Your Partner in the Roll Forming ren/2016/... · PDF fileI Winding I High-frequency welding I Hydroforming I Sweeping I Stretch Bending I Crash Simulation. ... I Automatic scanning

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R o l l f o r m i n g t h e F u t u r e ®

data M Your Partner in the Roll Forming Industry


COPRA® RF 2017 - Linked Products and Industry 4.0Integrated linked-up COPRA® productsThe core of the integrated products and the data exchange is the RLM roll management. The COPRA® RF Software as well as the COPRA® RollScanner are able to directly transfer the respective information to the RLM data base and make common use of it. CADFinder Project- and Document Management I Professional Project- and Document Management System for Roll FormingI Integrated Revision Control for the tracking of design changesI Checkout of Network projects for further local processingI Project- Preview and Data Export for COPRA® ProfileScanI User defined Project Attributes

SpreadSheet – flexible parametric Flower Design with Punch Hole EditorI Fully parametric Flower Design with integrated Roll Form TechnologyI Definition of company specific Profile Features like dovetail or hem that can completely individual be combinedI Cross- Project copying of Profile Segments and Unfolding SequencesI Integrated Punch Hole Editor, direct transfer of punched Sections from 3D models

SmartRolls – the fastest and most simple way of Roll DesignI Design in only one User Environment I CAD- functions are made more or less obsoleteI Significant reduction of mouse clicks, time saving up to 50%!I Free definable Roll Geometries – Roll Design without Limits!I Easy modification of Radii, Diameter, Widths, Relief Angles and Roll GapsI Automatic overlay of virtual intersection points of Sections and RollsI Clone Rolls in a Station or over the complete Project

RLM – Database driven Roll Lifecycle ManagementI Simple and reliable Management also of huge Stock Roll InventoryI Easy expandable search function based on the required Roll AttributesI RLM SmartSearch: quick Roll Search, no parameter input necessaryI Cross- referencing of Rolls: in which projects is a Roll already in use?I Create Bill of Material for purchasing, booking out of RollsI Industry 4.0 with RLM and COPRA® RollScanner – effective inventory management and quality control


Automatic FEA model creation within secondsI Easy pre-processing, effective post-processingI FEA model preparation direct from COPRA® RF Roll DesignI Analysis of roll forming process and connected process stepsI Helps to understand the material behaviour during formingI Easy and quick optimization of roll form designI Cost effective, virtual setup of a roll form toolingI Automatic mesh preparation for pre-, post- and inline punchingI Simulation with rotating rolls and friction to understand interaction between stations

COPRA® FEA RF - Advanced RestartI Allows a remeshing as required for roll forming applicationsI Helpful tool for sections for which the definition of the correct bending positions is difficult to define – e.g. the simultaneous deformation of multiple bendsI Significantly improves the quality of the simulation results I Avoids time-consuming search for the correct bending positionI No need to start a simulation from the beginning and make use of the already simulated stations - even if the mesh was adaptedI Inline- and post-punching supportedI Mesh adaptation at any point of simulationI Simple restart of a simulation after power cut off

COPRA® FEA RF - Shaft deflection and Station StiffnessI Calculation of Shaft StiffnessI Roll Gap Change caused by forming forces is calculated I The additional FEA simulation with the adapted roll gap is no longer necessary

COPRA® FEA RF - The Standard in Roll Forming Industrydata M roll form specialists profit from over 20 years of FEA simulation experience in research and industry; thus contributing to the software‘s continuous advancement.Optimized for roll forming operations, COPRA® FEA RF is easy to use as no FEA expertise is required for the handling of the software and evaluation of the results.


COPRA® RF 2017 - Integrated Roll Forming Solution ConceptRoll formed tubes, profiles and wires are used for many different applications in various industry fields, while the requirements of each line of business vary greatly. data M offers with its COPRA® software an integrated model of all operations and processes the material undergoes. This is an essential prerequisite assuring simulation results and practical results are matching. It covers parametric design, 3D options, roll tool management, and high-end finite element (FEA) simulation, including pre-, post- and inline operations such as:

I Stretch Bending 1 - Failure not enough Stretching

I Stretch Bending 2 - OK sufficient Stretching

I Stretch Bending 3 Finished Component

I Winding I High-frequency welding I Hydroforming

I Sweeping I Stretch Bending I Crash Simulation


Completing the work process of roll profile development, data M developed a profile scanner and a roll scanner.

Quality Management with COPRA® ProfileScan

I High-precision laser inspection

I Significant reduction of time to scan

I Complete integration into the COPRA® RF workflow

(COPRA® RF & COPRA® FEA RF)

I Simple tools to define jobs and tolerances

I Automatic scanning report

I Ideal for quality management

The new COPRA® RF feature “AssemblyCheck” allows to overlay designed and scanned roll contour in the Station Assembly. This is made possible with the link of COPRA® RLM Roll Lifecycle Management and the COPRA® RollScanner. Designed and scanned rolls can simply be overlaid in COPRA® RF. It is possible to overlay individual rolls as well as the complete assembly.

Integrated Roll Management

I Scanning of the roll contour with very high accuracy

I Automatic transfer of the roll contour to the COPRA® RLM database

I Immediate use of contours with the COPRA® RF design software

I Designed and scanned roll contours can easily be overlaid in COPRA® RF

I Overlay individual rolls or the complete assembly in COPRA® RF

I If changes were applied during roll setup, the roll design can be

updated instantly

I The acquired data can be used for the reworking of a complete roll set;

Save time and expenses through flexible reusing of discarded rolls

I COPRA® RLM offers intelligent roll management features;

The new feature SmartSearch allows a fully automatic real-time

search during the design process

I With the feature COPRA® RF „Regrind“ the contours necessary

for reworking worn rolls can easily be determined


data M Sheet Metal Solutions GmbHAm Marschallfeld 17 I 83626 Valley, GermanyTel.: +49(0)8024-640-0 [email protected] I www.data-m.com

TROPHY 2 “Thermoplastic, rollformed profiles in hybrid design 2“

This research and development project is funded by the German Federal Ministry of Education and Research (BMBF) and managed by the Project Management Agency Karlsruhe (PTKA). The author is responsible for the contents of this publication.

data M “Rollforming the Future” – Research and Development at the Highest LevelSince its founding almost 30 years ago data M has been striving to offer innovative, high-quality and state-of-the-art products and services to the roll forming industry. Research and development has thus always played decisive role in our daily work.

Due to its future-oriented approach data M has ever since been engaged in many research projects and has worked together closely with renowned universities and development partners around the world.

Currently data M is proud to be partner of the following projects:

SERVROLL (Start: 1.05.2016 / period: 30 months)“New servo-control, process design and set-up strategy for holistic optimization of roll forming”

The project SERVROLL is implemented in the European research framework „Eurostars“. Its German partners are funded by the German Federal Ministry of Education and Research (BMBF).

In the course of its R&D activities data M has cooperated for many years now as a project owner or project member with prominent partners all over the world including:

PtU Darmstadt, Deakin University Australia, IFUM University Hannover, KUAS University Taiwan, Dalarna University Sweden, NCUT China, Ohio State University USA, IUL TU Dortmund, Mondragon University Spain, LFT University Erlangen, TU Munich, Fraunhofer Institute IWU Chemnitz, LZH Hannover.

data M is a member of the following associations:

Your Partner in the Roll Forming ren/2016/... · PDF fileI Winding I High-frequency welding I Hydroforming I Sweeping I Stretch Bending I Crash Simulation. ... I Automatic scanning

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