The Bavarian company data M is introducing their new versions of COPRA® RF and COPRA® FEA RF at EuroBLECH 2018 with various improvements, particularly the newly developed feature "Automatic Report". This tool shortens the complete verification procedure, providing project managers as well as designers with an abundance of data about the simulated roll forming process.

Managing director Albert Sedlmaier is looking forward to meeting new and existing customers at EuroBLECH: "For years, data M has been developing soft and hardware solutions meant for process optimization and efficiency enhancement. The new releases and especially the new feature Automatic Report are further steps in this direction".

With the function „Automatic Report“, COPRA® FEA RF 2019 allows the analysis of the simulation results geared to each target group. With the function "Automatic Report", COPRA® FEA RF 2019 allows the analysis of the simulation results geared to each target group.

With various auxiliary functions and customizable templates, COPRA® FEA RF 2019 allows for significant time saving. Although simulation times are reduced due to powerful CPUs, evaluation time for designers is increasing with complex projects. The templates facilitate quick and automated breakdown of results, provide numerous analysing possibilities and help with establishing a company standard.

COPRA® FEA RF 2019 pre-processes the results of the simulation geared to the respective target group, enabling the project manager to keep track or the designer to select detailed result quantities due to the reproducible templates. There is even a tailored report for the operator. By this approach, the simulation becomes the "digital twin" of the roll forming machine, providing detailed insights into the manufacturing process.

Depiction of Four-Roll-Welding-Pass in COPRA® RF 2019.Depiction of Four-Roll-Welding-Pass in COPRA® RF 2019.

If requested, all evaluation parameter of interest will be broken down to each individual station. Particularly the designers - usually focusing on specific result quantities- will be called to attention by other important values. The "Automatic Reports" can still be standardized as desired by the customer and thus facilitate comparisons of different simulations.

The latest COPRA® RF 2019 will also be introduced at EuroBLECH. The leading design software likewise has various new functions. Designers can now mark coated or visible areas of a cross section. The primary material is more often delivered with already coated surfaces that must not be damaged by the subsequent shaping process.

Designers can mark coated areas of a cross section in COPRA® RF 2019.Designers can mark coated areas of a cross section in COPRA® RF 2019.

The design of flower and roll tools has been shortened once again, due to the possibility of cutting in points of intersection. Additionally, the roll dimensioning can be laid out in tabular form with the coordinates of the contour points. For producers of round and rectangular tubes, COPRA® RF 2019 will automatically generate a four-roll-welding-pass.

Finally, the axis configurator allows for saving and loading of the axis positions related to each individual project. Following the "digital twin"-concept, the positions can thus be kept up to date in the machine as well as within the project.

data M Sheet Metal Solutions Presents Training Packages for Simulation Software COPRA® FEA RF

The Bavarian company data M Sheet Metal Solutions is presenting its extensive service- and training-packages for the software solution COPRA® FEA RF at the TUBE fair 2018. The packages contain for instance complete example models including video-tutorials for the integration of pre- and post-processing operations with a focus on embossing and tube bending.

Fig. 1: Tube bending of a roll formed tube in COPRA® FEA RFFig. 1: Tube bending of a roll formed tube in COPRA® FEA RF

The industry demands precisely fitting and complex products with small bending radius to wall thickness ratios. This makes manufacturing ever more demanding. The leading software solution COPRA® FEA RF visualizes and verifies the production process within a virtual environment and thus prevents deviations during production. By taking into account previous roll forming procedures, pre- and post-processing steps can be optimally calculated thus improving the forming process as a whole.

With the training packages for the software, roll formers will be able to integrate additional processing steps into the forming process. The designers learn among other things how to utilize the advanced functionalities of COPRA® FEA RF. An applicable package contains a ready-to-use simulation model as well as 3D models for any necessary tools. These can be used immediately with the 3D import functions of COPRA® FEA RF 2017. Furthermore, a manual for the creation of example models including a video tutorial is also added to the portfolio. Finally, the detailed instructions for the application of COPRA® FEA RF 2017 enables roll formers to create better models for future projects. Special trainings can also be conducted upon request.

