Copra Roll Forming Full Download
Elisabetta Buendia
But COPRA RF has always remained just one thing, despite massively increased complexity: An effective design tool with simple usability. The most important functions are included in the basic versions of COPRA RF Tubes for welded tubes as well as COPRA RF Sections for profiles. However, these can be extended by further optional modules from the COPRA workflow and thus always be adjusted to specific requirements.
Together with the other optional modules such as COPRA RF Flower Technology or COPRA RF Roll Design, our software solution covers all necessary stages for the continuous processing of roll formed profiles or welded tubes of the highest quality.
Always included is COPRA RF Spreadsheet, which allows a simple parametric design of the forming flower. The program automatically updates changes over the entire flower and also adjusts the bending angles.
While working with COPRA RF and COPRA RF Spreadsheet, the user can switch between 2D and 3D views at any time. The integrated browser simplifies navigation, and "CADFinder" with its integrated document management also eases the organization of individual projects.
COPRA RF roll forming software provides a large number of predefined and, as required, customizable forming strategies. This makes simple roll design almost as easy as setting up complex roll forming systems.
Our simulation software COPRA FEA RF rendes cost-intensive trial and error processes obsolete. The module calculates even complex rollforming operations with hundreds of stations as well as pre- and post-processing manufacturing steps reliably and fast. Model creation is fully automized - there is no need for a dedicated FEA specialist.
Using simulations based on finite elements it is possible to avoid not only costly defects and insufficient product quality. Intelligent collaboration with further COPRA software solutions allows simulation results to be immediately available for optimization and error correction in COPRA RF. If required, the flower pattern can be adjusted automatically. As a side effect, consistent simulation of the forming strategy generates valuable know how within the company.
Material alterations during the rollforming process are often problematic for manufacturers ofprofiles and tubes, but do not pose a problem for COPRA FEA RF. Common defects likecorrugation of sheet edges, twists or other bends can often be avoided beforehand through verification.
The quick and reliable simulation with COPRA FEA RF not only optimizes the rollforming process, but also reduces wearout of roll tools to a minimum. Using finite element simulations, the greater part of the implementation of a rollforming line can literally be conducted by the software. Consistent simulation also avoids machine downtimes and ensures a cost-effective process.
Keep track of everything in complex forming processes: At the end of a simulation, COPRA FEA RF generates a dynamicanimation of the rollforming process and visually displays the results. This includes such crucial information like forming forces, driving torques as well as pressure and tension conditions. The data of the simulated cross sections will be automatically compared to the data derived from the design. Acomprehensive, three dimensional representation of the (virtual) product is also generated.
Process simulation not only reduces expences for prototypes, roll tools and the commissioning of rollforming lines. Consistend and documented verification of design also generates valuable know how within the company.Quite a number of customers report medium-term cost reductions due to a more efficient rollforming process and reduced wearout of their roll tools.
COPRA FEA RF 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.
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COPRA RF has been global market leader in the field of roll forming software. That is not only because we make the design process as effective as possible for producers, but also our employees constantly advance our solutions and acommodate ever changing demands from the industry.
Since modern roll formed products go through extremely long lines with additional steps like welding, embossing, bending or also Inline measurements. This means tough requirements for solutions that are merely met with good software alone. COPRA RF comprises all the experience of our long-serving employees that are not only software devolopers or engineers, but rather genuine roll forming experts.
COPRA RF covers the whole roll forming process chain and provides tailor-made software solutions for tube makers and profile manufacturers alike. It is integrated in the COPRA workflow and thus allows unlimted possibilities for process optimzation. Therefore, you can successfully conduct a simple roll tool design as well es the implementation of a complex roll forming line.
Most tube and pipe producing companies know that if the roll tooling design is not correct, you will experience increased scrap, due to marking, difficult setups, welding, and other formation problems.
Knowing that the importance of the perfect tube and pipe roll design is so critical, Roll-Kraft developed its own proprietary roll tooling design software in 1985. It was created so that we can build the best possible tooling for you. It combines proven design practices and experiences gained since the company was founded in 1963. Because we have developed and use our own proprietary software, it gives our customers the security of knowing their roll design will be perfect to produce their products. We have made numerous updates to our tooling design software over the years because we know that our customers are producing tube and pipe products with more exotic materials compared to years ago. We will continue to improve our design capabilities by adapting to this ever-evolving industry.
Roll-Kraft utilizes the Copra FEA RF (data M Sheet Metal Solutions GmbH) software. Specifically created for the tube, pipe, and roll forming industry, this software simulates the roll tooling design in order to predict the final result of the strip. This technology allows the designer to investigate multiple designs and materials in order to make any necessary revisions before the roll tooling is manufactured. When used in a prototype or R&D capacity, the software provides a scientific approach to roll design. Roll-Kraft has been using this software since 2003 and our experience is unmatched within the industry. The most critical element of this software is translating and understanding the data. Therefore, the more often the software is used, the more accurate the roll designs become. Our experience is the reason that we are so confident in our designs. If you are not satisfied in any way with our products, you will receive a complete refund.
Click here to see a tube mill configuration comparison using FEA. Use our contact form for more information on our capabilities for tube design, pipe design, and roll tooling design, or call us toll free at 888-953-9400.
COPRA FEA RF is used to simulate the roll forming operation by non-linear elastoplastic calculation. The COPRA RF design data can be automatically converted to a 3D SOLIDWORKS model via an interface.
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Feature papers represent the most advanced research with significant potential for high impact in the field. A FeaturePaper should be a substantial original Article that involves several techniques or approaches, provides an outlook forfuture research directions and describes possible research applications.
Abstract:Cold roll forming can fabricate products with complex profiles, and its parameter optimization can achieve high quality and improved precision of products. In this paper, taking the side shield as a typical product, the cold roll forming of a complex section of stainless steel SUS301L-ST is analyzed, establishing a 3D finite element model by using the professional roll forming software COPRA. We propose a floating roll device for complex sections with asymmetry and large depth. We use an orthogonal experiment to obtain the inter-distance between rolls, friction coefficients, the diameter increments, and line velocities to investigate the effects on the maximum longitudinal strain of the edge. Results show that the diameter increment has the greatest influence on the maximum strain, and its increases can reduce the strain. The inter-distance value needs a suitable range. A small value is not conducive to the release of elastic deformation, while a large value will cause unexpected displacement and increase the cost. The friction coefficient increases; although it helps to reduce the strain, it will cause scratches and other defects on the stainless steel. The increase in velocity increases the strain. We derive the optimal parameters for the complex section, providing a theoretical basis for practical production.Keywords: roll forming; finite element analysis; stainless steel; parameter optimization
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