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Copra: RF Software

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460 views107 pages

Copra: RF Software

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abhimanyu alwani

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COPRA® RF Software

User Manual . General Functions

Open Sections & Closed Sections

Trapezoidal Sections
©
Copyright data M Software GmbH

Unlawful reproduction, in any way, of this manual and its contents is strictly prohibited.

data M Software GmbH makes no warranty, either expressed or implied, regarding

these materials and makes these materials available solely on an "As is" basis. In
no event shall data M Software GmbH be liable to anyone for special, collateral,
incidental, or consequential damages in connection with the use of the materials
provided.

The sole liability to data M Software GmbH shall not exceed the purchase price of
the materials described herein.

Information in the manual is subject to change without notice and does not represent a
commitment on the part of the vendor. The software described in this manual is furnished
under a license agreement and may be used or copied only in accordance with the terms
of the agreement.

©
Copyright data M Software GmbH
All Rights Reserved
data M Software GmbH
Am Marschallfeld 17
D-83626 Valley/Oberlaindern
Germany
www.datam.de

Table of Contents

General Functions 1
1. Shortcuts 1
2. Entity Selection 2
3. COPRA® Memory 2
3.1. COPRA® Database 2
3.2. Computer RAM 3
3.3. The CPM File 3
3.4. Archive Files 4

4. The COPRA® Explorer with CADFinder 5

4.1. CADFinder/The box Project data 5
4.2. Flower 6
4.2.1. Flower data 6
4.2.2. Pass (x) 6
4.3. Rolls 7
4.3.1. Station 7
4.3.2. Axis 7
4.3.3. Roll Data and Attributes 7

COPRA® Basictools 8
1. The COPRA® toolbar 8
®
1.1. Starting COPRA 8
1.2. Project Manager – Please do no longer use 8
1.2.1. Dialogue box: Project Manager 9
1.3. The Base Functions toolbar 11
1.3.1. Settings 11

1.3.2. Material Choice 14

1.3.3. Station Attributes 15

1.3.4. Roll numbering 16

®
1.3.5. COPRA Zoom on/off! 17
1.3.6. Create Project Slide! 17
1.3.7. Save current Project! 18
1.3.8. Reload current Project! 18
®
1.3.9. Erase COPRA Database 18
1.3.10. Erase Screen! 18
®
1.3.11. Create COPRA Polyline 19
®
1.3.12. COPRA Screen Menu 19

2. The COPRA® Database toolbar 19

2.1. View Flower 19
2.2. Get Pass 19
2.3. Save Pass 20
2.4. Delete Pass(es) 20
©
Copyright by data M Software GmbH I
Table of Contents

2.5. Append Pass 20

2.6. Insert Pass 20
2.7. Fade-in Profile 21
2.8. Fade in Rolls 21
3. The COPRA® Utils toolbar 21
3.1. COPRA® Copy 21
3.2. COPRA® Paste 21
3.3. COPRA® DB Undo 21
3.4. COPRA® DB Redo 22
3.5. COPRA® Redraw 22
3.6. Entity Information 22
®
3.7. COPRA ? 22
4. Machine file for bearing seats 22
4.1. Modify 23
4.1.1. Pre-settings for creation of drawing 23
4.1.1.1. Settings Assembly Plan Dimensioning 23
4.1.1.2. Breakdown/Fin Pass 24
4.1.1.3. Intermediate/Idler Pass 24
4.2. Copy 25
4.3. Delete 25
4.4. Identifications 25
4.5. Current Machine 25
5. Convert Database 25
5.1. Action 26
5.2. Reference 27

Open & Closed Sections/Trapezoidal Sections 28

1. Profile design with COPRA® RF SpreadSheet 28
2. Profile Design with COPRA® RF 28
2.1. The Create Profile toolbar 28
2.1.1. Create Sections or add Entities 28
2.1.2. Add Entities to the Beginning 29
2.1.3. Mirror Profile 29
2.1.4. Centre 29
2.1.5. Delete one Entity 29
2.1.6. Delete a Sequence of Entities 29
2.1.7. Delete Current Section 30
2.2. The Profile Utilities toolbar 30
2.2.1. Edit Profile Section 30
2.2.2. Move Profile 35
2.2.3. Rotate Profile 35
2.2.4. Split Entity 35
2.2.5. Join Entities 35
2.2.6. Join All Entities 36
2.2.7. Same Number of Entities for 2 Profiles 36
2.3. The Profil Utils toolbar 36
2.3.1. Write Part of Profile to File 36
2.3.2. Read Part of a Profile from File 36
2.3.3. Write a Sequence of Passes to File 37
2.3.4. Read a Sequence of Passes into Flower 37
2.3.5. Material thickness 38
©
II Copyright by data M Software GmbH
Table of Contents

3. Profile of AutoCAD 39
4. Strip Width Calculation 41
4.1. Theoretical Basis 42
4.1.1. Bending 42
4.2. Profiling/Roll forming to Shape 46
4.2.1. Calculation of Neutral Line 46
4.3. General Observations 47
4.4. Calculation in Accordance with German Standard DIN 6935 49
4.5. Algorithm according to Proksa 51
4.6. Algorithm in accordance with Bogojawlenskij 55
4.7. Calculation in accordance with VDI guideline 3389 55
4.7.1. Creating a Data Table of Gauge Factors 59
4.8. Calculation according to Oehler 60
4.9. Standard Formula 61
4.10. Table 62
4.11. User 62
5. Punching 63
5.1. The Punching toolbar 63
5.1.1. Insert Single 63
5.1.2. Insert Multiple 63
5.1.3. Delete Single 63
5.1.4. Delete Multiple 64
5.1.5. Delete All 64
5.1.6. Copy 64
5.1.7. Move 64
5.1.8. Property 64
5.1.9. Information 65

6. Statics 66
6.1. Section Characteristics 66
6.2. Static Values 66
6.2.1. Geometrical Moment of Inertia 66
6.2.2. Surface Centre of Gravity 66
6.2.3. Principal Axes 67
6.2.4. Torsion Moment of Inertia 67
6.2.5. Section Modulus 67
6.2.6. Maximum Distance from Edge 67
6.2.7. Radius of Inertia 68
6.2.8. Shear Centre 68
6.2.9. Vaulting Resistance 68
6.2.10. Principal Axes Angle 68
6.3. Abbreviation 68
®
6.3.1. COPRA Calculated Values 68
6.3.2. Max. Distance from the Edge 68
6.3.3. Boundary Conditions 69
6.4. Formulas 69
7. Create Unfolding 70
7.1. Unfolding via Table with COPRA® RF SpreadSheet 70
7.2. The Flower toolbar 70
7.2.1. Plane of Unfolding 70
7.2.2. Unfolding 72
7.2.3. Fold 73
7.2.4. Folding with Angle/Radius Calibrating Method 73
7.2.5. Bending Straights 73

7.2.6. Splitting Straights for Over-bending Purposes 73

7.2.7. Automatic Unfolding 74
7.2.8. Execute Unfolding 75
7.2.9. Dynamic Flower 75
7.2.10. Dynamic Unfolding 76
7.2.11. Dynamic Folding 76
7.2.12. Plane of Unfolding 76
7.2.13. Symmetrical Profiles 76
7.2.14. Calibrate 76
7.2.14.1. Constant Radius Method 77
7.2.14.2. Constant Length of Neutral Line Method 77
7.2.14.3. Track holding Method 78
7.2.14.4. Angle/Radius Method 78
7.2.14.5. Power Bending Method 79
7.2.15. Reference Point 80
7.3. The Profile Utilities toolbar 81
7.3.1. Edit Profile Section 81
7.3.2. Move Profile 85
7.3.3. Rotate Profile 85
7.3.4. Split Entity 86
7.3.5. Join Entities 86
7.3.6. Join All Entities 86
7.3.7. Same Number of Entities for 2 Profiles 86
7.4. The Profil Utils toolbar 87
7.4.1. Write Part of Profile to File 87
7.4.2. Read Part of a Profile from File 87
7.4.3. Write a Sequence of Passes to File 88
7.4.4. Read a Sequence of Passes into Flower 88
7.4.5. Material Thickness 88
7.5. Adapt Flower 89
8. COPRA® Trapezoidal Section 90
8.1. Manufacturing Problems 90
8.2. Profile Design 91
8.3. Bending Sequence Trapezoid 92
8.3.1. Run a Bending Sequence 93
8.4. Unfolding Flower 94
8.5. Outline: Wire Model 95
8.6. Strip Edge 95
8.7. Tangential Transition 96

General Functions

You will find important tips, which you should follow under this sym-
bol.

Under the star symbol you find useful tips.

1. Shortcuts
In the modules Profile, Flower, Rolls and NC Data’s the shortcuts "+", "-",
"+-", "++" and "--" are available.
If changes are made you will be asked whether the changes should be
saved in the last actual pass.
Please note that that pass number 1 is the end profile, if numbering with
passes is chosen. If numbering with stations is chosen station number 0 or 1
(depending on your settings) is the flat strip. You may chose the numbering
in COPRA® Settings – Pass- and Roll-numbering. .

(+)
The shortcut "+" loads the data of the next higher pass number from the data-
base. If the current pass is the last saved in the database, then pass number one
will be loaded.

(-)
The shortcut "-" loads the data of the next lower pass number from the database.
If pass number one is the current one, the highest pass number will be loaded.

(+-)
The shortcut "+-" loads the data of the current pass from the database. So all not
yet saved changes in a pass will be reserved.

(++)
The shortcut "++" loads the last pass / end profile of the flower from the data-
base.

(--)
The shortcut "--" loads the first pass / first station of the flower from the database.

2. Entity Selection
Some COPRA® dialogue boxes supply a list of entities for modification purposes.
Entities can be highlighted in the list using the crosshairs and then be modified. To
modify multiple entities in the same way it is possible to highlight all the entities to
be modified in the list.

The limits of the, from and to values, are within the filter selection set.

If the Use Filter for bend angle and Use Filter for Radius are both se-
lected, only those entities will be taken care of when selecting the Select! or
Deselect!, which match both the angle and the radius of the filter selection
set.

3. COPRA® Memory

3.1. COPRA® Database

All data of a project are saved in the COPRA® database on the hard disk of your
computer. This is project information, common data and the geometry of sections
and rolls of all passes. The database covers the COPRA® work files.

The database consists of the following files:

• ALLGEM.DB → Project information
• PROFIL.DB → Section data of all passes
• RAHMEN.DB → intern data
• VERWTG.DB → Administration of the passes
• WALZEN.DB → Roll data of all passes

All database files are saved in the project directory. To modify the data of a pass,
they need to be loaded into the computer memory. After the current pass data has
been modified, it is written to and updated on, the hard disk database.

There are various possibilities to save the data of the current pass to hard disk:
• The current pass is saved with the Save DB option.
• A new pass is loaded into the computer memory with the Get Show option
and the Save current pass is selected.
• The Save current pass option is selected when exiting a module.

3.2. Computer RAM

In the computer memory, only the data of one individual pass are loaded.

Only the data of one pass can be loaded into the computer memory.
This is the current pass.

In case of a computer breakdown only the modifications made to the current

pass will be lost.

Modifications made to a pass are only saved in the computer memory until a Save
to database is being executed.

The design work made with COPRA® is very much faster if, in the first step,
modifications are only made in the computer memory.

Exiting AutoCAD without saving the current pass may cause a loss of
data that are only available in the computer memory.

3.3. The CPM File

When opening a new project from the project directory, a project file with the
name "PROJECT".CPM will automatically be created. In this project directory all 5
files of the database with the extension *.DB are saved.

The 5 work files *.DB of the database are saved compressed in the project
file. This saves a lot of disk space. To have access to the project data the
project file has to be uncompressed. The database files will be created when
uncompressing a project file.

The project file should be used to save the latest design situation.

If a project file with the latest design situation is existing, it is possible to do

test modifications on the project. If the modifications should be discarded, the
original design situation can be reloaded from the project file. If the modifica-
tions are OK, the new design situation can be saved in the project file.

The information of the current project is saved in the project file. When fin-
ishing a project, the data of the last design situation should be saved in the
project file. All data concerning the section, the flower or the rolls can be
used if later modifications of the project should be necessary.

3.4. Archive Files

Function:
Important design steps should be saved in Archive files
An Archive file has the same file format as the Project file.

In Archive files the 5 database files *.DB are also saved compressed and
therefore cannot be modified directly.

Opposite to the one Project file, as many as necessary Archive files may be
created.

The Archive files should be used to save important steps in the design. It is like a
snapshot of the current design situation. Especially after having worked with the
modules Profile, Flower and Rolls it makes sense to create an Archive file.

Archive files can be very useful if changes need to be made to the project or
if a similar section has to be designed later.

The project file is always located in the project directory. The project file-
name cannot be changed. The location of the Archive files, as well as the
Archive file names, are defined by the user.

The COPRA® database was changed several times since the first re-
lease. Therefore it may happen that an old database would have to be
converted first. Archive files of previous releases can always be
®
loaded. Therefore all COPRA databases should also be saved as Ar-
chive files. Before old Archive files are loaded a new project should be
created with the Project Manager.

4. The COPRA® Explorer with CADFinder

Function:
Quick navigation during design

The COPRA® Explorer allows a quick navigation during design and provides a
clearly-structured overview of the existing projects. With the help of files it is pos-
sible to page between the individual stations and to determine their profile and roll
data. Radii, angles and neutral line can be checked quickly. Furthermore, you can
select another option by clicking the mouse, e.g. a different pass number. The
pass number incl. the required data will then be automatically displayed as the
® ®
current pass. COPRA Explorer can be switched on in the toolbar COPRA Ex-
plorer.

The COPRA® Explorer is divided into the main options Flower, Project, Rolls and
CADFinder.

4.1. CADFinder/The box Project data

All data concerning your COPRA® project are displayed in this box. It can be
opened via the button “Projects” in Explorer. If you click the current project with
right mouse key opens a window. Click on Properties (at the bottom of the box) to
open the dialogue Project Properties .
You may see and change the name of your project under Project name. Below
the Project name is the Project path displayed. Click the button in order to
change the Project path. Next are the items Project comment and Document
no.-prefix listed.
A click on the button Attribute opens the dialogue Project attributes. You may
define general Project attributes such as Company or Profile Number further
®
you may modify COPRA Project attributes as Sheet Thickness. Confirm with
Accept for saving changes.

What are the features of this solution?

COPRA® CADFinder is a document management system that allows also to or-
ganise any files independent from a defined file structure on a storage device. To
do so the user creates a nested project structure. The documents can then be
assigned to a project in this structure via a document number. The organisation of
the documents and the assignment to the physical file path is done by a data base
server (e.g. MS SQL Server or an alternative data base with SQL and ODBC sup-
port for the multi user version or the MSDE data base in a single user environ-
ment).

Furthermore user defined attributes can be linked with projects and documents.
This ensures a fast retrieving of documents via specific search functions. These
attributes in the COPRA® version of CAD-Finder may also be used to complete
the title block information in an AutoCAD template.

Also a structured view of projects (project manager) and belonging documents as

any number of flexible working catalogues are available for displaying different
search results. From here the individual documents can be opened, modified,
completed with new attributes, copied and moved very easy and comfortable. The
design of the structured view is similar to the Microsoft Windows-Explorer in order
to guarantee an intuitive working in a well known environment.

A revision control and workflow system is also available for the individual docu-
ments. So an older version of a document may be – if desired – saved before
modifying in order to have access to previous releases of this document. The his-
tory of a file may be saved. The link to the respective project is maintained. So for
a document multiple work situations may be saved. The workflow system recog-
nizes if a user works on a document and sets the workflow status to "Modifica-
tion". In that case any other user may only view the document. When the modifica-
tions have been completed the status is set back and the document may be modi-
fied by another user. Any number of workflow situations maybe defined by the
user.

Please refer to the COPRA® RF CADFinder manual for a detailed explanation

as well as further information.

