists etc. using the integrated project manager
COPRAŽ RF Setup
(definition of directories in the project manager; definition of roll numbering strategies; insertion of forming stations after the initial roll tool set has been manufactured; separate definition of idler stations vs. driven stations)
Attributes of forming stations
(definition of station attributes and change of roll numbering in COPRAŽ RF)
Finite Element Analysis of the Roll Forming Process
(COPRAŽ FEA RF project manager; generating the COPRAŽ FEA RF model; definition of material properties; mesh generation; definition of roll form process parameters; strating the FEA analysis; interpretation of the simulation results using COPRAŽ FEA RF; longitudinal strain values)
by the way:
The demo does not show all features/ functions of COPRAŽ RF nor does it show the specific sulutions like COPRAŽ Tube Mill Roll or Trapezoidal sections etc. The purpose of this demo is to give an impression of the integrated workflow in the roll design- and engineering process.
We are looking forward to hearing your comments and / or questions.

For a list of software release notes showing the development of COPRAŽ RF software in the past years, please click here...

Following are some demo files (animated GIFs) and brief explanations of some of the features implemented in COPRA RF software. 
Notice: Most of the demos are taken from previous COPRAŽ RF software versions and do therefore not show the most actual revision.

Part 2 - COPRAŽ RollForm Software - Demos (please click on one of the following headlines):

COPRAŽ Browser
Profile
Stripwidth
Static Properties
Flower Design
Springback
Simulation
Down Hill Forming
Roll Design
Roll Dimensioning and Assembly Plan
COPRAŽ Automatic Tube Mill Roll Design
COPRAŽ Roll Attributes  
COPRAŽ FEA RF (under construction/will be shown soon)

Some of the animated gif-files (demos) shown have a resolution of 1024 pixels. This means you have to scroll in your browser if you are using a low resolution monitor.

NEW: AVI file (6,7 MB) -> Interface between COPRAŽ RF and Inventor

COPRAŽ Browser You Can... Show Me... Your advantage... From COPRAŽ 2003 on Version you have the feature "COPRAŽ Browser" This allows you to get access to all design- and editing funtions instantly  In the first register you see the information about your project. In the second register you get info about the flower, number of passes, etc. If you select a pass COPRAŽ will load automaticly this pass as well as respective program icons and on the right side you can see the profil entities. The third register is for roll information ...Saves your time Is Windows-like and easy to use Automatically pops up the program command icons you need top

Profil You Can... Show Me... Your advantage... COPRAŽ offers you: Profile design via macro technology. This is an effective and comprehensive tool box for the design of new shapes. COPRAŽ also offers direct entry (list editor) via spread-sheet like input Design of shapes using AutoCAD features like Polyline (analog with HP ME 10) No external CAD design or data transfer of profile sections required - because COPRAŽ is integrated within CAD systems (Only one CAD system to work with) And finally: COPRAŽ allows designers to "mix up" and combine all the possibilities ...Design your own profile with COPRAŽ's profile library (standard shapes) Standard profiles such as C-Channel, U-, Hat-profiles and even corrugated wide profiles can be designed quickly ...Convert an AutoCAD polyline to a COPRAŽ Profile Flexibility to design very complex shapes Easy modification of existing shapes Transfer of existing drawings into COPRAŽ's data base management system ... top

Stripwidth You Can... Show Me... Your advantage... ...calculate strip width by several methods, such as DIN Standard, standard formulas or company specific parameters (in total 7 different methods) Access to proofed calculation formulas Exact result by combination of different calculation methods for different types of arcs Easy adaptation of your own experience values by defining a parameter table, which will be taken into account by COPRAŽ top

Static Properties You Can... Show Me... Your advantage... COPRAŽ calculates the static section codes and prints out result lists or adds the results to the CAD display on screen together with the reference system. Important: The reference system can be selected independently (strain directions!) The user is free to choose whether it is an open or a closed profile (e.g. unidirectional lock seams) Even punched profile sections will be considered! ...calculate values of static stability of profiles such as: geometry moment of inertia sections modulus torsional geometrical moments and other values . An accurate result within seconds  Time consuming calculation is not necessary anymore   top

