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Thursday, November 26, 2020


Deformation Technology Module

COPRA® RF DTM calculates the maximum theoretical deformation elongation values in longitudinal and transversal direction.

The knowledge of these deformations are extremely helpful in order to successfully develop a new roll set. COPRA® RF DTM is not based on finite elements but on the theory of thin shells. The fast computing time of this analysis software tool has made it possible for the very first time to develop optimized roll sets taking into account parameters like profile cross section, forming length (not to be mixed up with "horizontal distance of passes...") and respective geometry, strip thickness, tool diameter and coil material.

The main target during development of this software program was the need of a fast and ergonomic tool for roll form simulation for the roll tooling engineer.

  • COPRA® RF 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® RF DTM is based on extensive FEA calculations and research results (data M Sheet Metal Solutions GmbH has been working using high end FEA solvers since 1992...)
  • COPRA® RF DTM is a software program of the "third generation"
  • data M Sheet Metal Solutions 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.
  • COPRA® RF DTM has always been (and still is) continuously improved by our developers.

With COPRA® RF DTM the tool designer gets hints on the profile quality before any foot/ meter gets into production. The computer model of the roll forming process is being generated automatically. This means: the designer doesn't need to care about modeling the roll forming process, except the definition of the so called flower pattern and mill/machine parameters. The values required are put in by means of easy to use and self-explaining dialogue boxes. Company specific values can be stored in the system's data base.

The coil is being displayed in a 3 dimensional view where the user can choose from various viewpoints and perspectives.
Up to now the only way to verify a tool design was the practical test on the roll forming mill. Using COPRA® RF DTM the designer has become able to verify his design and to correct or optimize it at an early stage.
The known "stomach aches" before setting up a new roll set have gone now. The often unknown time and costs for the setup period of a new roll set can be reduced and estimated much more accurately now.

COPRA® RF DTM is the only commercial strain/stress analysis software on the market taking into account in its analysis the influence of the forming roll tooling (roll position or roll diameter) on the material's theoretical strain values. COPRA® RF DTM also shows you the influence of coil thickness, strain distribution on top or bottom surface (elongation- or compression zone) and the sheet metal curvature in the forming area (allowing you a comparison with your actual forming line). You may find some nice looking screen diagrams or photographs somewhere else (having only a more or less similar accuracy like data M's wire-frame-model from 1990), but no comparable quality of results like COPRA® RF DTM which was released in its first version 1995.

Simulation history of COPRA® RF:

  • 1987: COPRA® Strip Edge Strain
  • 1990: COPRA® Wire Frame Model
  • 1992: First presentation of FEA analysis at Tube Düsseldorf (based on LS-Dyna 3D)
  • 1995: COPRA® RF DTM (Deformation Technology Module)
  • 2000: COPRA® FEA RF (Finite Element Analysis Roll Forming)
  • 2002: COPRA® FEA RF with MSC.MARC solver
  • 2003: COPRA® TQM (Total Quality Management)

System requirements

What are the requirements for a successful operation of COPRA® RF ?
COPRA® RF is available for Windows operating systems and requires AutoCAD or AutoCAD Mechanical (both registered trademarks of Autodesk).