4.2. Flower
By pressing the button "Flower" appears a list with all passes .

4.2.1. Flower data

The flower data box gives you information about the number of elements, outside
and inside length of the profile, the length of the centre and neutral line - as well
as the value oft strip width.

4.2.2. Pass (x)

All passes of the design are listed under Flower. Double click on a pass opens the
pass automatically in model view. If you click on the + sign of any station a further
list with all elements the profile consists of in the selected pass is displayed. You
will get detailed information about the arcs and straight entities the profile consists
of if you double click on any element.

Arcs:
Double clicking on an arc element opens a small box giving information about the
neutral line, radii and angle.

Lines:
Double clicking on a line element opens a small box giving information about the
length and the start angle of the straight element.

4.3. Rolls
By click on "Rollers" are all Stations, their axes and rolls listed in a box. The button
station attributes appears if you select a station and click it with right mouse key.
Please refer to Station attributes for further information about station attributes.

4.3.1. Station
By double click on a station or by clicking on the + sign, all side, top and bottom
axes are listed.

4.3.2. Axis
By click on Axis top/bottom/left or right opens a list with all existing rolls. The start
and endpoint coordinates of the axis are listed.

4.3.3. Roll Data and Attributes

By click on any listed roll appears a list showing the following parameters under
roll data:
• Roll name
• Maximum width
• Maximum diameter
• Number of entities
• Roll type
• Weight

By click on any listed roll appears under attributes a list showing all available at-
tributes like:

• Material
• Roll bore
• Keyway
• Roll type top
• Roll type bottom
• Combination roll
• Stamping number
• Stamping groove width
• Stamping groove depth
• Inner diameter
• Bearing
• Roll number
• Roll type

COPRA® Basictools

1. The COPRA® toolbar

®
In the COPRA toolbar the following functions are involved:

The icons containing a small black triangle in the lower right corner can be
expanded with a click of the left mouse key so that additional information will
be available.

1.1. Starting COPRA®

Function:
®
Initialise the COPRA Roll form Software, or flip back to the last, active screen menu page.
During initialisation of COPRA®, the system checks whether the required settings
®
are available. For example, all layers required by COPRA will be created auto-
matically. If the AutoCAD commands of the Screen menu are used during design-
ing, it will always be possible to return to the last active screen menu.
This has to be the first command after AutoCAD has been loaded or a new draw-
ing has been created. The last actual project is loaded automatically.

1.2. Project Manager – Please do no longer use

In previous COPRA® version was this function used to create an manage projects.
® ®
But now COPRA ´s latest function, the COPRA RF CADFinder may be used for
that – see COPRA® RF CADFinder manual. The old COPRA® project manager will
®
no longer be available in the next upcoming COPRA version. .

If a project is set current in COPRA® CADFinder it will also be the current one
in project manager and the other way round.

Function:
Create new, display or update existing projects
The COPRA® Project Manager is a tool for easy project administration. All pro-
jects ever created with the Project Manager will appear in a project list.

One directory may contain one project only.

1.2.1. Dialogue box: Project Manager

Last current:
Shows the current project and its path.

Selected:
Shows the selected project and its path.

Project Mainfolder:
Shows the selected main directory. An additional main directory for projects can
be created.

COPRA® Setting files and prototype drawings should always be set.

More:
It can be used to reload projects, which have been removed from the project list. If
selected, a file dialogue box for project files will be opened. Project files do have
the extension .CPM. A double click on the filename or highlighting it and pressing
OK, brings this project back into the project list.

Sort Projects:
The project list can be sorted in alphabetical, chronological order or in groups.

New:
A new project can be created when selecting this button. If the directory of the pro-
ject path selected does not yet exist the user has to confirm the creation of the
directory. The project path defines the directory where the COPRA® database and
its related files will be saved. If the directory was created, the Material’s dialogue
box comes up and the coil material used has to be selected. It can be selected,
either from the list box or, if a proper material is not yet available, be created by
the user with the help of Create. The selected material is the default for all techni-
cal calculations like Spring-back and Deformation Technology.

data M Software does not guarantee that the material properties

shipped with COPRA® are correct as the natural deviations of the coil
material may be quite high.

After confirmation of the material, additional project information can be entered.

This information is optional and may be left blank.

Save:
Compresses and saves the current design data of the COPRA® database to the
project file. When exiting the modules Profile, Flower or Rolls, the project file
may be updated automatically by appropriate selection.

This function can also be used outside the Project Manager by selecting the
Save current Project, option from the pull-down menu.

Modify:
Project name and project directory can be modified.

Copy:
Copies an existing project to another directory, which can be selected.

Remove:
Removes the highlighted project name from the project list. The project data it-
self are not removed from the hard disk. A project that has been removed from
the project list can be reloaded by using the <more...> button (see <more...>).

Info:
Information about the highlighted project will be displayed and can be changed if
necessary. In the headline of the box selected Project name, Project path, Pro-
ject file and Material are shown. The additional information shown can be modi-
fied and customised. The material Thickness entered is the one used when de-
signing a new section. Customer, Product, Drawing Number, Design Date, De-
signer and Comment can be entered optionally.

Material:
Shows the coil material used for the highlighted project.

1.3. The Base Functions toolbar

Function:
®
Lists all basic functions of COPRA . See the following descriptions:

1.3.1. Settings

Function:
®
Change the default settings of COPRA

Language:
The desired language can be selected in the list box. Languages are connected
with the unit (mm) except English (US), which is connected with the unit (inch).

Centre of Profile:
Displays the section’s centre line.

Split Lines in Profile:

If toggle is set, split lines between arcs and lines will be shown.

Automatic Zoom:
If selected, a ZOOM EXTENTS and ZOOM <FACTOR>x is done after every
modification. The factor may be set to values between 0.5 and 1.0. If case the fac-
tor is set to 1.0 the ZOOM <FACTOR> option will not be executed.

Automatic redraw:
If selected, an automatic redraw is done when loading a new module. The screen
is updated with the current section and/or rolls. The current drawing entities will be
erased depending on the updating screen setting in the bottom of this dialogue
box.

Fade out Plane of Unfolding:

If this feature is active, the plane of unfolding will be faded out.

Fade in next Section:

If selected, the next section saved in the COPRA® database is also being dis-
played on the screen.

Fade in previous Section:

If selected, the previous section saved in the COPRA® database is also being dis-
played on the screen.

Pass and Roll Numbers:

Gives access to all options regarding pass or roll designations. By selecting the
Fade in spacer dimensions, option the widths and diameters of the space rings
will be faded in.

Please refer to chapter Rollnumbering in COPRA® Rolldesign & Rolltechnol-

ogy manual, too.

Numbering of the different Stations:

The numbering with station provides with further options, like separate numbering
with station types.

Use COPRA® Numbering:

The standard COPRA® numbering with passes or stations will be used.

All continuing:
If your stations should be numbered continuously select the button next to All
continuing.

The resp. stations separated:

If you would like to have a separate numbering for each station type enable the
checkbox The resp. stations separated, please. This means that the station
types will have an own numbering within their group e.g. Turk head 1, Turk head 2
and so on.

Please refer to the in following explained point “Rollnumbering”, too. You

have got the possibility to create individual roll numbers.

Idlerstations:
Enable the toggle Idlerstations if you would like to have a separate numbering for
the intermediate stations in addition to All continuing or The resp. stations
separated. In this case the idler stations will be as such identifiable and their
numbering will eg. be 1-2 .

Attach stationtype to profilenumber:

Enable the toggle Attach stationtype to profilenumber in order to make the sta-
tion type always visible. Thereby the chosen station type (eg. calibration idler sta-
tion) will be attached to the profile number when updating screen.

Layer Control:
Allows modification of all COPRA® layers according to his/her requirements.

COPRA® Paths:
Provides an overview of all paths used by COPRA® for the current project. Names
can be modified according to your requirements.

Technology:
Determines the decimal signs used during export.

COPRA® Options:
Provides the option to fade in dialogue boxes for the selection of functions. Fur-
thermore, the settings for automatic background backups can be defined. Up to 30
archive files can be backed up, i.e. the 31st file will overwrite the first file etc.

Contours as Polylines:
If selected, all section and roll contours are drawn as polylines.

Clear only COPRA® Layers when updating Screen:

If selected, all drawing entities placed on COPRA® layers will be erased when a
®
COPRA Redraw (C Redraw) or any other updating of the screen is being made,
e.g. when using the command Get&Show.
If not selected, all drawing entities will be erased when a COPRA® Redraw (C Re-
draw) or any other refreshing of the screen is being made, e.g. when using the
command Get&Show.
This option is very useful when e.g. designing the rolls. For the construction lines a
layer of its own can be created. If selected, all construction lines will still be visible
®
after the COPRA Redraw or Get&Show command has been executed.
A typical example is to connect the endpoints of the roll axis with a construction
line and use this to create the necessary offset lines to get e.g. even spacer ring
dimensions.

Clear also COPRA® help layers when updating screen:

Deletes all drawn lines on COPRA® layers including the help layer during a re-
draw.

Automatic redraw when changing project:

A redraw will be done automatically when enabling this option and changing into
another project and the project will be displayed. If there is actually no data in this
project the screen will not change. It is recommendable to enable this toggle.

Delete X-References:
COPRA® works with X-references when creating assembly plans and/ or when
defining individual roll- and station-attributes. It is recommendable to enable this
toggle because then the external AutoCAD drawings will be only loaded as indi-
vidual roll- or station-attributes when you browse between passes. If an X-
reference is saved to network another user may have changed it, so enabling this
toggle guarantees that you have always the latest version loaded on screen. Fur-
ther you do not have to delete the X-references from the assembly plans manually
if you enable this toggle.

The dialog box roll information:

Show info in Rolls:

It is possible to show raw diameter, weight, sequential number for top/bottom rolls,
sequential number for side rolls, material and rolls type in the rolls.

Alignment:
Show the info on the left, right or center position.

Description:
The roll info described above can be set on none, as prefix or as suffix.

1.3.2. Material Choice

Function:
Select the material you want to use
You may choose a material in a dialogue box, further you may edit material or
create a new one and its properties. In the past this could only be done via the
Project Manager.

1.3.3. Station Attributes

Function:
Station types can be individually named
For each station can be defined which station type it is, e.g., a driven station, side
rolls or a welding station or a drawing die and so on.

COPRA® takes automatically the station types from tube mill map layout eg.
turk heads if a flower design exists. This needs to be taken into account when
®
working with the COPRA Module M3 (Automatic tubemill map. The listed
station types can not be modified if there is data in tube mill map de-
fined. If there is no data in tubemill map COPRA® shows you in the dialogue
box Station Attributes a hint: There is no data available in tube mill map.

The single stations of your design are listed in a table. In order to link any specific
attribute click it with left mouse key, please. At the very left of the table is the Sta-
tion numbering with COPRA® displayed, on the right next to it the numbering
with machine.

Station type:
You may choose between the attributes main, idler, Turk head, welding, drawing
die, lineal and strip guide.

Inserted station:
If you have later inserted a station - mark the check box Inserted station , please.
Then already existing roll numbers will not be changed. The roll number of the
later inserted station will be marked with an A. If you want you may adapt these
roll numbers via the individual roll attributes.

Station sub type:

Depending on the chosen station type are additional attributes as pre bending, or
calibration available that may be linked to the station.

Station:
You may define the corresponding number that the station has got on machine
here.

1.3.4. Roll numbering

Function:
Individual roll numbering global for all or for single projects

You may define an own roll numbering for your company here. The settings
are either valid for all projects or for the current one – depending on your set-
tings.

A dialogue opens if you click the icon Roll numbering.

*ATTENTION* – Please take care whether main- or idler station is chosen (see
left side on top of the box). Depending on your choice either the numbering for the
main or the idler stations may be defined.

The column Selection:

Please select here which information you want to add to your individual roll num-
ber. Furthermore the option „Delimiters“ is available. You may add e.g. a hyphen
between two chosen information in roll numbering.

The column Format:

Depending on your needs you may add the information complete or as short cut.
E.g. drawing number (complete) or DNo. (abbreviated). Æ see also „Abbrevia-
tions“

Selected elements:
Your selection is displayed here. The line Example at the bottom of the dialogue
gives you a preview on how your roll number will look like later.

If you need to delete an element from list mark it, please (e.g. Pass number| Ara-
bic number) and click this symbol , the symbol is available between the Format
and Selected elements column.

Click this symbol for deleting all available elements at once the symbol is
available between the Format and Selected elements column.

For changing the sequence of two chosen elements in top direction you may use
this symbol: .The symbol is available between the Format and Selected ele-
ments column. If you want to change the sequence in bottom direction you may
use this symbol . The symbol is available between the Format and Selected
elements column.

Short cuts:
You may adapt short cuts to your needs using this function. Just click the respec-
tive button and a dialogue listing all available short cuts will open.

User defined text:

By right mouse key click in the column "Format" you may enter a user defined text
if you have chosen this option. The information may then be linked to your roll
number.
It can be linked to roll number if you mark it and press this button . The user
defined text may be deleted in the column "Format" by pressing the "Delete" key.

ATTENTION when deleting user defined text!

If user defined text is deleted from "Format" column it automatically disappears at
the right site in the column "Selected elements".

Set as Default:
The user defined roll number will be used global, for all projects.

Set for Project:

The user defined roll number will be used for the current project.

Numbering of later inserted stations:

Please refer to station attributes (point 1.3.2).

1.3.5. COPRA® Zoom on/off!

Function:
®
Switches the automatic COPRA Zoom on or off

1.3.6. Create Project Slide!

Function:
Exchange automatically created project slide by customised one
After the Strip Width Calculation a project slide is automatically being created
showing the final section in the preview of the COPRA® Project Manager. With the
Create Project Slide function this project slide can be replaced by a user defined
one. The content of the screen is independent of any restrictions. It may be the
flower, a 3D wire-frame model or even a roll form simulation picture including the
rolls.

In case it should not be possible to create a project slide, check whether the
project name contains a dot.

1.3.7. Save current Project!

Function:
Save the design data of the current project
All design data of the current project can be saved in a project file. Project files
have the extension CPM (COPRA® Project Manager). The contents are the same
as in Archive files.
Opposite to the Archive module the user does not have to enter a filename. The
filename is put together automatically from the project name.
The Project file should not be used to replace the Archive files! With the Archive
files a history of the design process can be created. In a Project file only the last
design situation is being saved! The Project file is only an additional option to save
the design data. When exiting the modules Profile, Flower or Rolls the Project file
can be updated by crossing the respective toggle.

1.3.8. Reload current Project!

Function:
Load the design data from the Project file into the current project
The content of the latest saved Project file is loaded into the COPRA® database.
An existing database will be overwritten.

1.3.9. Erase COPRA® Database

Function:
®
Erase the COPRA database files from hard disk
The design data of the current project are saved in the COPRA® database files.
These database files are work files that should be saved as an Archive or Project
file. Sometimes it is necessary to have more than one flower in a project. In this
case the COPRA® database files can be erased from hard disk and a new section
®
can be designed. Before the COPRA database files are being erased their con-
tent can be saved in the Project file. If the design data are not saved in the Project
file, an additional user confirmation is necessary.

1.3.10. Erase Screen!

Function:
The content of the screen is erased depending on the Delete options setting
If the Clear only COPRA® layers when updating screen is selected, then all
drawing information placed on COPRA® layers will be erased. The names of the
COPRA® layers are set in the Settings. If the switch is set to all active layers, all
drawing information will be erased.

1.3.11. Create COPRA® Polyline

Function:
Design of the outside, inside or centre section contour as a polyline
The final section of roll formed profiles is very often dimensioned by its contour in-
tersection points. When using the standard design possibilities of a CAD system
this can be a lot of work. The contour needs to be designed with the help of con-
struction lines and then has to be redrawn.

®
1.3.12. COPRA Screen Menu

Function:
®
Loading the COPRA Screen Menu
In contrast to the OEM standalone version, this function is currently still available
in AutoCAD.