Flower Design You Can... Show Me... Your advantage... The user is not only able to unfold the profile. He can even bend up (fold) individual elements. For practical application this means that users are not restricted to work from the finished flower to the flat sheet. During the process he can bend or overbend individual areas (even straight elements!). Experience has shown that functions like these are especially important, in order to open undercuts (to be able to form them with top or bottom rolls).   There are much more than just three arc types (known from flower drafting packages). With COPRAŽ, users have even more powerful methods at their disposal: With each unfolding step the user can freely choose (and even change!) the desired calibration method. Instead, the user selects calibration method and profile element via mouse click on screen and chooses the respective unfolding or bending angle and immediately the new geometry will be displayed on screen. It is no problem to change between constant radius method and power bending (or any other procedure).   The following calibration methods are available: Arc bending Constant radius method - the methods allows to calculate the length compensation pieces at the front and at the back or with any desired distribution (percentage) at the front, the middle or at the back. Of special importance is thereby the so-called track-holding unfolding method, during which the compensation pieces are calculated in a way that the strip guide is straight (important with undercut shapes, where material flow is impaired, e.g. dovetailed shapes). Track-holding unfolding is a unique COPRAŽ feature! For lock-seams or sharp edges (internal radius = 0) COPRAŽ also provides a calibration method (the so-called Angle / Radius Method). Arc profiling should not be confused with tube profiling, which is also implemented in COPRAŽ. The method allows to unfold arc elements even if adjacent features are not straight. The method was especially developed for round tube forming or for open profiles with similar pre-requisites. Specific calibration methods for trapezoidal shapes (optionally available; not in the standard package).   For actual design of the unfolded flower COPRAŽ offers a variety of additional powerful functions. COPRAŽ bending sequences; This is a database-supported software module for automatic unfolding of profile sections. "Combination Tool Sets - module". This allows users to exchange and combine section or flower parts. The function is also provided in the COPRAŽ roller tools module. ...Define plane of unfolding in different points in profile Flexibility to set the correct position of profiles in the machine ...Use different calibration methods to process the bending arcs of profiles, as well as functions for folding and unfolding Accurate result This means better forming  quality. ...Use automatical unfolding strategies (automatic bending sequence) with customised values You save time and increase effectivity by applying an optimised bending sequence for certain types of arcs. ...Dynamic unfolding of bending areas You may work on as many bending zones as you like to simulteneously Allows the design of even upmost complicated bending zones - e.g. lock seams, undercuts etc. Feasibility studies on specific cross sections top

Springback You Can... Show Me... Your advantage... COPRAŽ offers two different  methods for the calculation of elastic recovery: Method according to Oehler-Sachs and Method according to Biswas. By the way: The method according to Oehler Sachs (which is the only method in competing software products) does not work with large radii (because the formula is not valid with large bending radii). Consequently, COPRAŽ additionally uses the method according to Biswas. ...Calculate the spring back (elastic recovery) effect with proofed formulas such as Biswas and Oehler / Sachs You can see the result of the calculation instantly without having to look up tables or diagramm Save time and machine time to find out the correct shape of the profiles in the machine in extreme cases top

Simulation You Can... Show Me... Your advantage... COPRAŽ Deformation Technology Module offers an effective way to simulate the roll forming process and therefore to optimize the roll tool design. The following links to other chapters of data M's web-site will provide you with more technical infos about the technical back-ground. Some of these chapters may require an additional password in order to get access to. In this case, please contact a data M sales representative or data M directly. We will provide you with your personal account with pleasure. You may find some more infos about COPRA roll form simulation at this address... Some infos about the development of roll form simulation from strip-edge-strain calculation via wire-frames to COPRA Deformation Technology... How Precise is COPRA DTM (Deformation Technology Module)? ...Calculate the theoretical strain values with a state of art calculation method ...Optimise your roll design and increase your products quality part 1 part 2 A close to reality result  within a very short time (minutes); Thus by optimising the values you can improve the quality of your roll formed  products You can identify possible problem zones long before the production starts... This means cost saving by a drastical reduction of machine down-times (due to roll setup and - modification). top

Down Hill Forming You Can... Show Me... Your advantage... The so-called "down-hill" forming method is a way to reduce strain values in the roll-formed material and therefore to increase the product quality. COPRAŽ offers two functions for the calculation of minimum strains. The first one is the way to keep the center of gravity of each forming pass at a constant height. This is the common way and being used in industry. The second - and much more effective - way is done using an optimization program determining the best downhill forming curve possible. This way is exclusively available in the COPRAŽ package and has been verified by scientific means. ... Reduce longitudinal strain by down hill forming of the flower ...Chose the common down hill forming method according to constant center of gravity ...Choose the (optimised) down hill forming method according to minimum strain calculation ...Better forming within a limited numbers of forming stations ...Achieve the optimum down-hill forming result top