Fig. 2: Simulation of the embossing process in COPRA® FEA RFFig. 2: Simulation of the embossing process in COPRA® FEA RF

data M Sheet Metal Solution keeps working on training and service products for existing and new customers. The company is thereby also reacting to the rising demands of the industry. The packages are aimed predominantly at roll formers and tube makers planning to expand their product portfolio with additional processing steps without losing control over the entire manufacturing process.

About data M

data M Sheet Metal Solutions GmbH specializes in software solutions and services for roll formers. The programs COPRA® RF and COPRA® FEA RF are the leading solutions for design and simulation worldwide. The company also offers the optical measuring systems COPRA® ProfileScan Desktop and COPRA® RollScanner for efficient quality control of products and roll tools. In addition, data M is also a service provider for design, simulation and analysis in forming and maintains an international partner network and has subsidiaries in India, Poland and Great Britain.

Monday, 10 October 2016 21:12

data M at EuroBLECH in Hanover

The Bavarian company data M Sheet Metal Solutions (Hall 27, Booth G142) presents an integrated solution concept for roll forming at the EuroBLECH 2016. Along the lines of the fair’s slogan „The New Generation of Sheet Metal Working“, data M showcases innovative soft- and hardware products for roll formers. Among other things, the fully integrated solution concept is demonstrated using the example of a roll formed bumper. All assembly steps including stretch bending can be processed with COPRA® products.

4 datam logoIn recent years, data M further refined its product portfolio and especially focused on consistent interconnectedness of the various COPRA® solutions. data M engineers demonstrate how the setup of a new roll formed profile becomes comprehensible with the design software COPRA® RF, the COPRA® RollScanner as well as the roll tool database RLM. With the new feature “AssemblyCheck”, the design will be instantly updated after modification of the forming stations with subsequent scan of the roll tools. The designer will get an overview about the state of the modified tools in mounted condition compared to the initial design. For this purpose, the designed as well as the scanned roll contour will automatically show overlaying in COPRA® RF.

Furthermore, the portable COPRA® ProfileScan Desktop provides accurate measurement of the profile after each station. Consequently, the designers can verify if the profile matches the designed contour after each forming step. With this method, potential deviations can be located immediately and not only after the profile is finished – which involves a tiresome search for the source of error.

The simulation solution COPRA® FEA RF verifies the design and is the only respective software worldwide that handles the roll forming process automatically and thereby provides a transparent user interface. Additionally, pre-built models allow the model processing and calculation to be comparatively fast.

COPRA® FEA RF not only simulates the roll forming process, but also handles the complete production process for modern and complex profiles. Nowadays, pre- and post-operations like stamping, embossing or welding are as important as the roll forming itself. An accurate simulation of the roll formed base profile is eminent for additional calculations like stretch bending, since occurring strains and stresses during roll forming may influence the results significantly.

The simulation module identifies and visualizes possible defects like strip edge waviness or unwanted collisions between the roll and strip edge during the (virtual) forming process. With the results, the new roll design can be instantly implemented and verified. Additionally, the new version COPRA® FEA RF 2017 is equipped with Marc/Mentat 2015 and contains an integrated model browser. Furthermore, data M introduces new import functions: Besides IGES, new formats like STEP and SAT or native formats like e.g. from COPRA® Inventor® can be imported and edited.

Lastly, data M developed a simple model that incorporates station stiffness. Thus, alterations of the roll gap due to forming forces and the respective impact on the profile are already considered.

data M Sheet Metal Solutions GmbH was founded 1987 by Albert Sedlmaier and Stefan Freitag and specializes in software solutions and services for roll formers. The programs COPRA® RF and COPRA® FEA RF are the leading solutions for design and simulation worldwide. The company also offers the optical measuring systems COPRA® ProfileScan Desktop and COPRA® RollScanner for efficient quality control of products and roll tools. In addition, data M is also a service provider for design, simulation and analysis in forming – it maintains an international partner network and has subsidiaries in the USA, India, Poland, Sweden and Great Britain.

Published inSheet Metal

The Bavarian company data M (Hall 4, Booth F19) presents an over-all concept for roll forming of tubes, profiles and wire at the Tube & Wire 2016 fair. Besides the leading industry standard COPRA® RF and COPRA® FEA RF for design and simulation, the company offers an integrated portfolio of products and services for the sheet metal industry. At the data M booth visitors learn how to efficiently implement complex forming projects with different COPRA® solutions.