2. The COPRA® Database toolbar

The COPRA® database toolbar includes the following functions:

2.1. View Flower

Function:
Display flower of the current project
This function is an easy way to display the flower of the current project. It is avail-
able at any time and shows all passes saved in the COPRA® database. With the
Selection of passes option the passes to be displayed can be selected.

2.2. Get Pass

Function:
®
Load a new pass from the COPRA database and save the actual one
Before a new pass will be load from database the actual pass can be saved by
this function. A dialogue box with all necessary information will be displayed.

2.3. Save Pass

Function:
Save the current pass in the database
The Save DB function saves the module specific data of a pass in the COPRA®
database.

2.4. Delete Pass(es)

Function:
Delete a selection of passes from the database
The number of passes deleted will reduce the number of passes. The pass num-
bers following the deleted ones will be reduced by the number of passes deleted.
If rolls are already available, it is for example, possible to delete the tools only.

The actual pass number can only be deleted if it was selected.

2.5. Append Pass

Function:
Append the current pass to the database
The number of passes is increased by one.

Example:
The number of passes saved in the database is 5. The current pass number 3 is
appended to the database. The new number of passes is 6 and pass number 6
will be the current one. The contents of pass number 3 and 6 are identical.

2.6. Insert Pass

Function:
Insert the current pass into the database
The Insert pass function will insert the data of the current pass as a new pass in
the COPRA® database. The number of passes is increased by one.

Example:
The number of passes is 5. The current pass number 4 is inserted as pass num-
ber 2 in the database. The new number of passes is 6. The new current pass is 2
and is identical to pass number 4. The pass numbers 3 to 5 are moved one posi-
tion upwards.

See also station attributes for retraining of already existing roll numbers.

2.7. Fade-in Profile

Function:
Fade-in a selected section
Allows to fade-in any section from the database. The current pass will thereby be
maintained.

2.8. Fade in Rolls

Function:
Display rolls for a station
The rolls for the section can be faded in for any station.

3. The COPRA® Utils toolbar

3.1. COPRA® Copy

Function:
Copy rolls or sections
Rolls or sections have not to be designed anew. Instead, existing rolls or sections
can be copied.

®
3.2. COPRA Paste

Function:
Insert copied rolls or sections
The copied roll or the copied section can be inserted in any pass. Rolls can be
inserted at any position, for example, top rolls can be used as left or right rolls or
as bottom rolls. However, you have to choose the respective COPRA® module at
first.

®
3.3. COPRA DB Undo

Function:
Reset commands
This function is similar to the "Undo" in AutoCAD. Up to 5 steps can be reset pro-
vided that the data was not saved beforehand.

3.4. COPRA® DB Redo

Function:
Reactivate changes
This function allows you to reactivate the last 5 steps provided that the data was
not saved beforehand.

3.5. COPRA® Redraw

Function:
Redraw drawing

3.6. Entity Information

Function:
Opens a dialogue box with the entity data of a previously selected entity
All data associated with an entity can be checked and loaded in a dialogue box.
The roll data can be displayed on screen with function key F2 (Test Window).

3.7. COPRA®?

Function:
Opens the Online Help. The language depends on what was selected under Settings
If selected the Online Help will be loaded. The language thereby depends on what
was set under Settings.

4. Machine file for bearing seats

The relation of the rolls with the machine axes is defined in machine files.
These machine files are used in the following modules:
• Single Roll dimension
• Automatic contour dimensioning
• Assembly plan
• Dimensioned assembly plan
The selection of the machine and modifications of the bearing seats are possible
after selecting the Machine option in the main dialogue boxes of those modules.

If a machine is set as the current one in one module then this machine is
also the current one in other modules.

Verify that the settings are not contradictory. For example, the diame-
ter of bore must not exceed the inner diameter of stamping groove for
roll numbers (Settings for drawing generation).

After selecting the Machine, option the Machine data dialogue box is loaded:

Machine:
All existing machine files are listed here. In order to set the current machine or to
modify one, it has to be highlighted in the list.

4.1. Modify
The settings of the machine picked in the machine list can be modified.

4.1.1. Pre-settings for creation of drawing

After selecting the Modify..., the Settings dialogue box will be opened, in which
the values for the borehole chamfer and stamping groove are defined.

Fig. 1 Bore for pass number

The inner ∅ of the stamping groove has to be greater or equal to the ∅

of the borehole plus twice the chamfer of the borehole. The ∅ of bore
for (T/B) can be found in the Breakdown/Fin Pass. The ∅ of bore for
(L/R) can be found in the Intermediate/Idler Pass.

4.1.1.1. Settings Assembly Plan Dimensioning

Illus. 2 Settings Assembly Plan Dimensioning

4.1.1.2. Breakdown/Fin Pass

Here, the details for the boreholes of the top and bottom rolls can be set.
These are the values for the borehole details of top and bottom rolls.

The inner ∅ of stamping groove (T/B) must be greater or equal to the

∅ of the borehole in the driven passes plus twice the borehole cham-
fer.

Illus. 3 Borehole details of the driven passes

A: ∅ of bore
B: ∅ of undercut
C: Supporting width (2x)
D: Fillet of undercut
x: Depth of keyway
y: Width of keyway

4.1.1.3. Intermediate/Idler Pass

These are the values of the side roll borehole details.

Illus. 4 Choose the machine for single roll dimensioning

A: ∅ of bearing
B: ∅ of borehole
C: Depth of bearing set
D: Fillet of bearing set

The inner ∅ of the stamping groove (L/R) must be greater or equal to

the ∅ of the borehole in the intermediate passes plus twice the bore-
hole chamfer.

4.2. Copy
The data of the machine highlighted in list are copied to a new machine. The
name of the new machine has to match the file format.

4.3. Delete
The machine highlighted in the list will be removed from the list. The correspon-
ding machine file is deleted.

4.4. Identifications
The name of the machine has to match the file format. Only 8 characters are al-
lowed. In the identification a detailed description of the machine is possible.

4.5. Current Machine

Displays the designation of the current machine.

Load of COPRA® Set:

®
Loads the plant data from the COPRA Set file.

Save to COPRA® Set:

Copies the machine data to the COPRA® Set directory.

5. Convert Database

Function:
Modify elements of construction

It can additionally convert axes or rolls for example, via a dialogue box.

Current:
Shows the actual pass.

Existing Profiles:
Provides information about the existing number of profiles.

Axes:
Displays the number of axes.

Selection:
This opens the Selection of Stations, dialogue box. The number of existing pro-
files and axes is displayed. By Max select, the selection of single, multiple or all
passes for a defined number of stations are possible.

Tool:
By Tool, it is possible to choose between top, bottom, left or right roll. Later the
selection will be modified.

Objects:
By activating this toggle the profile will be modified later.

Tool:
Axes and rolls can be enabled for modifying here.

5.1. Action
Offers the following options:
• Mirror horizontal
• Mirror vertical
• Move
• Convert
Depending on selected action the under objects chosen elements can be modified
respectively the action.

The different Actions:

Mirror horizontal:
The profile, axes and rolls can be mirrored horizontal. The action can be done by
point of unfolding, plane of unfolding or free point.

Mirror vertical:
The profile, axes and rolls can be mirrored vertical. The unfolding point, plane of
unfolding or free point, can do this.

Move:
The profile, axes and rolls can be moved. A vector of P1-P2 can be used. The
input of the x and y co-ordinates can be done by their values or by the selection of
the points by crosshairs. For selecting by crosshairs, use the buttons ->P1 and -
>P2.

Convert:
By entering a convert factor, the profile, axes and rolls can be enlarged or made
smaller by any value. Furthermore, conversion elements from mm to can be
made.

5.2. Reference
Here is the reference point for the selected action, thus, different reference points
are offered. Refer to the next point for a detailed description.

The different References:

Unfolding Point:
The unfolding point is used as the actions basic point.

Unfolding Plane:
The unfolding plane is the actions basis.

Free Point P1:

By defining the x and y co-ordinates any point can be selected as the actions ba-
sic point.

Vector P1-P2:
Two points that define the basis of the action can be selected with are two possi-
bilities:
1. By P1 (x1) (y1) to define the co-ordinates of the first point, and P2 (x2) (y2)
to define the co-ordinates of the second point.
2. Or click at the buttons ->P1 and ->P2. Then the points can be selected by
crosshairs. The co-ordinates of the selected points are automatically taken
into the dialogue box.

Convert Factor:
By entering a convert factor, objects can be made larger or smaller, or be con-
verted from mm to inches.

©
Copyright by data M Software GmbH 27
Open & Closed Sections/Trapezoidal Sections Profile design with COPRA® RF SpreadSheet

Open & Closed Sections/Trapezoidal Sections

1. Profile design with COPRA® RF SpreadSheet

Please refer to the COPRA® RF SpreadSheet user manual for further information.
Profile design an unfolding can easily be done in a table using COPRA® RF
SpreadSheet.

2. Profile Design with COPRA® RF

Function:
Create a section with the help of macros
This feature allows creating sections on the basis of entered parameters. By se-
lecting this icon, three toolbars are opened which will be described below.

2.1. The Create Profile toolbar

2.1.1. Create Sections or add Entities

Function:
New sections or entities can be added to the existing end of the section
After selection, a dialogue box with the respective section macros is opened.

Next:
Jumps to the next page with section macros.

Previous:
Jumps to the previous selection.
After selecting a section, a dialogue box is opened. Here, the section’s dimensions
can be entered with the help of parameters.

OK and new Entity:

Allows adding another entity to the end of the profile. As a section is existing, an
additional page with macros is provided.

OK and Section:
Creates the selected section.

When recalling the function, another entity can be added to the end of the section,
i.e. at the right end. At the highest entity number, COPRA® numbers the entities
from left to right.

2.1.2. Add Entities to the Beginning

Function:
New entities can be added to the beginning of the section
If selected, the same dialogue boxes as with the previous command are available.
The new entities will be automatically added to entity number 1. COPRA® num-
bers the entities from left to right.

2.1.3. Mirror Profile

Function:
Mirrors a section
This is a useful function for symmetrical sections. All entities will be mirrored. The
mirror line is the material thickness displayed at entity no.1 (the beginning of the
section) or at the last entity (the end of the section). All entities are mirrored in-
stantaneously. Entities of the same type will automatically be joined if chaining is
not set to off. If the valid number of entities is exceeded, a warning is shown in the
status line. To create e.g. trapezoidal sections, the Mirror option can be used
several times. Using the Mirror option a second time will cause all existing entities
to be mirrored.

2.1.4. Centre

Function:
Moves the centre of gravity of a section to the point 0,0
If a section was moved to another location or rotated by using the function, the
centre of gravity can be moved back to the point 0.0.

2.1.5. Delete one Entity

Function:
Remove one entity from the section

2.1.6. Delete a Sequence of Entities

Function:
Remove a sequence of entities from the section
A sequence of entities may be deleted by picking the first and last entity of the
sequence. All entities between the picked ones including these will be removed.
The remaining entities will automatically be chained again.

2.1.7. Delete Current Section

Function:
Deletes the current section data from memory
Entering the Del Curr, function will remove all entity data from memory. As a re-
sult you will get a blank screen. This function does not affect the content of the
COPRA® database. The shortcut +- allows resetting the changes. Another possi-
bility to reset the changes offers the COPRA®DB Undo, function from the
COPRA® Utils toolbar.

2.2. The Profile Utilities toolbar

2.2.1. Edit Profile Section

Function:
Modify dimensions and geometry’s of the section
Normally, it is not necessary to modify a section within a flower. This can be done
®
with the standard COPRA functions. There are only a few cases where function
is required.

This function allows modifying the calculated length of the neutral

line. Be careful with this function as it may give rise to problems.

Pass Data:
Supplies information about the current flower
• Number of passes saved in the data base
• Current pass number to be modified
• Number of entities in the current section
• Material thickness

Flower Data:
Provides a list of data for all sections within a flower.

Strip Width:
Supplies information about changes of the originally calculated strip width
• Original (old) strip width left of the section forming point
• Original (old) strip width right of the section forming point
• Current strip width left of the section forming point
• Current strip width right of the section forming point
• Difference between original and current strip width left of the section form-
ing point
• Difference between original and current strip width right of the section form-
ing point
• The differences between the strip widths are provided for verification of the
changes.

Listbox:
If selection with the crosshairs highlights an entity, its geometry data are trans-
ferred to the edit boxes at the bottom of the window. The values can be modified.
Selecting the OK button will make the changes permanent. The entities at the sec-
tion forming point (FP) are marked with an asterisk.

Radio Button S:
Enabled by COPRA®, if only a straight entity in the list is highlighted. A straight en-
tity can be changed into an arc entity by selecting B, and the previous data of the
straight are saved. If the arc entity is converted back to a straight, the previous
data will be restored.

Radio Button B:
®
Enabled by COPRA , if only an arc entity in the list is highlighted. An arc entity
can be changed into a straight entity by selecting S, and the previous data of the
arc are saved. If the straight entity is converted back to an arc, the previous data
will be restored.

Bend Angle:
The angle of all entities selected in the list is set to the pre-set value. Depending
on the selected procedure, the radii and lengths of the entities will be adjusted or
a length compensation is applied. This function is especially helpful if, for exam-
ple, not the inner radius but the outer radius is used as a basis.

Inside Radius:
The inner radius of all entities selected in the list is set to the pre-set value. De-
pending on the selected procedure, the angles and length of the entities are ad-
justed or a length compensation is applied.

Contour Radius:
The contour radius of all entities selected in the list is set to the pre-set value. De-
pending on the selected method the angles and lengths of the entities are ad-
justed or a length compensation is applied.

Length:
The length of the neutral line of all entities selected in the list is set to the pre-set
value. Depending on the selected procedure the angles and radii of the entities
are adjusted or a length compensation is applied.

% New:
The percentage of the neutral line with regard to the entire original strip width of all
entities selected in the list is set to the pre-set value. The lengths of the neutral
line are recalculated. Depending on the selected procedure, the angles and radii
of the entities are adjusted or a length compensation is applied.

For a description of how to select entities refer to General Information.

Profile Entity:
Here the number of entities in a section can be changed. In combination with the
function, dispense length compensation to selection, it is also possible to
separate entities.

Add:
If only one entity is highlighted in the list, it can be copied by using the, Add! op-
tion. The new entity will be inserted after the selected entity. If the copied entity is
a straight it can be converted to an arc if A is selected. If the copied entity is an
arc it may be converted to a straight.

The entity data of the new entity are similar to those of the copied entity.
Strip width differs by the length of the copied entity.

Remove:
All highlighted entities will be removed from the list.

Modification Procedures:
The different procedures have different effects on the section when changing an-
gle, radius or length of an entity. Several types of length compensations can be
applied.

Free:
This procedure is equal to the COPRA® calibration method Angle/Radii.

Change Angle Radius Length Length compensation

Angle Unchanged Is adjusted None
Radius unchanged Is adjusted None
Length Option: Adjust Option: Adjust None

Constant Length/Adjust:
This procedure is equal to the COPRA® calibration method Angle/Radii.

Change Angle Radius Length Length compensation

Angle Unchanged Is adjusted None
Radius unchanged Is adjusted None
Length Option: Adjust Option: Adjust None

Compensation with Straights only:

®
This procedure is equal to the COPRA calibration method Constant Radius.
Length compensation is done with straight entities only. If an adjacent entity of the
modified entity is not a straight entity, a new straight entity will be created auto-
matically.

Change Angle Radius Length Length compensation

Angle Unchanged Is adjusted With straights only

Radius Unchanged Is adjusted With straights only
Length Option: Adjust Option: Adjust With straights only

Compensation in Adjacent Entities:

This procedure is equal to the COPRA® calibration method Tube Profiling. Length
compensation is done with the adjacent entities of the modified entity, no matter
whether the adjacent entities are straight or arc entities.