Roll Design You Can... Show Me... Your advantage... COPRAŽ allows to automatically assign roller tools even to complex profile shapes, as especially developed programs calculate accessibility with top, bottom or side rolls. Actually, the automatically created roller sets are a kind of rough outline which can be adjusted quickly and precisely with the help of more than a dozen of especially developed graphic editing functions. By the way: COPRAŽ is completely integrated in the CAD system. The COPRAŽ commands can be used as easily as the CAD commands. Nevertheless, COPRAŽ has got a list editor as well, which basically allows to edit every roll shape. However, experience has shown that the graphic methods are even more effective. ...Create axes for the rolls globally, taking into account even parameters like 'diameter increase'. Left and right axes can be inserted easily by using easy-to-handle dialog boxes. Roll entities can be added interactively or automatically - just based on the forming flower ...COPRAŽ Roll Design module is tailored to meet the user's practical needs.   Rolls can be designed quickly and accurately by only a few mouse clicks. ...Modify the width, angles, or diameter of rolls with powerful tools provided by COPRAŽ ...Create entities like edge-rolls etc. automatically with automatised functions in COPRAŽ ...Easy functions to modify the shape of rolls to fulfill the technical requirements. ...Faster, accurate and easy roll-design through COPRAŽ macro functions   top

Roll Dimensioning and Assembly Plan You Can... Show Me... Your advantage...   COPRAŽ automatically creates dimensioned working drawings for individual rollers as well as the so-called assembly plans. There is no separate file transfer required because COPRAŽ is already 100% integrated into the AutoCAD CAD-Software (or ME10). For automatic dimensioning the user can choose from different strategies (NC-adjusted, corner dimensions, he can even use a parametric or company-specific macro language for dimensioning according to company standards, especially for tube manufacturers) ...After the rolls have been designed, they can be dimensioned automatically, taking into account details like bore hole or bearing seats etc. ...Choose between different dimensioning strategies, e.g. single roll dimensioning with reference edges ...Save your time for more important jobs ...The roll drawing is saved into your working directory automatically in AutoCAD format ...Or single roll dimensioning with all the entity intersection points   ...To meet the requirements at the CNC programm ...spacer rings can be added easily by entering the spacers specifications ...Dimensioned assembly plans can be generated through COPRAŽ automatically ...Overview with the main dimensions of rolls and spacers Including the roll numbers top

COPRAŽ Automatic Tube Mill Roll Design You Can... Show Me... Your advantage... COPRAŽ Professional Tube Design Bundle offers a complex program package for the needs of tube mill roll designers and manufacturers. The software is highly automised. Major tube making companies and tube mill manufacturers world-wide have been using this software package (just ask us for a reference list). ...Define the desired tube dimension ...Calculate the stripwidt, forming philosophy (one, two, or more arcs forming), round or rectangular tube in the dialog boxes. This example shows you a number of dialoque boxes for the easy setup and modification of tube-forming parameters. In practise, the user is able to decide which kind of paremeters he likes to change and may use just resprective dialoque box (not all of them - of course). COPRAŽ will generate the flower automatically ...Changes can be done afterwards in the respective dialogboxes and also for chosen/ single passes ...Just like tube flower,  respective rolls  will be designed automatically by COPRAŽ, according to  machine paremeters and roll-/forming specifications (stored in the data base) Easy to handle by 'windows-look-and-feel' technology The specifications  have  to be entered only once for each type of machine. ...Modification can be easily done through the Roll Parametric Module - even after desgn has been performed ...COPRAŽ Shaped Tubes Calibration steps from round tube to special shapes can be generated with COPRAŽ. Optimum shaping process will be achieved since every arc position is determined through the calibration steps. Individual machine definition You can build your individual tube mill showing the different types of forming stands, e.g. fin passes, break downs etc.   Individual setup of forming strategy Individual setup of forming sequences Calculation of forming flower pattern     to be continued soon...   top

COPRAŽ Roll Attributes You Can... Show Me... Your advantage... The Roll Attributes are a sopprted feature from COPRAŽ 2003 Version Using this command you can add individual properties for each roll You can even assign accessories (e.g. Autocad drawings) to specific rolls; these info will be shown during the design process accordingly or printed in the documentation process In this dialog you have 5 registers  In the first register you can see your general settings, and you can change the roll name so its now posibil to give each roll a intivitual name. In the second register you can define special settings for the bore hole. The following register is for the stamping groove information. Register 4 is for special settings for roll treatment. It means roll material, roll type.. etc. The last register we can assign accessories for every roll. This means that you can assign a AutoCAD drawing (Roll holders, pass drawing etc.)    ...Allows customization to your company specific needs When you select another register COPRAŽ also will activate the selected module Flower design, Roll Design top

COPRA FEA RF You Can... Show Me... Your advantage...   under construction! top