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Through close cooperation with customers and continuous innovations, data M became a highly demanded partner of industry and research worldwide. Alongside the renowned design- and simulation software, the company also offers solutions for quality control, error analysis as well as control technology. Additionally, data M guides customers in all project stages – from a feasibility study to conception and implementation of a roll forming machine. Albert Sedlmaier, data M managing director: “We have achieved a huge market share with our software due to our own research and because we have been working with the industry for years. Our employees are not only programmers and engineers but genuine roll forming experts. There is barely any roll forming related subject that we haven’t dealt with in the past.”

Among other things, data M presents a continuous software solution for the production of round- and rectangular, shaped as well as flexible tubes. COPRA® FEA RF simulates the entire production chain, including pre- and post-operations like welding, stamping, punching, bending and more. data M engineers demonstrate how an entire project for round tube shaping with subsequent reshaping into a square-, shaped- or rectangular tube can be realized quickly and cost-efficient. Using the example of a radiator tube the specialists also show how to conduct the forming with precursive embossing including the roll design.

By continuously expanding its product portfolio, the company from Upper Bavaria has incrementally developed into a genuine engineering service provider for roll formers. For instance, data M engineers designed a flexible tube for an oil platform that had to withstand enormous pressure. It consists of different layers like a wrapping layer, interlaced wire profiles and even a plastic layer. The specialists also support customers with error analysis and problem solutions. Just recently, a big coach company had difficulties with the closing edge on the bus roof. Through simulation of the entire production chain, the problem could be identified and a solution was worked out in collaboration with the customer. Managing director Stefan Freitag says: “Producers no longer just want our software. They also contact us when it comes to efficiently implementing highly complex projects and finding solutions for occurring problems.”

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Through own research as well as close cooperation with the industry, data M has been able to fulfil special requirements from roll formers. The company also sells optical measuring devices for quality control of profiles as well as roll tools. Additionally, the COPRA® RLM roll database is not only suitable for stock management but also fully integrated into the process chain. The entire roll stock can thus be searched for suitable tools as early as in the design phase. Furthermore, the function “Regrind” (COPRA® RF 2017) and the COPRA® RollScanner in cooperation with the database allow efficient reworking of worn out rolls and therefore saving tool costs.

data M Sheet Metal Solutions GmbH was founded 1987 by Albert Sedlmaier and Stefan Freitag and specializes in software solutions and services for roll formers. The programs COPRA® RF and COPRA® FEA RF are the leading solutions for design and simulation worldwide. The company also offers the optical measuring systems COPRA® ProfileScan Desktop and COPRA® RollScanner for efficient quality control of products and roll tools. In addition, data M is also a service provider for design, simulation and analysis in forming – it maintains an international partner network and has subsidiaries in the USA, India, Poland, Sweden and Great Britain.

In production of round and rectangular tubes, efficient use of roll tooling is crucial. Regarding time exposure as well as cost, it should always be the priority to rework an already existing tool. On the downside, it is far more difficult to just turn a worn out roll. This is because the contours need to be measured with sufficient accuracy, as the highest wearout among the tool set determines the value by which the other rolls need to be reworked.  Since there will frequently occur problems concerning this particular step, the easier but more expensive solution is most likely to just order a new roll and scrap the old one.

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The German company data M recently introduced the new feature “Regrind” to COPRA® RF and will present it at the upcoming Tube 2016 in Dusseldorf. This new function allows efficient reworking of roll tools together with the COPRA® RollScanner. It scans the roll contour with very high and thus sufficient accuracy. The respective data is automatically uploaded to the RLM database and thus available for assembling of the roll set. Subsequently, the Tube Design Module calculates the required reshaping of the tube and thereby identifies the roll with the maximum wearout. For direct comparison, the scanned and the designed contour can be displayed overlying. Due to the integrated parametrics, roll width and diameter can be adjusted if required. The acquired data is sufficient for the reworking of a complete roll set. The original, as well as the scanned or reworked contours will be displayed relative to the axis position. Furthermore, it is also possible to determine the minimal offset required for turning the roll contours.

data M Sheet Metal Solutions has almost 30 years of experience with software solutions and services in the field of sheet metal processing. In recent years, the company also added measuring systems like the COPRA® RollScanner, completing the product range towards an integrated process chain for roll formers.

Published inProcessing