Change Angle Radius Length Length compensation

Angle Unchanged Is adjusted Adjacent entities
Radius Unchanged Is adjusted Adjacent entities
Length Option: Adjust Option: Adjust Adjacent entities

Length Compensation:
If the selected procedure is based on direct length compensation, it can be de-
fined how the lengths are to be distributed at the right or left of the modified entity.

Outside:
Outside is the entity next to the modified entity, which is further away from the
point of unfolding and closer to the end of the section or, in case of closed sec-
tions, is closer to the welding point.

Inside:
Inside is the entity next to the modified entity, which is closer to the point of un-
folding and further away from the end of the profile or, in case of closed sections,
is further away to the welding point.

Adjust:
If changing the length of an arc or if an arc is used as a length compensation en-
tity, either the radius or the angle can be adjusted to the new length.

Angle:
If required, the angle of an arc entity is adjusted to the new length.

Radius:
If required, the radius of an arc entity is adjusted to the new length.

Length Difference:
After user-defined editing of the section data, a difference between the original
strip width and the new strip width may occur. This difference can be distributed to
the entities selected in the list.

Even:
The difference is divided by the number of selected entities. The resulting value is
added to each entity.

Percentage:
The difference is distributed as a percentage of the length of the entity. A longer
entity gets a higher percentage of the total difference and vice versa.

2.2.2. Move Profile

Function:
Move section
This function allows moving a selection of sections by defining reference and tar-
get points. The sections to be moved are displayed in the same colour. Optionally,
additional sections can be displayed which will be listed in a different colour. The
changes will be automatically saved to the database. If only one section was
moved, it could be saved optionally.

2.2.3. Rotate Profile

Function:
Rotate section
This function allows rotating a section as desired by selecting reference points.
The sections to be rotated are displayed in the same colour. Optionally, additional
sections can be displayed which are listed in a different colour. The changes are
automatically saved to the database. If only one section was moved, it could be
saved optionally.

2.2.4. Split Entity

Function:
Split one entity into two parts
Sometime it may be necessary to insert an entity where it cannot be done be-
cause of an existing entity. In this case the Split entity function can be used to
break an entity. The entity to be split has to be picked with the crosshairs. The
entity data will be displayed and the entity selection has to be confirmed. In case
of a straight the length to the break point has to be entered, in case of an arc the
including angle has to be entered. If the break position is valid, the entity will be
split in the position defined and the new section will be displayed.

2.2.5. Join Entities

Function:
Join split entities
If selected, two adjacent equal entities can be joined.
To do so, pick the entities with the crosshairs. All entities between, which have the
same geometrical values, will be automatically joined. In case of arcs, the inner
radii have to be equal.

2.2.6. Join All Entities

Function:
Join separate entities
If selected, all adjacent equal entities are joined within the section. In case of arcs,
the inner radii have to be equal.

2.2.7. Same Number of Entities for 2 Profiles

Function:
Adjust number of entities of two sections
The number of entities of the current pass and a second pass is adjusted. In the
occurring dialogue box the second pass has to be selected respectively.

2.3. The Profil Utils toolbar

2.3.1. Write Part of Profile to File

Function:
Writes a part of a profile for copying purposes to hard disk
In some types of sections there are repeated shapes. To avoid a new design of
these shapes they can be written to file with the Write PP option and copied with
the Read PP option.
A typical example would be stiffing ribs in a trapezoidal section.
Simply pick the first and last entity of the entities to be copied and enter a filename
describing that part. The entity data are written to file and are ready to be copied.

2.3.2. Read Part of a Profile from File

Function:
Reads a part of a profile from hard disk and inserts it in the current section
Each part of a profile written to hard disk can be inserted into the current section
with various options. After entering the filename these options are listed in the
status line:

Option 1: A - insert Part of Profile at the Beginning of the Section

Entering the option A causes the part of profile to be added to the beginning of the
section. The beginning of the section is at entity no. 1. The entity picked first when
writing the part of profile will be added to entity no. 1 as the first one.

Option 2: E - insert Part of Profile at the End of the Section

Entering the option E causes the part of profile to be added to the end of the sec-
tion. The end of the section is at the entity with the highest number. The entity
picked first when writing the part of profile will be added to that entity as the first
one.

Option 3: G - insert Part of Profile at a Location picked by Crosshairs

Entering the option G causes the part of profile to be added at a position picked by
crosshairs. The part of profile will be added before the entity picked by the cross-
hairs. The entity picked first when writing the part of profile will be added to that
entity as the first one.

Option 4: N - insert Part of Profile at a Location defined by an Entity Number

Entering the option N causes the part of profile to be added at a position defined
by an entity number. The part of profile will be added before the entity number
entered. The entity picked first when writing the part of profile will be added to that
entity as the first one.

2.3.3. Write a Sequence of Passes to File

Function:
Write flower to file
This function allows saving a flower or part of a flower to a file.

2.3.4. Read a Sequence of Passes into Flower

Function:
Read flower from file
This function allows reading a flower or part of a flower from a file.

2.3.5. Material thickness

Function:
Change material thickness subsequently
This function allows to subsequently change the sheet thickness for a complete
flower. In the occurring dialogue box you can choose between several methods.
After having selected a method, a slide provides a preview of how sheet thickness
will change.

Select:
Select the passes, whose material thickness is to be changed.

Plate Thickness old:

Information on the old material thickness.

Plate Thickness new:

Dialogue field for the new sheet thickness value.

Datum Line:
Defines the reference line for the modification of sheet thickness.

Iternal Radius constantly:

The inner radius of the section remains constant.

Outer Radius constanty:

The outer radius of the section remains constant.

Outer Contour constantly:

The outer contour of the section remains constant.

Centre Line constantly:

The centre line of the section remains constant.

Iternal Contour constantly:

The inner contour of the section remains constant.

3. Profile of AutoCAD

Function:
Creating a profile by AutoCAD polyline
The first step when designing a new roll set is the definition of the final section
shape. This can either be done with the COPRA® Profile Module or by designing
the section with the help of the CAD system. The handling is very easy. The final
shape of the section is designed and drawn with CAD functions. For the conver-
sion of the shape from a CAD drawing to a COPRA® section the CAD Profile
Module has to be loaded and the contour polyline has to be picked with the
crosshairs. In terms of AutoCAD, the design of the section has to fulfil the follow-
ing conditions:

Conditions:
• COPRA® has to be initialised
• Polyline from a contour or centre line of the profile must be on the screen
• The contour has to be drawn as a polyline
• Only inside, outside or centre line contour are necessary for the conversion
• If the section is designed with material thickness, COPRA® will cancel the
conversion.
• The intersection points between arcs and lines must be tangent
• The inside radius of the section may not be smaller than 0 during the con-
version

One of the following Options can be selected:

Erase Database:
The COPRA® database in the current project path will be removed. The number of
sections and passes will be zero. A completely new section can be created.

Continue:
®
The COPRA database in the current project path will not be removed. After the
conversion of the contour the new contour may be added to the existing section.

Cancel:
Exits the CAD Profile module. No data will be removed and no conversion is done.
After having identified the polyline, a dialogue box appears allowing you to define
the settings for section conversion.

Material Thickness :
The material thickness for the profile can be entered.

Centre Line:
The centre line is the reference for sheet thickness.

Contour Line:
The contour line is the reference for sheet thickness.

Centre of Gravity in 0.0:

If toggle is crossed, the centre of gravity of the section will be moved to the point
0.0 after the conversion of the polyline.
If there is already a section saved in the COPRA® database, which has not been
removed when loading the program, a dialogue box comes up offering various op-
tions.

Append:
The converted section will be appended to the database. If one pass was existing,
the new section will be saved as pass no. 2.

Overwrite:
The current pass, which is pass 1, will be overwritten with the converted contour.

Insert:
®
The converted section can be inserted in the COPRA database. The respective
pass number has to be user-defined. The definition can be done in an extra dia-
logue box.

No:
®
The converted section will not be saved in the COPRA database.

4. Strip Width Calculation

Function:
Calculation of theoretical strip width
The strip width calculation takes into account the stretching of the material during
the forming process. The inside radius of the material will be compressed and the
outside radius will be stretched. The neutral line of the material moves towards the
inside of the radius during being bent. This causes the length of the geometric
centre line to be different from the actual strip width.
After having selected the Strip Width function, a dialogue box appears which will
be described below.

Window:
The dialogue box appears, showing a list of all elements. Including, entity no.,
bend angle, the inside radius, the ratio inner radius/material thickness Ri/s0, the
length of the geometric centre line, the length of the calculated neutral line, the
calculation method used for a bend, a correction factor being dependent on the
calculation method and the difference between centre line and neutral line deltaB.

Calculation Method:
Allows selecting the method for strip width calculation.

Factor:
Enter the factor for defining the position of the neutral line.

Bend Selection:
The options Select, Deselect, Inverse, Filter and Crosshairs allow selecting
several arc entities to which the respective calculation methods can be assigned.

Calculation Methods:
Shows the selected formula or the value from the used table.

Section Data:
Shows the current data of the section as well as the calculated strip width.

Results:
The calculated strip width can be saved to a file. The name of the file can be se-
lected independently. The file is copied to the Project Directory, Info directory.

4.1. Theoretical Basis

4.1.1. Bending
Bending is a process of cold forming which industrial engineering often applies.
Leaving aside edge deformation, the process of bending is limited to a 2D reflec-
tion, which allows a ratio of unbent length b, and material thickness t, of more than
5. Thus, for the major part of all bending applications, we can use this simplifica-
tion.
Due to the elasticity of the material, the actually given bending angle of a finished
piece is inferior to the originally bent angle. The importance of the spring-back de-
pends on the amount of residual elastic stress before relief.

Fig. 5 Stress and strain condition with bent parts of different curvature

a : Stress value at yielding point

b : Stress value in plastic zone
I : Major bending angle; here we only have residual elastic strain.
II : Sharply bent metal; here we have besides residual elastic stress tensions in the plastic
zone accounting for the major share.

Hardly bent sheet metal with a much higher bending radius r, compared to its
thickness s, will therefore show a considerable tendency to spring-back into its
original position. The higher the ratio ri/s0, the higher the share of residual elastic
stress will be. This means that a square-edged curvature has a minor tendency to
spring back compared to metal with a significant bending radius.
The spring-back which first of all depends on the ratio of bending radius rI, and
material thickness s0, will in addition be influenced by the hardness and the mate-
rial micro-structure, however it is not influenced by the load period.

For an exact determination of the spring-back, the gauge factor k has been intro-
duced; k can be determined by tests. The spring-back ratio K is the ratio of bend-
ing angle after spring-back and bending angle before spring-back.

r1 + 0, 5 ⋅ s α 2
K= =
r2 + 0, 5 ⋅ s α1
The spring-back angle ρ therefore is:
 1 
ρ = α1 − α 2 =   ⋅α 2
 K − 1

Fig. 6 Spring-back diagram to determinate the value K

K : Spring-back relation
r1 : Inner bending radius
r2 : Inner bending radius after spring-back
s : Sheet thickness
α2 : Bending angle after spring-back
α1 : Set bending angle during the bending process
ρ : Spring-back angle

Exact values regarding the spring-back behaviour are indispensable if tool design
depends on the bending angle, e.g. in case of positive locking bending to shape.
During the forming of edged profiles, the spring-back can be compensated by a
deeper lowering of the bending rail with a greater side-angle of the bending de-
vice.
The process of bending causes a shift of the material towards the bending zone.
Due to the compressive stress in the inner zone of the curvature, the material is
upset and the layers of material will become thicker. In the external zone the ma-
terial will be lengthened due to tensile stress and the layers will accordingly be-
come thinner.

Fig. 7 Sheaf of lines in an arc of circle

The curvature can be subdivided in two zones in which only tensile stress or com-
pressive stress occurs.
A third zone has to be introduced in which the material is first upset and after-
wards stretched again. A limit elongation fibre has been defined as delimitation.
This is a fibre where no more alterations due to stretch will occur. At the beginning
of the bending process, it is identical to the median fibre and moves during the
bending process towards the inner side passing the whole range of the final inter-
mediate zone.
The fibre, which at the end of the bending process has the same length as before
shaping, is the so-called neutral line.

Fig. 8 Total elongation of individual layers depending on the edge elongation ea

Fig. 9 Bending radii shown at a shaped sheet metal

ra: outside radius

rmo: radius of the original centre fibre
rm: radius of the centre fibre
ru: radius of the neutral line
rg: radius of the limit elongation fibre
ri: inner radius

The non-lengthened fibre does not coincide with the centre fibre of the curvature.
This is due to the change in sheet thickness in the bending zone. The curves of
tensile and compressive yield stress are usually not the same for one material and
the influence of lateral strain should not be underestimated. The thicker is the
sheet and the smaller is the bending radius the more differs the position of the
neutral line from the centre fibre.
The micro-graph section of a square-edged aluminium sheet shows the actual
course of the fibre.

Fig. 10 Micro-graph of Al 99 h

Because of elongation the external fibre is subject to a smoothing of the curvature

so that in the centre of the curvature the external radius of curvature will be supe-
rior to the one of the lateral zones of curvature. Due to compressive stress in the
interior of the curvature, the margin texture might break down so that one cannot
classify it as a useful internal radius of curvature. Besides, the illustration shows
that because of the material shifts the fibres do no longer follow concentric circles.

During the bending of thick sheets with small bending radii, those edge deforma-
tions occur frequently. Because of the pressure the material on the inside is even
subject to lateral yielding. The fibres on the outside, however, are lengthened,
which causes a weakening of the sheet; it not only decreases the original thick-
ness but also the original width in the external zones.

4.2. Profiling/Roll forming to Shape

As for shaping, the roll forming or profiling technique is quite similar to the bending
process. Due to its continuous process, however, not only the desired changes in
shape appear but also undesired longitudinal deformations, which influence the
shaping behaviour unfavourably.
In calculating the position of the neutral line those longitudinal deformations are
disregarded.
Exact calculation of the coil stock width is required in order to guarantee stability
of dimension within given tolerance limits of a profile to be designed.
There are different methods to determine longitudinal modifications in the curva-
ture zones. Those methods often use different physical mathematical approaches.

4.2.1. Calculation of Neutral Line

Introduction
In order to take alterations appearing within the curvature zone during the bending
process into account one starts with a neutral line, which is neither lengthened nor
upset by the bending process. In unbent condition the length of this fibre corre-
sponds to the length of the work-piece that is to be bent. In bent condition the po-
sition of the neutral line defines the dimensions. The greater the distance to the
centre fibre in direction of the centre of the curvature, the shorter will be the neu-
tral line and the shorter will be the unbent length. The length of an arc is calcu-
π
lated as follows: ϕ ⋅ r ⋅
180
In practical life, compensation factors or gauge factors were introduced for differ-
ent materials so as to calculate the length in unbent condition. First a work-piece
to be shaped is designed in unbent condition. Thus the final dimensions are de-
fined. Tables and diagrams indicating the gauge factor for a certain material, de-
pending on sheet thickness and bending radius, were created in order to obtain
the dimensions for cutting to size of sheets. We only have to add this value to the
longitudinal dimensions of each curvature so as to receive the length in an unbent
condition. Those tables and diagrams were generated during tests with different
materials. Since the bending programme only uses contours and curvatures, the
dimensions always refer to them.

Thus, the coefficient of the position of the neutral line is used to calculate the
length of the bending zones; the coefficient can be deduced from the compensa-
tion factors. The gauge factors could be converted at once and be stored in a new
table for the position of the neutral line.

Nevertheless, the table of the gauge values was chosen as a basis for the calcu-
lation of the programme, in order to get easy control of the values. It is highly
probable that gauge factors for new materials will also be defined by tests so that
they can directly be included in the table. In addition, recalculating the gauge fac-
tor for each curvature does not involve major efforts.
With the present bending programme the position of the neutral line was entered
as a coefficient in relation to the thickness. For defining a curvature this coefficient
is automatically pre-set to 0.5 in order to provide for a minimum of changes in ex-
isting programmes.
Only during positioning of a piece, i.e. in calculating and appending the individual
elements of the work-piece the coefficient is calculated according to the material
and depending on the bending radius and sheet thickness and the pre-set value
will be overwritten. That enables you to proceed with the positioning of a new ma-
terial at any moment. The coefficients will be redefined.

4.3. General Observations

Calculating the coil stock width is mainly based on the following assumption: due
to deformation and constriction of material, see Fig. 11, in the bending area con-
nected with it, there will be a lengthening of the latitude co-ordinate of the work-
piece with given retention of volume.
In order to produce an arc element with a defined opening angle, and a median
length of arc b, as necessary for the production of a profile required, you have to
envisage a length element of the unformed material that corresponds to the me-
dian length of the arc of the finished profile, minus lengthening.
The value for the coil stock width of any profile required, results from the length of
unfolding of a finished profile minus the total of elongation’s that occurred in the
bending areas.

Fig. 11 Constriction in bending areas

All methods divide the profile into straights and arc elements for calculation. The
calculation of the initial width according to methods 1 to 3 is done in two steps.
First the theoretical lengthening is defined for each arc element of the profile, fol-
lowing the respective calculation rules of the chosen method. The total of those
lengthened is subtracted from the length of the profile after unfolding. And the re-
sult will be the coil stock width required, as the total of those lengthened of all ref-
erence zones, is the dimension by which the latitude co-ordinate of the material
will be increased due to the shaping process.

Fig. 12 Lengthening ∆b in a bending area

A model depiction of the lengthened ∆b in a bending zone is shown in Fig. 12. It is

supposed that the dimensions of straight sections will not change during shaping.
These reflections will lead to an inconsistent alteration of material thickness within
the transition zone between straight and arc elements. Nevertheless this approach
should be maintained provided the following points are taken into consideration. It
is known from studies that the material thickness s of bending areas reaches its
minimum at the vertex of the curve and will only reach the original material thick-
ness so far out at the adjacent side. We can assume that the surfaces between
the real and the imaginary course of the external borderline have the same di-
mension at each side of the transition in question. See also Fig 13.

Fig. 13 Transition from straight to arc

Thus, the transverse strain may be still defined on the basis of volume retention.
The method according to S+B proceeds slightly different in detail.

It approaches the arc elements with straight elements following certain rules. In
combination with further gauge values depending on the bending angle one ob-
tains the production width necessary for the arc element. Using the S+B method,
the coil stock width for a profile, results from the total of the defined production
widths for arc and straight elements.

4.4. Calculation in Accordance with German Standard DIN 6935

The German standard DIN 6935 on cold forming to shape includes a gauge factor
K, which takes the longitudinal alterations, based on the bending process into ac-
count.
This factor indicates the difference between unbent fibre and centre fibre of an arc
element and thus makes the calculations of the unbent fibre possible.
1 r 
k = 0.65 + ⋅ lg   k ≤ 1
2 s
This standard is valid for bent pieces of flat steels dedicated to the use in
mechanic engineering.

Fig. 14 Position of the neutral line according to German standard DIN 6935

r : internal radius of the curvature

s : material thickness
β : opening angle
a, b : leg length
v : gauge factor
L : stretched length
L = a +b+v

Thus, k/2 results for the coefficient of the position of the neutral line, since this
coefficient refers to the thickness s.
s
k = s ⋅ Koeff.
2
The DIN standard uses the factor k to calculate the gauge value. In the pro-
gramme however, you can immediately use the formula for calculation, since even
the choice of a certain dimensioning method does not allow the generating of a
homogenous table of gauge factors between German standard DIN and VDI
guidelines.

The conditions of this method which are to be taken into account regarding mate-
rial and bending radii admitted are shown in DIN standard 6935. The table 15
shows a material key list that is to be used for calculations according to DIN 6935.

steels with guaranteed minimum tensile strength

steels up to 390N/mm2 over 390 up to 490 over 490 up to 640
N/mm2 N/mm2
gen. structural QST 34-2 QST 42-2 QST 52-e
steels
according to DIN QST 37-2 QST 42-3
17100
QST 37-3 QST 46-2
Table 15

Table 16 lists minimum the bending radii (internal radius) admitted for the choice
of certain material thickness values and materials. The indicated values are valid
for bending angles α <=120°. For α >120° the following value in the table is to be
inserted.

smallest bending radius r admitted for thickness s

Steels during
with bending
over over over over over over over over over over over over over over
A guar- cross-
anteed wise or

L mini- parallel 1 1 1.5 2.5 3 4 5 6 7 8 10 12 14 16 18

mum to

Tensile direc- up up up up up up up up up up up up up up
strength tion to to to to to to to to to to to to to to

N/mm2 of roll- 1.5 2.5 3 4 5 6 7 8 10 12 14 16 18 20

ing

up to cross 1 1.6 2.5 3 5 6 8 10 12 16 20 25 28 36 40

390 wise

parallel 1 1.6 2.5 3 6 8 10 12 16 20 25 28 32 40 45

Over cross 1.2 2 3 4 5 8 10 12 16 20 25 28 32 40 45

390 up wise
to 490

parallel 1.2 2 3 4 6 10 12 16 20 25 32 36 40 45 50

over cross 1.6 2.5 4 5 6 8 10 12 16 20 25 32 36 45 50

490 up wise
to 640

parallel 1.6 2.5 4 5 8 10 12 16 20 25 32 36 40 50 63

Table 16

The lengthening of a bending zone is calculated with a non-dimensional correction

factor K with a value between zero and one. This factor indicates the deviation
towards the median line of an arc element and thus allows defining of the non-
lengthened fibre.

Fig. 17 Graphical depiction of the correction factor K

The delta value for the bending zone is calculated with the following equation:
a ⋅ π ⋅ s0 ⋅ (1 − K )
∆b =
360
opening angle α in (degrees)

Depending on the specific inner radius R ( := inner radius/material thickness ), the

calculation is subdivided into several process parts which deliver different values
for the correction factor K.

1. R>5 K = 1.0
2. 5, 0 ≥ R > 0, 05 K = 0.65 + 0.5 * log(R)
3. 0, 05 ≥ R ≥ 0 K = 0.0
4. 0.0 > R impossible after def of R
This division allows covering all possibilities of an arc element regarding bending
radius and opening angle relevant in practical life. Thus, the total of all calculated
Db values has to be subtracted from the unfolding of the finished profile in order to
define the coil stock width.

4.5. Algorithm according to Proksa

In order to allow for an overall application, the calculation according to Proksa is
subdivided into three calculation parts which are chosen and dependent on the
specific inner radius R (:= inner radius/material thickness). The lengthening ∆b,
which occurs in the zone of deformation due to the bending process, is calculated
respectively.

1. R >5 ∆B = 0.0
2. 5, 0 ≥ R ≥ 0,1 [ (
∆b = α 360 ⋅ π ⋅ 2ri ⋅ (1 − s ) + s 0 ⋅ 1 − s 2 )]
3. 0,1 ≥ R ≥ 0, 0 ∆b = α 360 + π ⋅ s0 ⋅ 0,12
4. 0.0 >R impossible after def of R

The division method shown in the second line is based on calculation rules de-
veloped by Proksa.

In this formula the specific material thickness S (= current material thickness/initial

material thickness) is used. Proksa uses a differential equation to calculate the
specific sheet thickness S and for the modification to material thickness he uses S
=s /so as a function of the specific internal radius R.

dS S ⋅ (e − A − 1)
=
dR s + R ⋅ (e − A + 1)

1 − 0.25 ⋅ χ 2  1 + 0.5 ⋅ χ 
with A = K ⋅ ln   ⋅ ln  
 S2  1 − 0.5 ⋅ χ 

2⋅S
it is valid χ= :curvature
2⋅ R + S

kv
K= :material factor
2 ⋅ k0
kv :coefficient of hardening
ko :yield point in shear

The solution of this non-linear differential equation of first order is only possible
with the numerical method of approximation. Here we chose the method of
Runge-Kutta. For plane metal (condition before shaping) the value for the specific
inner radius R = ri/so approaches the infinite set. As there is no constriction, the
specific sheet thickness = 1.0. For practical calculation R has to be chosen high
enough to be able to define a problem of initial value. In this application the values
have been set in the following way.
independent variable: R = 10.0
dependent variable: S = 1.0
The choice we made for the specific inner radius R is in any case sufficient be-
cause even calculations with a much higher initial value for R confirm our choice.
In order to proceed to a numerical solution we use an initial step of -1.0, which will
be commanded variably during the calculation programme so as to reduce the
error to a minimum. The solution range of the differential equation is also limited
by the abscissa value R = 0.01 to the amount of values relevant for the calculation
of the material width requested according to Proksa.
Fig. 14 shows a depiction of these solutions for several material factors K. The
solution curves are ending in the straight S = 1.0 with increasing R.
As comparison the curves for ideal plastic-rigid (kv = 0.0) and ideal elastic material
(ko = 0.0) are marked.

Fig. 18 Alteration of material thickness s/so as function of specific inner radius ri/so

The material factor K is a parameter of this differential equation and specifies the
given characteristics of the material used for production. The definition of factor K
requires the definition of the values kv and ko. For this purpose the yielding curve
of the material is replaced by a straight. However, you have to make sure that the
slope of this straight corresponds approximately to the slope of the yielding curve
in the middle of the zone of adaptation. Also, you have to make sure that the sur-
faces below the yielding curve and of the substitute straights are nearly of the
same size in the middle of the zone, see Fig 19. It is useful to carry out this ap-
proximation of the yielding curve with several straights, see Fig 20.

Fig. 19 Approximation to the real yielding curve by a straight

Using the example of the material UQST36, the determination of the factor K is to
be shown. First of all the appropriate areas are defined. The curve sections of the
different areas are approximated each by a straight in accordance with the above
mentioned criteria. From a depiction as shown in Fig. 16, you can get the values
required for the calculation of K.

Fig. 20 Yielding curve for material UQST36 with substitute straights approximated for different areas

The following interrelations are valid

k
k0 = r 0
3
k v = 0, 66 ⋅ tan β
β : slope angle of substitute straights

Now you may define the individual part of material K1 to K3 for the three areas in
our example. You will obtain:
K1 = 2.128

K2 = 1.021

K3 = 0.647

The arithmetic average of these three values is the material factor that is to be
used for the material UQST36.
KUQST36 = 1.27

With the information now available concerning material factor and differential
equation, the latter can be solved. The result will be a table with the solution points
(S; R) from which you can get the dependence of R and the value for the modifi-
cation of material thickness S. With acceptable exactitude a linear interpolation
can be used for intermediate points. The specific sheet thickness S has two appli-
cations in the above method of calculating the ∆b value.
As for the method in accordance with DIN standard 6935, all possibilities for an
arc element regarding bending radius and opening angle, relevant in practical life,
are covered by a sub-division into three steps. For the definition of the coil stock
width the total of all calculated ∆b values is subtracted from the unfolding of the
finished profile here.

4.6. Algorithm in accordance with Bogojawlenskij

The method according to Bogojawlenskij is based on the method of mathematical
statistics. The measured values necessary for this purpose have been obtained
especially from angle and U profiles.
As explained in the previous section, the calculation of the coil stock width is
based on the determination of the ∆b values for the individual bending areas.
For carbon and low-alloy steels this value is obtained as a result of the following
formulae which are chosen depending on the specific internal radius R.

1. R >5 ∆b = 0.0
2. 5, 0 ≥ R > 0,1 ∆b = 0, 1172 ⋅ nB ⋅ ∆S 0,1157 (mm)
3. 0,1 ≥ R ≥ 0, 0 (Falzung) ∆b = α / 360 ⋅ π ⋅ s0 ⋅ 0,12
4. 0.0 >R impossible after def of R

nB : number of bending areas of a profile

∆s = so * 0.0032 * α0.53 * 1.26 * R-0.55
α : opening angle in degrees
R : specific internal radius ri/so

The equations mentioned under 2, and the formula for the determination if the ∆s
value, have been developed by Bogojawlenskij only for applications with so = 1-
8mm, R = 5-35mm. α = 0-90° and material widths between 100mm and 350mm.
The deduction is based on angles and U profiles as already mentioned. For this
reason application is not recommended for all profiles.
According to literature this method obtained very good calculation results for angle
and U profiles.
In accordance with the methods explained, the coil stock width results from the
difference between unfolding of finished profile and total of all ∆b values.

4.7. Calculation in accordance with VDI guideline 3389

The VDI guideline 3389 page 3 deals with forming under bending conditions by
wedge shaped tool with 90°. The indications of the document are especially des-
tined to meet with high demands of 90° wedge-shaped bending and to forward
tested standard values to practise. Those standard values were derived from re-
sults of long-term statistical interpretation. The deviations of bent pieces caused
by unequal quality within one kind of material can be neglected in practical life.
Since each curvature is treated separately by the bending programme, it is suffi-
cient to take V bending into account disregarding e.g. U shaping, since the pro-
gramme interprets both curvatures as two V curvatures.
Due to material strain during shaping, the non-lengthened fibre is placed in a posi-
tion, which is not coaxial to the bending radius. Since the position cannot be de-
fined in geometrical terms and thus is of no use in determining the stretched
length, the gauge factors for bending angles of 90° have been determined by trial
and error by bending tests.

They are shown in diagrams in the VDI guideline 3389 page 3. On the basis of
these gauge values the position of a theoretical neutral line required by the bend-
ing programme is to be calculated.

Fig. 21 Stretched length according to VDI

s : thickness of the work-piece

ri : internal radius of the curvature
l1, l2 : internal side length
L : stretched length
x : gauge values

L = l1 + l2 + x

Fig. 22 Stretched length according to the position of the neutral line

a, b: lengths of the unmodified areas

Koeff.: position of the neutral line

dS
=
(
S ⋅ e−A −1 )
(
dR s + R ⋅ e − A + 1 )
©
56 Copyright by data M Software GmbH
Open & Closed Sections/Trapezoidal Sections Strip Width Calculation

π
The arc of the circle is calculated by ϕ ⋅r
180

The radius of the neutral fibre results from the internal radius. By equating the two
equations you will get an equation for the coefficient depending on the gauge fac-
tor. As the gauge factors for an angle of 90° are included in the VDI guidelines, ϕ
equals 90°.
dS
=
S ⋅ e−A −1( )
(
dR s + R ⋅ e − A + 1 )

Fig. 23 Dimensioning according to VDI

l1 and l2 can geometrically be divided into a, b and 2 * ri.

Thus for the first equation is:
L = a + b + 2 ri + x

π
By equating results: a + b + 2ri + x = a + b + (ri + s ⋅ Koeff.) ⋅
2
π
s ⋅ π ⋅ Koeff.
2ri + x = ri +
2 2

Resolution for the coefficient:

r ⋅ (4 − π ) + 2 x
Koeff. = i
s ⋅π
This equation allows calculating a single valued coefficient using the values of
bending radius, thickness of work-piece and material, as the gauge factor x is a
function of these three values and no other parameter appears. If the material is in
addition, compressed in the bending area, you will have to consider the stretching
stress for each zone of shaping.

In practical life the following deduction values K proved useful which were in-
cluded as a table in the VDI guidelines:

Thickness of work-piece s in (mm) K

in(mm)

≤0.5 ≤ 0, 5 0.05

>0.5≤1 > 0, 5 ≤ 1 0.1

>1≤2 > 1 ≤ 2 0.15

>2≤4 > 2 ≤ 4 0.2

L = l1 + l 2 + x − K

Regarding the bending programme, this factor k has to be considered as well for
the coefficient of the position of the neutral line. The geometrical reforming of the
value of deduction will lead to a new coefficient, coeff.*.

By inserting:
x=:x-K
in the equation of the coefficient you will have the following result for the new co-
efficient:

4.7.1. Creating a Data Table of Gauge Factors

Calculating the coefficient of a position of the neutral fibre is an independent pro-
gramme and thus has to transmit the following variables:
• internal radius of curvature
• thickness of work-piece
• material

For flat steels according to DIN 6935 the coefficient can directly be calculated with
the formula. Gauge values for the length calculation were established for the fol-
lowing materials and were listed and shown in diagrams in the VDI guideline 3389:

material identification material material number

1 UST 1204 r 1.0330.504
2 CuZn 37 F 38 2.0321.26
3 CuZn 37 F 45 2.0321.30
4 AlMgSi 1 w 3.2315.10
5 AlMgSi 1 F 28 3.2315.71
6 AlMgSi 1 F 20 3.2315.51
7 CuSn 8 F 46 2.1030.26
8 CuSn 8 HV 170 2.1030.31
9 CuNi 18 Zn 20 F 38 2.0740.10
10 CuNi 18 Zn 20 F 51 2.0740.30
11 CuNi 18 Zn 20 HV 160 2.0740.31
12

As the computer cannot derive gauge values from curves, the diagrams have to
be processed first. It is difficult to transform a curve into a formula; on the one
hand it requires a considerable amount of time, on the other hand it is quite un-
likely to obtain an exact formula for each material. A case study only inflates the
programme content.
One possibility is due to the fact that the curves have a major curvature and thus
can easily be subdivided into linear sections without losing its accuracy. Individual
points of the curves are stored so that the computer can interpolate points in be-
tween them.
Additions for different bending radii are indicated above material thickness s. As
the gauge value depending on the bending radius is nearly linear, it is also possi-
ble to interpolate a value for each chosen radius with utmost accuracy. A data ta-
ble for the gauge values was created which you are free to complete with values
for new materials, which is one basic requirement for a flexible programme.

In order to obtain a fixed order in the table we have chosen the following radii for
each material:
in (mm)

0.2 0.6 1.0 2.0 3.0 4.0 6.0

The following sizes have been defined as material thickness in the table: in (mm)

0.1 0.6 1.0 1.5 2.0 2.5 3.0 4.0 5.0 6.0

As not all materials are scheduled for major material thickness, you may arrange
the columns according to radius, the lines according to materials and sub-ordinate
according to material thickness.
This method has the advantage that new materials can be added at the end of the
table, and do not have to be inserted into the table at different positions. This
would even cause alterations to the existing data sequence and would lead to ad-
ditional tests of the material data already tested. Furthermore you may leave out
the lines with material thickness values that are not included in the diagrams.
Thus, you avoid unnecessary inflation of the table.
In order to get a gauge value, the programme takes the gauge values for material
thickness and bending radius for the material required from the table, which are
stored in an adjacent position. By linear interpolation the exact value will be calcu-
lated. Gaps in the table of values will be reserved by a variable symbol, a value
that will never appear like this in the table. This value is pre-set to: "111".

4.8. Calculation according to Oehler

The method of the neutral line according to Oehler is also calculated with a correc-
tion factor ξ .

a, b straight elements
α angle between straight elements
ri inside radius
s material thickness

Π⋅a  s 
Cut length L = a + ⋅ ri + ⋅ (ξ ) + b
180  2 

The factor ξ will be determined from the graph in Fig. 8.19 depended on rm / s
with rm = ri + 0.5 ⋅ s .

The angle for calculation according to Oehler must be between

α = 150° and α = 30°.

Fig. 24 Determination of the factor ξ from the relation of rm / s according to Oehler

4.9. Standard Formula

Using the calculation method according to standard formulae, you can define the
position of the neutral line by the input of a factor (0 < Factor <=0.5).

Fig.. 25 Position of the neutral line

4.10. Table
Background of this calculation is a table containing correction factors for bends
depending on the ratio inner radius/material thickness Ri /s0 and the bending an-
gle. Individual companies may have tables for the calculation of the neutral line.
The correction factors have been found by years of experience and therefore may
match the way processes are undertaken on the shop floor.
It is possible to modify the values in the table. Select the from Table function and
Table... option to get a list of the current settings. The values shipped with
COPRA® are coming from the DIN 6935 calculation and can be individually ad-
justed according to the company specific experience.

4.11. User
This function allows entering the neutral line directly.

The directly input of the neutral line should be inside of 10% of the cal-
®
culated methods. Otherwise, there can be errors in different COPRA
functions like DTM.

5. Punching
Today a roll formed product is going to be more than a simple section. Additional
processes are necessary to make it as close a final product as possible. Pre-
punched material is one of those processes. But adding new technologies to the
product causes new problems. When using pre-punched material one of the prob-
lems is how to find the correct position of a hole in the coil. For that purpose, the
Punching Module was introduced. It allows placing holes in the final section.
COPRA® takes the elongation of the material during the roll form process into ac-
count so that the hole position in the coil is after unfolding in the right position.

5.1. The Punching toolbar

The Punching toolbar contains all functions required for punching a section.

5.1.1. Insert Single

Function:
Add single punch hole to the final cross section
A dialogue box shows the current hole parameter.
• Width: width of a hole in cross section direction
• Length: length of a hole in roll form direction
• Offset: possibility to define different levels of punch holes
• Radius: radius with different locations in different punch hole shapes
• Relief Angle: possibility to place a hole in the strip under angle entered
• Other Shape: possibility to select a different hole shape

5.1.2. Insert Multiple

Function:
Add multiple punch holes to the final cross section
A dialogue box shows the current hole parameter. Depending on the type of hole
the parameter are the same as described in Insert Single.

5.1.3. Delete Single

Function:
Removes single punch hole from the final cross section
Pick the punch hole to be removed with the crosshairs. The current section and all
other sections saved in the database will be instantly updated. After the removal
®
COPRA returns to the option line.

5.1.4. Delete Multiple

Function:
Removes multiple punch holes from the final cross section
The punch holes to be removed can be picked with the crosshairs. The current
profile and all other profiles saved in the database will be updated immediately.

5.1.5. Delete All

Function:
Removes all existing punch holes from the final cross section
The removal of all punch holes has to be confirmed by the user. If done so, all
holes are removed and the complete flower is being updated instantly.

5.1.6. Copy

Function:
Copy existing punch hole within current cross section
Pick the punch hole to be copied with the crosshairs. The base point is the punch
hole centre. Next pick the target point of the punch centre with the crosshairs. If
the target point cannot be selected with the standard AutoCAD snap modes, it can
be designed by adding a line in the respective position. After copying the hole the
complete flower will be updated instantly.

5.1.7. Move

Function:
Move existing punch hole within the current cross section
Pick the punch hole to be moved with the crosshairs. The base point is the punch
hole centre. Next pick the target point of the punch centre with the crosshairs. If
the target point cannot be selected with the standard AutoCAD snap modes, it can
be designed by adding a line in the respective position. After moving the hole the
complete flower will be updated instantly.

5.1.8. Property

Function:
Change the properties of a punch hole within the current cross section
When command is selected the dialogue box with the geometric properties is
loaded. It is possible to change either the geometry of the existing hole or to select
another punch hole shape. For more information refer to the description of the
Insert Single function. When accepting the settings from the dialogue box, the
holes for which the properties should be changed have to be picked with the
crosshairs. After changing the hole properties the complete flower will be updated
instantly.

5.1.9. Information

Function:
Display the properties of a punch hole within the current cross section
After having selected the icon, the system asks you to pick the desired type of
punching. A box containing the punching data is opened:

Punch Hole Statistics:

Number of Selected Hole:

Defines the hole number of the punching.

Total Number of Holes:

Shows the total number of punch holes.

Punch Centre in Entity:

Shows the entity, in which the centre of the hole is positioned.

Punch Hole Orientation in Section:

Punch Hole Offset:

Displays the set hole offset.

Orientation Angle:
Shows the entered position angle.

Punch Hole Position in Section:

Punch Hole pos. absolut:

Shows the position of punching on the flat strip, measured from the left edge of
the strip to the centre of the hole, the absolute.

Punch Hole pos. relativ:

Displays the position of punching on the flat strip, measured from the point of un-
folding to the centre of the hole, the relative.

Shape of Punch Hole:

Shows all entered hole data.

6. Statics
Roll formed sections have got outstanding characteristics in ruggedness and stiff-
ness which predisposes them to carry loads or to build a framework. Therefore,
the section characteristics or properties are to be calculated thoroughly. They are
the base for beam calculations supplying results like deflection, carrying capacity
®
and others. Sections calculated by COPRA may be open or closed. Closed sec-
tions may be welded or lock-seamed.

6.1. Section Characteristics

Function:
Calculate the cross section characteristics
The statics module and the related dialogue box are loaded.
After starting the static module, the dialogue box will be loaded.

6.2. Static Values

Below find an explanation of the most important values:

6.2.1. Geometrical Moment of Inertia

The geometrical moment of inertia is defined as the resistance of a rotating sec-
tion against its changing rotating velocity. The moment of inertia of a point of a
plane is the product of its surface and the square of its distance from the axis of
revolution. The moment of inertia of a section consequently depends on its sur-
face and the distribution of this surface in reference to the respective axis of revo-
lution. The moment of inertia can only be calculated if the surface and its distribu-
tion is known. The simplest example is a thin circular ring, all surface entities of
which, have got the same distances from the axis of revolution.
Basically, it has to be distinguished between axial and non-axial moments of iner-
tia where the axes are created by the reference co-ordinate system. A non-axial
moment of inertia is called deviation moment or centrifugal moment. In the princi-
pal axis system the deviation moment is zero.

6.2.2. Surface Centre of Gravity

Is defined as the surface centre of a section, which we can be imagined to com-
bine the total surface of a section. The centre of gravity of a surface is the origin of
force of the net force of all its partial surfaces. A section suspended in the centre
of gravity is in balance for every position it may have. A freely movable section will
rotate around its centre of gravity with constant velocity.

6.2.3. Principal Axes

Any number of rotation axes may intersect the centre of gravity of any plain sur-
face. For two exactly defined perpendicular axes the geometrical moment of iner-
tia are at a minimum or at a maximum respectively. A stable rotation of a freely
movable section is only possible around these two axes. They are called the prin-
cipal axes of a surface.
• For any plain surface there are two perpendicular principal axes, for which
the geometric moments of inertia will take minimum and maximum extreme
values while the deviation moment will disappear.
• The deviation moment will increase to a maximum for those reference axes
that are rotated by 45° as compared to the principal axes.
• The transverse strain of the principal axes system is zero.

6.2.4. Torsion Moment of Inertia

A torsion moment Mt will cause transverse strains in a section. These strains are
called torsion stresses. Their distribution is ever more complex than the direct
stresses caused by transverse moments. The maximum transverse strain is
yielded from the ratio of Mt/W t, whereas W t is the section modulus. The torsional
moment of circular rings grows linear with the distance from the centre of gravity.
The maximum value occurs at the edge. The maximum transverse strain of rec-
tangular sections can be found in the middle of the long sides. Along the long
sides it falls about in a parabolic manner down to zero in the edges. Roll formed
sections can be looked at as stripes composed of long rectangular sections. This
gives rise to a similar distribution of stresses as in rectangular sections.
The values for the section modulus and the torsional moment of inertia calculated
by COPRA® are the basis to find out whether a section will stand the transverse
strains caused by a torsional moment. To do so the material supplier has to state
the maximum acceptable torsional stresses.

6.2.5. Section Modulus

The transverse moment around a principal axis causes direct stresses. The pa-
rameter of the section modulus is calculated from the moment of inertia and its
corresponding distance from edge. The minimum loading capacity is calculated by
the minimum moment of inertia and the corresponding maximum distance from
the edge. This is valid provided that the moments of inertia were calculated in ref-
erence to the principal axes system.

6.2.6. Maximum Distance from Edge

Points of a section with the greatest distance to the reference co-ordinate system.
Together with the moment of inertia it is used for the calculation of the section
modulus. The section modulus will be at a minimum where the distance from the
edge is at a maximum.

6.2.7. Radius of Inertia

The radius of inertia is equal to the radius of a thin circular ring in which the sur-
face of a section is being distributed to get the corresponding moment of inertia for
that section.

6.2.8. Shear Centre

Loading a section with a positive lateral force not intersecting the centre of gravity
will give rise to transverse strains. In reference to the centre of gravity, the trans-
verse loads will cause a torsional moment, which may not be neglected for thin-
walled open sections. It will be compensated if the load plane does not intersect
the centre of gravity but the shear centre.

6.2.9. Vaulting Resistance

In addition to normal deflection a section loaded with an axial force will have a
spatially curved and twisted balanced position if the origin of force does intersect
the shear centre. This will result in additional transverse strains loaded on the sec-
tion. The vaulting resistance is a measure for the impediment of the warpage. It
can be used to calculate loads composed of torsion and axial loads.

6.2.10. Principal Axes Angle

The principal axes angle depends on the surface distribution of a section.
• Referring to the principal axes angle the geometrical moments of inertia are
minimum and maximum extreme values while the deviation or centrifugal mo-
ment disappears.
• Referring to the principal axes angle the transverse strains are zero.

6.3. Abbreviation

All abbreviations are taken from the Dubbel, Taschenbuch für den Maschi-
nenbau, a standard mechanical engineering textbook in Germany.

6.3.1. COPRA® Calculated Values

Surface A
Own weight Q
Co-ordinate of centre of gravity: yS, zS
Moment of principal axes: Iy, Iz
Section Modulus: W y, W z

6.3.2. Max. Distance from the Edge

Radius of inertia: iy, iz
Shear centre : yM, zM
Angle of principal axes: Φ
Torsional moment: Wt
Vaulting resistance: CM

6.3.3. Boundary Conditions

Length of Profile: l
E: E-Modul
Normal Force: FN
Lateral Force: FQ
Shear Force: FS
Moment of flexion: My , Mz
Angle of torsion: fi
Torsional Moment: Mt

6.4. Formulas

All abbreviations are taken from the Dubbel, Taschenbuch für den Maschi-
nenbau, a standard mechanical engineering textbook in Germany.

Tensile Load and Compression Stress:

Tension: σ = FN /A
Deformation work: W = σ2*A*l/(2*E)

Shearing:
Shearing stress: τa = FS /A

Bending Load:
Normal Bending:
Bending load: σ = -(Mb/Iy)*z
Extremal stress: σ1 = -Mb/W y1,σ2 =+Mb/W y2

Transverse bending:
Bending load: σ = -(Mby/Iy)*z+ -(Mbz/Iz)*y

Torsion:
Torsion angle: fi = (Mt*l)/(G*It)
max. Shear Stress: τmax = Mt /W t

Overturning:
The Overturning is result from the solution of the differential equation:
2
E*CM*fi´´´ -G*It*fi´´ -(My /(E*Iz) -My´´*zF) *fi = 0

7. Create Unfolding
With COPRA®, the design of the forming steps starts from the final section. The
reason to do so is in fact to be as close as possible at the finally desired result.
Although there may be small deviations of the actual forming product from the de-
signed shape, this method provides a better result than forming from flat to the
final section. Of course, you can also decide for the other possibility. It’s up to you.
COPRA® provides both possibilities. During interactive unfolding, a bend is formed
step by step down to flat. Each bend selected includes an individual calibrating
method and its length compensation pieces. They are added as an attribute to
each bend from pass no. 2 on. The final section, pass no. 1, does not contain
these attributes.
On using different calibrating methods for different bends in previous versions of
COPRA®, it may have happened that the calibrating methods where mixed up in
one bend. For example, one bend was unfolded by the constant radius calibrating
method, the next bend by the constant length of neutral line method. When creat-
ing the flower step by step, the calibrating method had to be changed each time
the other bend should be unfolded. If this was forgotten it could happen that some
steps were performed with constant radius and some with constant length of neu-
tral line method. Now the calibrating method is added as an attribute to each
bend. If a bend is selected, the current calibrating method is automatically applied.
If required, it is, of course, possible to select a different calibrating. The Unfold
command can be loaded via the screen menu or by entering -- <ENTER> on the
keyboard. Pick the arc to be bent.

7.1. Unfolding via Table with COPRA® RF SpreadSheet

Please refer to the COPRA® SpreadSheet user manual for further information.

7.2. The Flower toolbar

The Flower toolbar contains all functions required to create a flower.

7.2.1. Plane of Unfolding

Before a flower can be created, the plane of unfolding has to be defined. If the
Flower function is opened for the first time in the current project, a defining the
point of unfolding dialogue box automatically appears:

Entity Centre:
Allows picking the respective entity with the crosshairs. The point of unfolding is
positioned in the middle of the selected entity.

Before Entity:
Allows picking the respective entity with the crosshairs. The point of unfolding is
positioned at the point of separation from the selected entity. COPRA® direction:
from left to right.

After Entity:
Allows picking the respective entity with the crosshairs. The point of unfolding is
positioned at the point of separation after the selected entity. COPRA® direction:
from left to right.

Point picked by Cursor:

Allows picking a certain point within an entity. The point of unfolding is at the de-
fined point. The proposed point, which is marked with a cross, reflects the centre
of strip width.

COPRA® Proposal:
®
COPRA proposes to select the point of unfolding on a long straight part. The re-
spective legs are directed to the top.

Rotate Profile:
After having selected the point of unfolding, the section can be subsequently ro-
tated by a defined angle. The defined point of unfolding thereby serves as a refer-
ence point. If no point of unfolding is defined, the centre of the strip width will be
assumed to be the reference point.

Mirror Profile:
After having defined the point of unfolding, the section can be subsequently mir-
rored at the defined point. If no point of unfolding is defined, the centre of the strip
width will be assumed to be the reference point.

Rotate Profile Automatically:

When selecting an entity, that is not positioned on the horizontal plane, the section
will be rotated in a way that the entity is in a horizontal position.

After selection the point of unfolding is displayed and the system asks you
whether you will be content with the plane of unfolding.

Yes:
If you confirm with Yes, you are done and the plane of unfolding will be defined.

No:
If you enter No, the system asks you whether the pass should be recreated. If you
confirm with Yes, the defining the plane of unfolding dialogue box reappears.

Cancel:
If the procedure is cancelled, no plane of unfolding will be defined.

7.2.2. Unfolding

Function:
Step-by-step unfolding of individual bending steps with user-defined settings
If selected the system asks you to pick the arc to be unfolded with the help of the
crosshairs. Do so and the Interactive Unfolding dialogue box appears:

Entity Parameters:
The current entity data are displayed for the purpose of information.

Bending Parameters:
Displays the defined bending data.

Bending Angle:
Shows the value for the angle to be unfolded.

Bend Angle:
Shows the value of the arc angle after unfolding of the arc by the value of the
bending angle.

And/Or:
This function is only available, if the Constant Length calibration method was
used. When activating this command, a new inner radius can be applied manually.

Length Neutral Line:

Defines the length of the neutral line in the selected arc.

Calculation Method:
The selected method for strip width calculation is displayed for the purpose of in-
formation.

Select Entities:
Refer to General Information, point 2.

If unfolding is repeated, always the last applied selection of entities is

active.

Chain Equal Entities automatically:

All equal entities will be joined automatically.

Calibrating Method:
Allows selecting among different calibration methods. For detailed information,
refer to 6.1.14 Calibration Methods.

7.2.3. Fold

Function:
Fold individual bends step by step with customised settings
Normally, flower creation starts from the final section and is unfolded step by step,
or automatically, to the flat strip. But sometimes it may be necessary to continue
folding the strip, e.g. to create a section with over-bent angles and radii or to fold a
straight.
The Fold function is similar to the Unfold function. In the following we only want to
describe the differences between the two functions.

7.2.4. Folding with Angle/Radius Calibrating Method

The Angle/Radius calibrating method cannot be used for folding an arc. If the
Angle/Radius calibrating method is used for continuous folding of a bend, the
Calibrating Method/Length Compensation dialogue box will be loaded with the
calibrating methods Angle/Radius and Power Bending being both disabled. To
modify both angle and radius for continuous folding, use the Power Bending cali-
brating method.

7.2.5. Bending Straights

For better access to undercut bends it may be necessary to over-bend straights.

7.2.6. Splitting Straights for Over-bending Purposes

If a straight is over-bent, the complete length will be converted to a bend. If only a
part of the straight should be bent, it can be split into two parts by using the Split
entities option from the Profile Utilities toolbar.

7.2.7. Automatic Unfolding

Function:
Automatic unfolding of bends with pre-defined bending sequences
Today, more and more roll formers use standard rolls to save the costs for making
new rolls. Above all, standard sections are very often created with combination
rolls. The angles of these rolls are known which makes it possible to automatically
create a flower for these sections if there is a possibility to enter the bending se-
quence of the rolls. This is provided by the COPRA® automatic unfolding option.
After having selected the icon, the system asks you to select the arc to be un-
folded with the crosshairs. Do so and the Automatic Unfolding dialogue box is
opened. Just as with the Interactive Unfolding dialogue box the following func-
tions are available:

Initial Step:
Normally, this value should be 1. However, if several bending sequences are
combined, the initial step has to be defined accordingly.

End Angle:
Allows defining a certain final angle.

No. of Steps:
Defines the number of unfolding steps.

Or Angle:
Defines the unfolding angle.

View Window:
Shows the selected bending sequence.

Bending Sequence:
A dialogue box is opened allowing you to select an existing bending sequence:
Adjust, Create, Modify, Copy or Delete.

Bending Sequence Trapezoidal:

The system calculates a bending sequence whereby calculation aims at obtaining
an even inlet for the strip edge. For detailed information refer to Trapezoid below.

Bending Sequence:
Shows the selected bending sequence.

Angular Sum:
Shows the total sum of the angles.

Sequence of Angles:
Displays the angle steps.
All other functions see 6.1.2 Unfolding.

7.2.8. Execute Unfolding

Function:
®
Execute the bending parameters entered and save new section in COPRA database

7.2.9. Dynamic Flower

Function:
Predefine dynamic step-by-step unfolding or folding
This feature allows you to fold or unfold arcs dynamically. After having selected
the icon, the Dynamic Unfolder dialogue box is opened:

Pass Data:
Shows the current pass data for the purpose of information.

View Window:
Displays all entities and their respective values.

Entity Selection:
See, General Information point 2.

Calibration Method:
Allows you to choose from several calibration methods. For detailed information
see, 6.1.14 Calibration Methods.

Increment (Angle >0):

The value by which the arc is to be unfolded.

Increment (Angle <0):

The value by which the arc is to be folded.

Unfold/Fold:
The arc is unfolded or folded by the entered value. Check the value in the view
window.

7.2.10. Dynamic Unfolding

Function:
Dynamic unfolding
This function allows you to unfold the arc by the entered value to the desired posi-
tion. This feature is quite helpful, for example, for checking accessibility of the
rolls.

7.2.11. Dynamic Folding

Function:
Dynamic folding
This function allows you to fold the arc by the entered value to the desired posi-
tion. This feature is quite helpful, for example, for checking accessibility of the
rolls.

7.2.12. Plane of Unfolding

Function:
Definition of the point of unfolding, redefine plane of unfolding
See, point 6.1.1.

7.2.13. Symmetrical Profiles

Function:
Split symmetrical sections
Symmetrical sections can be split to make design faster by only unfolding one half
of it. COPRA® automatically recognises a symmetrical and loads the required dia-
logue box.

7.2.14. Calibrate

Function:
Select the default calibrating method
The calibration method depends on the section to be formed. In practice, the cali-
bration methods constant length of neutral line or constant radius are the most
common ones. However, some roll forming processes require more advanced
methods. The inner radius Ri, the bend angle α and the length of neutral line LNL
describe each bend.

COPRA® provides 5 different Calibrating Methods:

• Constant radius
• Constant length of neutral line
• Track holding profiling
• Angle/radius profiling
• Tube profiling/power bending

7.2.14.1. Constant Radius Method

This calibration method uses a constant radius among all forming steps. This
means that the material has to be taken from the inner, the outer or from both
legs. By the term legs, we understand the unbent neighbour entities. When un-
folding starts from the final section, this process is inverted: the material may be
distributed to the inner, the outer or to both legs. The entities created during this
process are called the length compensation pieces. The default distribution of
the length compensation pieces is 50% to the outer leg and 50% to the inner leg.
The inner leg is the leg, which is closer to the section forming point. The length of
the length compensation pieces depends on the calculated neutral line. Depend-
ing on the bending angle, material strain has to be considered. Therefore the
theoretical strip width, which equals the length of the neutral line, is smaller than
the actual centre line of the final section. The length compensation pieces may
also be positioned in the middle of a bend; this is, however, very rarely made use
of.

Pros and Cons of this Calibrating Method:

Pro: low spring back rate
Con: bending areas tend to be cornered
Restrictions: a bend cannot be folded with this method if the neighbour entities are
also bends

Characteristics of the Constant Radius Method:

Inner radius: constant
Bend angle: variable
Length of neutral line: variable
Length compensation: yes

7.2.14.2. Constant Length of Neutral Line Method

If used, the calculated length of the neutral line remains constant throughout all
passes, the inner radius is automatically being calculated depending on the un-
folding angle of the bend. Material strain is considered during all forming steps. No
length compensation pieces are created during the unfolding process. Optionally,
straight entities may be folded by using that calibrating method.

Pros and Cons of this Calibrating Method:

Pro: bending areas are not cornered
Cons: higher spring back rate

Characteristics of the Constant Length of Neutral Line Method:

Inner radius: variable
Bend angle: variable
Length of neutral line: constant
Length compensation: no

7.2.14.3. Track holding Method

This method is a variant of the constant radius method. Just as with the constant
radius method, the radius remains constant during all forming steps. The only dif-
ference is that the length compensation pieces are not defined by the user but
calculated by COPRA®. Calculation results in a constant intersection point of the
inner line of inner and outer leg. This calculation method is only valid for bending
angles between 1° and 90°.

Pros and Cons of this Calibrating Method:

Pro: high accuracy of dimensions
Con: difficult machine set-up

Characteristics of the Constant Length of the Track holding Method:

Inner radius: constant
Bend angle: variable
Length of neutral line: variable
Length compensation: yes

7.2.14.4. Angle/Radius Method

It may be necessary to not only modify the angle of a bend, but also the inner ra-
dius. Examples are Dutch bends with a bend angle of 180° and an inner radius of
0mm. For a proper layout of this area it is necessary to find the correct pre-shape.
For example, it would not be possible to start forming from flat with an inner radius
of 0mm. When modifying the angle as well as the inner radius the length of neutral
®
line has to be recalculated. When working with version 12c4 of COPRA or higher,
the applied strip width calculation method is added as an attribute to the bend.
Thus it is possible to recalculate the length of neutral line for the bend with the
same conditions. When working with a database created with version 12c3 or
lower, the strip width calculation method is not an attribute added to the bend. In
this case the user has to take care of using the correct strip width calculation
method.
The length compensation pieces can be taken from the inner or the outer leg. The
length compensation pieces may be positive or negative depending on the modifi-
cation. If, e.g., the angle is not modified and the radius increases, they will be
negative. If the radius decreases, they will be positive.

The adjacent entities increase or decrease respectively. The default distribution of

the length compensation pieces is 50% to the outer leg and 50% to the inner leg.
The inner leg is the leg, which is closer to the section forming point. The length
compensation pieces can also be positioned in the middle of a bend.

Pros and Cons of this Calibrating Method:

Pro: less restrictions than the above described methods: angle as well as
radius can be varied
Con: the length of the neutral line has to be recalculated. This may give
rise to little deviations within the flower. Pre-requisite is that the cal-
culated strip width remains constant.
Restrictions: length compensation pieces cannot be taken from adjacent entities,
if these are bends

Characteristics of the Angle/Radius Method:

Inner radius: variable
Bend angle: variable
Length of neutral line: variable
Length compensation: yes

7.2.14.5. Power Bending Method

This option is known as “tube profiling“ from earlier versions of COPRA®. Actually,
it can not only be used for tubes. It is an advanced Angle/Radius calibrating
method without the restrictions described above. The length compensation piece
cannot only be selected via a percentage of the neighbour entities but also by
picking the entity the material should be taken from or distributed to. To select this
option, activate crosshairs.

Pros and Cons of this Calibrating Method:

Pro: None of the restrictions of the above described methods: angle as well as
radius can be varied; folding is possible even if adjacent entities are bends
Con: The length of the neutral line has to be recalculated. This may give rise to
little deviations within the flower. Pre-requisite is that the calculated strip
width remains constant.

Characteristics of the Power Bending Method:

Inner radius: variable
Bend angle: variable
Length of neutral line: variable
Length compensation: yes

7.2.15. Reference Point

Function:
Modify the vertical position of a flower
In COPRA® the vertical position of the section forming point is constant by default.
In most cases this is also the way of how a section will be manufactured. But
sometimes it is necessary to change the vertical positions of individual sections
within a flower. A typical example would be a section with a dovetail.
The vertical position could now be changed with the RefPoint or Move options
from the FLOWER screen menu. Selecting the RefPoint option will open a new
dialogue box.

Fig. 26 Unfolding Reference Point

Fig. 27 Modified Reference Point

7.3. The Profile Utilities toolbar

7.3.1. Edit Profile Section

Function:
Modify dimensions and geometry’s of the section
Normally, it is not necessary to modify a section within a flower. This can be done
with the standard COPRA® options. There are only a few cases where this func-
tion is required.

This function allows modifying the calculated length of the neutral

line. Be careful with this function as this may give rise to problems.

Pass Data:
Supplies information about the current flower
• Number of passes saved in the database
• Current pass number to be modified
• Number of entities in the current section
• Material thickness

Flower Data:
Provides a list of data for all sections within a flower.

Listbox:
If an entity is highlighted by picking it with the crosshairs, its geometry data are
transferred to the edit boxes at the bottom of the window. The values can be
modified. Selecting OK, will make the changes permanent. The entities at the sec-
tion forming point FP are marked with an asterisk.

Radio Button S:
Enabled by COPRA®, if only a straight entity in the list is highlighted. A straight en-
tity can be changed into an arc entity by selecting B. The previous data of the
straight are saved. If the arc entity is converted back to a straight, the previous
data will be restored.

Radio Button B:
Enabled by COPRA®, if only an arc entity in the list is highlighted. An arc entity
can be changed into a straight entity by selecting S. The previous data of the arc
are saved. If the straight entity is converted back to an arc, the previous data will
be restored.

Profile Entity:
Here the number of entities in a section can be changed. In combination with the
function Verteile Längen-Differenz auf Auswahl it is also possible to separate
entities.

For a description of how to select entities refer to General Information.

Add:
If only one entity is highlighted in the list, it can be copied by using the, add! op-
tion. The new entity will be inserted after the selected entity. If the copied entity is
a straight it can be converted to an arc if selecting A. If the copied entity is an arc
it may be converted to a straight.

The entity data of the new entity are similar to those of the copied entity.
Strip width differs by the length of the copied entity.

Remove:
All highlighted entities will be removed from the list.

Modification Procedures:
The different procedures have different effects on the section when changing an-
gle, radius or length of an entity. Several types of length compensations can be
applied.

Free:
®
This procedure is equal to the COPRA calibration method Angle/Radii.

Change Angle Radius Length Length compensation

Angle Unchanged Is adjusted None
Radius unchanged Is adjusted None
Length Option: Adjust Option: Adjust None

Constant Length/Adjust:
This procedure is equal to the COPRA® calibration method Angle/Radii.

Change Angle Radius Length Length compensation

Angle Unchanged Is adjusted None
Radius unchanged Is adjusted None
Length Option: Adjust Option: Adjust None

Compensation in Adjacent Entities:

This procedure is equal to the COPRA® calibration method Tube Profiling.
Length compensation is done with the adjacent entities of the modified entity, no
matter whether the adjacent entities are straight or arc entities.

Change Angle Radius Length Length compensation

Angle Unchanged Is adjusted Adjacent entities
Radius Unchanged Is adjusted Adjacent entities
Length Option: Adjust Option: Adjust Adjacent entities

Compensation with Straights Only:

Change Angle Radius Length Length compensation

Angle Unchanged Is adjusted With straights only

Radius Unchanged Is adjusted With straights only
Length Option: Adjust Option: Adjust With straights only

Length Compensation:
If the selected procedure is based on direct length compensation, it can be de-
fined, how the lengths are to be distributed at the right and at the left of the modi-
fied entity.

Inside:
Inside is the entity next to the modified entity, which is closer to the point of unfold-
ing and further away from the end of the profile, or, in case of closed sections, is
further away to the welding point.

Adjust:
If changing the length of an arc or if an arc is used as a length compensation en-
tity either the radius or the angle can be adjusted to the new length.

Angle:
If required, the angle of an arc entity is adjusted to the new length.

Radius:
If required, the radius of an arc entity is adjusted to the new length.

Even:
The difference is divided by the number of selected entities. The resulting value is
added to each entity.

Percentage:
The difference is distributed as a percentage of the length of the entity. A longer
entity gets a higher percentage of the total difference and vice versa.

7.3.2. Move Profile

7.3.3. Rotate Profile

7.3.4. Split Entity

Function:
Split one entity into two parts
Sometime it may be necessary to insert an entity where it cannot be done be-
cause of an existing entity. In this case the Split Entity function can be used to
break an entity. The entity to be split has to be picked with the crosshairs. The
entity data will be displayed and the entity selection has to be confirmed. In case
of a straight the length to the break point has to be entered, in case of an arc the
including angle has to be entered. If the break position is valid, the entity will be
split in the position defined and the new section will be displayed.

7.3.5. Join Entities

7.3.6. Join All Entities

Function:
Join separate entities
If selected, all adjacent equal entities are joined within the section. In case of arcs,
the inner radii have to be equal.

7.3.7. Same Number of Entities for 2 Profiles

Function:
Adjust number of entities of two sections
The number of entities of the current pass and a second pass is adjusted. In the
occurring dialogue box the second pass has to be selected.

7.4. The Profil Utils toolbar

7.4.1. Write Part of Profile to File

Function:
Writes a part of a profile for copying purposes to hard disk
In some types of sections there are repeated shapes. To avoid a new design of
these shapes they can be written to file with Write PP and copied Read PP.
A typical example would be stiffing ribs in a trapezoidal section.
Simply pick the first and last entity of the entities to be copied and enter a filename
describing that part. The entity data are written to file and are ready to be copied.

7.4.2. Read Part of a Profile from File

Option 1: A - insert Part of Profile at the Beginning of the Section

Option 2: E - insert Part of Profile at the End of the Section

Option 3: G - insert Part of Profile at a Location picked by Crosshairs

Option 4: N - insert Part of Profile at a Location defined by an Entity Number

7.4.3. Write a Sequence of Passes to File

Function:
Write flower to file
This function allows saving a flower or part of a flower to a file.

7.4.4. Read a Sequence of Passes into Flower

Function:
Read flower from file
This function allows reading a flower or part of a flower from a file.

7.4.5. Material Thickness

Select:
Select the passes, whose material thickness is to be changed.

Plate Thickness old:

Information on the old material thickness.

Plate Thickness new:

Dialogue field for the new sheet thickness value.

Datum Line:
Defines the reference line for the modification of sheet thickness.

Internal Radius constantly:

The inner radius of the section remains constant.

Outer Radius constanty:

The outer radius of the section remains constant.

Outer Contour constantly:

The outer contour of the section remains constant.

Centre Line constantly:

The centre line of the section remains constant.

Internal Contour constantly:

The inner contour of the section remains constant.

7.5. Adapt Flower

Function:
Create combinations of primary flowers
This function changes the dimension of the flower. It comprises the preliminary
work to be done for adjusting the flower with the Store Rollset and Read Rollset
options in the WZ Utility toolbar.
It is not unusual to design sections on the basis of the same basic shape, but with
different dimensions. Those sections are called combinations. Combined roll sets
are used if only the dimensions of a section are to be changed whereby is shape
should remain unchanged. Typical examples are U or C shapes. The basic idea
behind that is that the rolls have to be designed for a primary roll set which nor-
mally has the smallest dimensions. All other dimensions can then be created with
the help of the COPRA® functions.
The Adapt Flower option allows creating the required section combinations. To
do so, only the dimensions of the final profile have to be modified by selecting the
respective leg. The related flower will be calculated automatically.
When using this module, the current contents of the database are changed. The
following should be done before using this function:
• Save primary flower with the help of the archiving module
• Use a unique logical name

8. COPRA® Trapezoidal Section

The COPRA® Roll form Software is a general tool for the creation of roll-formed
profiles and the construction of the respective roll tools. In addition to general fea-
tures, which allow to design profiles of any desired shape, there are also func-
tions, which are especially suited for special profiles such as trapezoidal profiles.
In general, manufactures concentrate on the production of either profiles or trape-
zoidal profiles. For this reason, COPRA® provides individual solutions, which are
tailored to the respective needs of our customers. Consequently, there is also a
solution for trapezoidal profiles.

8.1. Manufacturing Problems

One of the problems occurring with the production of trapezoidal profiles is that
large strip widths have to be used. The material has to be drawn from the outside
to the inside. Mostly, the strip material is flat. During roll forming, the strip edges of
the material have to take a curve. With flat materials, this gives rise to partially
high shearing forces, which may result in a plastic longitudinal elongation in the
area of the strip edge and consequently, in the typical waviness of trapezoidal pro-
files.

Fig. 28 Strip insertion with trapezoidal profiles

Material strain on shearing and

resulting plastic longitudinal shape
deformations

Fig. 29 Outline: Strip insertion of trapezoidal profiles

During forming, the strip insertion must not be too large, see Fig. 29, because of
the occurring shearing forces. The best results can be achieved, if the strip inser-
tion is as constant as possible. In this way, material strain will be almost similar for
every step and peaks in elongation can be avoided. COPRA® provides the respec-
tive calculation algorithms during flower design, so that optimal results can be
automatically calculated on the basis of the respective entries.

8.2. Profile Design

Function:
Design a profile
COPRA® provides several features for profile construction.
The CAD Profile feature allows you to convert any steady (tangential transitions)
polyline into a COPRA® profile. This assures that any steady profile can be cre-
ated with the help of the COPRA® software.
®
Furthermore, COPRA provides a variety of profile macros for standard profiles.
Besides, existing profiles can be copied or mirrored. These features make it easy
to create a trapezoidal profile.
The COPRA® Profile Editor has a variety of features supporting the construction
of the final cross-section of trapezoidal profiles. Dialogue boxes help you to freely
combine profiles and profile parts.
Level 1 provides profile elements such as straight lines and bends. Level 2 con-
tains standard profiles and on level 3 you have access to standard profile parts
including connecting dimensions to an existing profile.

Fig. 30 Trapezoidal profile

A variety of profile macros and the features for copying and combining profile
parts help you to quickly and easily create even complex profiles. Last but not
least, it is also possible to design the cross section of the final profile with the help
of the CAD features and to edit it automatically for COPRA®.
If the profile is complete, the strip width will be calculated automatically. A variety
of formulas are available for calculation.
The calculated strip width will be output. The difference between the theoretical
centre line and the actual strip width is significant due to the high number of bend-
ing points.

8.3. Bending Sequence Trapezoid

Function:
Creation of an automatic bending sequence
For unfolding of a trapezoidal profile COPRA® automatically creates a bending
sequence. The aim is to have a constant insertion of the strip edge. In the outline
the strip edge should be positioned on a straight. This straight will be rounded off
by the insertion steps from the flat strip and by the outlet steps to the final profile.
The bending angles will be calculated automatically, so that we will have a con-
stant insertion value for the entire forming procedure. Only in the area of the inser-
tion and outlet stations the value is respectively lower.
The newly created bending sequence is displayed in the list. The code of the
bending sequence indicates the bending angle and the number of forming steps.
For detailed assignment a comment can be entered.

Curve of the Edge of Arc:

Describes the curve of the strip width during insertion from station to station. The
length of the neutral line in the selected arc is displayed.

No. of Steps Total:

Defines the number of unfolding steps.

No. of Steps Initial Area:

Defines the number of steps with which the inlet of the strip edge is sophisticated.

No. of Steps Final Area:

Defines the number of steps with which outlet of the strip edge is sophisticated.

Method:
When calculating the angles, the neutral line can be considered, i.e. the bending
angles will get smaller or larger.

Curve of the Edge of Arc:

The angle of the arc edge is defined by the distance of the stations.

Orientation of Arc:
Displays the initial angle of the strip edge.

Code:
Displays the designation of the bending sequences, which is composed of angle
sum, step number, main angle and version.

Angular Sum:
Shows the total sum of the angles.

Sequence of Angles:
Lists the calculated angle sequence.

Round Angle to:

Allows rounding angles.

Compensation of Rounding:
Automatically compensates rounding errors, so that the angle sum will be
achieved.

Comment:
Allows entering a special comment for the bending sequence.

8.3.1. Run a Bending Sequence

Function:
Execute the unfolding steps
When closing the Automatic unfolding dialogue box, the angles of the bending
sequence will be saved as unfolding steps. Forming is yet not performed. The un-
folding steps of additional arcs in the profile can be defined. In our example the
dialog box was set up to unfold all arc elements with the same bending sequence,
as all arcs have an angle of 60°. Consequently, you do not have to click every arc
individually. The unfolding steps of the bend elements have been created and
saved. Unfolding is done on the basis of the respective entries.

Fig. 31 Perform unfolding steps

As all calculations are done automatically, the flower for the trapezoidal profile
displayed above will be completed within a few seconds. Even if forming is done
rib by rib, the flower can be created within a few minutes with the help of the fea-
tures available for element selection and automatic calculation of insertion.

8.4. Unfolding Flower

The reference point of the flower is the point of unfolding. In our example, the
point of unfolding is in the upper middle of the flower, unfolding is done down-
wards.

Fig. 32 Unfolding flower

The available features allow you to easily modify the position of the individual pro-
files within the unfolding flower.

Fig. 33 Unfolding flower with a strip edge of constant height

Fig. 34 Unfolding flower with planar centres of gravity with constant heights

8.5. Outline: Wire Model

The outline of the wire model of the unfolded trapezoidal profile shows forming at
the strip edges. As we can clearly see, all angles are equal.

Fig. 35 Outline and elongation graph

8.6. Strip Edge

In the outline, the strip edge is on a straight at a certain angle. This is similar to a
constant insertion of the strip material. Due to the sine/cosine relation, the bending
angle in the first stations is always relatively large and decreases considerably
depending on the type of forming, the simultaneous forming of all bending points
or forming rib by rib. In the last stations the bending angle is often only changed in
steps of 0.5°.

Fig. 36 Strip edge angles

8.7. Tangential Transition

By selecting the insertion steps of the bending sequence the transition of the flat
strip to the linear insertion of the strip edge was rounded off tangentially. This re-
sults in a smooth insertion of the strip material into the forming straight. Of similar
importance is the smooth outlet of the material, which can be achieved by the in-
sertion and outlet steps described above.

Fig. 37 Tangential rounding

A
Archive-Files.....................................................................................................................................................4
Assembly Plan Dimensioning .........................................................................................................................23

B
Bend Angle ...............................................................................................................................................31, 82
Bending Sequence...........................................................................................................................................74
Bending Sequence Trapezoidal.......................................................................................................................74
Bending Straights............................................................................................................................................73
Bogojawlenskij ...............................................................................................................................................55
Breakdown/Fin Pass........................................................................................................................................24

C
CADFinder........................................................................................................................................................5
Calibrating Methods........................................................................................................................................77
Cancel .............................................................................................................................................................39
Center Line .....................................................................................................................................................40
Centre of Gravity in 0,0 ..................................................................................................................................40
Centre of gravity to point O,O ........................................................................................................................29
Change material thickness...............................................................................................................................38
Clear also COPRA® help layers when updating screen...................................................................................13
Clear only COPRA® Layers when updating Screen........................................................................................13
Computer RAM ................................................................................................................................................3
Contour as a polyline ......................................................................................................................................19
Contour Line ...................................................................................................................................................40
Contour Radius .........................................................................................................................................32, 82
COPRA® Calculated Values ....................................................................................................................... 68
COPRA® Paths ..............................................................................................................................................13
COPRA® Proposal ..........................................................................................................................................71
Copy..........................................................................................................................................................10, 25
CPM-File ..........................................................................................................................................................3
Create a section with the help of macros.........................................................................................................28
Create combinations of primary flowers .........................................................................................................89
Create new, display or update existing projects ................................................................................................8
Creating a profile by AutoCAD polyline ........................................................................................................39

D
Delete..............................................................................................................................................................25
Design a profile...............................................................................................................................................91
Display rolls for a station ................................................................................................................................21
document management system..........................................................................................................................5
Dynamic folding .............................................................................................................................................76
Dynamic unfolding..........................................................................................................................................76

E
Erase Database................................................................................................................................................39
Execute the bending parameters......................................................................................................................75
Execute the unfolding steps ............................................................................................................................93

F
Flower Data...............................................................................................................................................30, 81
Folding with Angle / Radius Calibrating Method ...........................................................................................73

G
German Standard DIN 6935 ...........................................................................................................................49

I
Initialize the COPRA® Rollform Software .......................................................................................................8
Insert Part of Profile at a Location defined by an Entity Number...................................................................37
Insert Part of Profile at a Location picked by Crosshairs................................................................................37
Insert Part of Profile at the Beginning of the Section .....................................................................................36
Insert Part of Profile at the End of the Section ...............................................................................................37
Inserted station................................................................................................................................................15
Inside Radius ............................................................................................................................................31, 82
Intermediate/Idler Pass ...................................................................................................................................24

L
Load of COPRA® Set .....................................................................................................................................25

M
Material Thickness..........................................................................................................................................39
Mirror Profile..................................................................................................................................................29
Modification of Entities ....................................................................................................................................2
Modification Procedures...................................................................................................32, 33, 34, 83, 84, 85
Modify ............................................................................................................................................................10
Modify dimensions and geometries of the section ....................................................................................30, 81
Modify Machine .............................................................................................................................................23
Modify the vertical position of a flower .........................................................................................................80
Move section.............................................................................................................................................35, 85

N
Neutral Line ....................................................................................................................................................46
Numbering of the different Stations: ..........................................................................................................12
Numbering with Machine ............................................................................................................................15

O
Oehler .............................................................................................................................................................60

P
Pass Data ............................................................................................................................................30, 75, 81
Plane of Unfolding....................................................................................................................................70, 71
Project Mainfolder............................................................................................................................................9
Proksa .............................................................................................................................................................51
Punch Hole Orientation in Section..................................................................................................................65
Punch Hole Position in Section.......................................................................................................................65
Punch Hole Statistics ......................................................................................................................................65
Punching .........................................................................................................................................................63

R
Reactivate changes..........................................................................................................................................22
Remove...........................................................................................................................................................10
Reset commands .............................................................................................................................................21
roll information...............................................................................................................................................14
Roll numbering ...............................................................................................................................................16
roll numbers will not be changed ....................................................................................................................15
Rotate section ...........................................................................................................................................35, 85

S
Save ................................................................................................................................................................10
Save the design data of the current project .....................................................................................................18
Save to COPRA® Set ......................................................................................................................................25
Settings ...........................................................................................................................................................11
Shortcuts ...........................................................................................................................................................1
Split symmetrical sections...............................................................................................................................76
Splitting Straights for Overbending Purposes .................................................................................................73
Statics..............................................................................................................................................................66
Station attributes .............................................................................................................................................15
Station numbering with COPRA® ................................................................................................................ 15
Strip Width................................................................................................................................................31, 81
Strip Width Calculation ..................................................................................................................................41

T
Trapezoidal Section ........................................................................................................................................90

U
Unfolding ..................................................................................................................................................70, 72
Unfolding flower.............................................................................................................................................94
Unfolding via Table ........................................................................................................................................70

V
VDI guideline 3389 ........................................................................................................................................55

W
Write flower to file..........................................................................................................................................37

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