Copra: RF Software

COPRA® RF Software
User Manual . General Functions
Round Tubes & Rectangular Tubes

Shaped Tubes and Drawing Rings
©
Copyright data M Software GmbH
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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.
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Copyright data M Software GmbH
All Rights Reserved
data M Software GmbH
Am Marschallfeld 17
D-83626 Valley/Oberlaindern
Germany
www.datam.de
©
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Table of Contents
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

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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
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1.3.9. Erase COPRA Database 18
1.3.10. Erase Screen! 18
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1.3.11. Create COPRA Polyline 19
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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
2.5. Append Pass 20
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2.6. Insert Pass 20

2.7. Fade-in Profile 21
2.8. Fade in Rolls 21
3. The COPRA® Utils toolbar 21
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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
COPRA® Round & Rectangular Tubes 28

1. Archive Files 28
2. The Flower toolbar 29
2.1. Plane of Unfolding 29
2.2. Unfolding 30
2.3. Fold 31
2.4. Automatic Unfolding 32
2.5. Execute Unfolding 33
2.6. Dynamic Flower 33
2.7. Dynamic Unfolding 34
2.8. Dynamic Folding 34
2.9. Symmetrical Profiles 34
2.10. Calibrate 34
2.10.1. Constant Radius Method 35
2.10.2. Constant Length of Neutral Line Method 35
2.10.3. Track-holding Method 36
2.10.4. Angle/Radius Method 36
2.10.5. Power Bending Method 37
2.11. Reference Point 38
2.12. The Profile Utilities toolbar 39
2.12.1. Edit Profile Section 39
2.12.2. Move Profile 43
2.12.3. Rotate Profile 43
2.12.4. Split Entity 44
2.12.5. Join Entities 44
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2.12.6. Join All Entities 44

2.12.7. Same Number of Entities for 2 Profiles 44
2.13. The Profil Utils toolbar 45
2.13.1. Write Part of Profile to File 45
2.13.2. Read Part of a Profile from File 45
2.13.3. Write a Sequence of Passes to File 46
2.13.4. Read a Sequence of Passes into Flower 46
2.13.5. Material Thickness 46
3. Tubemill map Selection 47

3.1. Selected Tubemill map 48
3.2. Import/Export 48
4. The Tubemill map Layout 50
5. Flower (round Tube) 51
5.1. List of Additions 52
5.2. Strip Width 54
5.3. Forming Steps 55
5.3.1. No. of Arcs 55
5.3.2. Calculations 56
5.3.2.1. Calculation Method 56
5.3.3. Ovalism 57
5.3.4. Angle 58
5.3.5. Radii 59
5.3.6. Fin Width 59
5.3.7. Arc Length 60
5.3.8. Profile Data 61
5.4. Use Calculations 63
5.5. Parameter 63
5.6. Replace Data 64
5.7. Constant Point of Gravity in sizing Stations 65
5.8. OK. 65
5.9. Flower 65
5.10. Flower and Rolls 65
5.11. And Project Slide 65
6. Flower (rectangular Tube) 65
7. Tubemill map Data 67
7.1. Machine File for Bore Details 69
7.1.1. The toggle: Name from Tubemill map 70
7.2. Type of Station 70
7.3. Horizontal Centres 71
7.4. Axes 71
7.5. Root Diameter 73
7.6. Minimum Roll Width 75
7.7. Diameter Defaults 76
7.8. Roll Distance and Gaps 81
7.9. Width Defaults 82
7.10. Parameter 84
7.11. The Block round Driven Rolls 86
7.12. The Block round Idler Rolls 86
7.13. The Block min. Gap 86
8. Tubemill map Roll Design Set-up 87
8.1. Type of Station 88
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8.2. Roll Widths 89

8.2.1. Roll Width Top/Bottom Roll 89
8.2.2. Roll Width Side Rolls 90
8.3. 4 Axes Station 91
8.4. Relief Angles and Radii 92
8.5. Chamfers and Fillet Radii 93
8.5.1. From Parameter 95
8.6. Ø List Blanks 95
8.6.1. RDL 96
8.7. Parameter 96
8.8. Machine and Roll Data 98
8.9. Max. Wall Thickness 98
8.10. Replace Data 98
9. Parametric Roll 100
9.1. Machine Data 100
9.2. Roll Data 100
10. Special Solutions in the COPRA® Tubemill map 101
10.1. Symmetrical Turk heads 101
10.2. 4 Axis Sizing Pass 101
10.3. Split Bottom Rolls 101
10.4. Define welding point new 101
10.5. Which Station Types can be used when? 102
10.6. Placing the Dependencies for the Forming 102
10.7. How to form a Rectangular Tube? 102
10.8. Create Flower new 103
10.9. How to design oval Side Rolls in the Forming? 103
10.10. Which Profiles can be designed in the Tubemill map? 103
10.11. How to set the Gap between the Turk head rolls on zero? 103
10.12. How to append a Pass ( Straightener )? 103
10.13. How to increase the Forming Radius on the Breakdown Rolls? 103
10.14. How to set the Diameters D1 and D2 in the Fin Pass equal? 104
10.15. Why is there a Gap in the flower when the Roll is closed? 104
10.16. How to get 4 Axes in Sizing Pass? 104
10.17. How to set or change the Gap Width? 104
10.18. Structure of the Tubemill map 104
10.18.1. Project Manager 105
10.18.2. Tubemill map Selection 105
10.19. Which Role does the Writing of an Archive File have? 106
COPRA® Shaped Tubes and Draw-rings 107

1. The Special Shapes/Draw-rings toolbar 107
1.1. CAD Profile 107
1.1.1. Redefine welding point 108
1.2. Unfolding Plane 108
1.3. Execute Transformation 109
1.3.1. Angle Modification 110
1.3.1.1. The Block Shaping Steps 110
1.3.1.2. Distribution 111
1.3.1.3. Optimisation Settings 111
1.3.1.4. Compression 114
1.3.1.5. Compression settings 114
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1.3.1.6. Distribution in Profile 115

1.3.2. Theoretical Basic Knowledge 116
1.3.3. Entities of shaping Steps 116
1.3.4. Compression Factor 117
1.3.5. Optimising Methods 118
1.3.5.1. Power Fit 118
1.3.5.2. Best Fit 120
1.3.5.3. Angle Fit 120
1.3.5.4. Percent Range 120
1.3.6. Topographical 120
1.3.6.1. Curve of Contour 121
1.3.6.2. Fillet Radius 123
1.3.6.3. Curve Parameter b 125
1.4. Optimise one Pass 126
1.4.1. Close Section 126
1.4.2. Optimisation Settings 126
1.4.3. Modify Section 126
1.4.4. Change Bend 131
1.4.5. Change Radius tangentially 131
1.5. Create 3D Draw-ring 131
2. The Profile Utilities toolbar 132
2.1. Edit Profile 132
2.2. Move Profile 136
2.3. Rotate Profile 136
2.4. Split Entity 137
2.5. Join Entities 137
2.6. Join all Entities 137
2.7. Same Number of Entities for 2 Profiles 137
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General Functions Shortcuts
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 sa-
ved 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.
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Copyright by data M Software GmbH 1
General Functions Entity Selection
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.
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General Functions COPRA® Memory
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 na-
me "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.
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General Functions COPRA® Memory
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.
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General Functions The COPRA® Explorer with CADFinder
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 o-
pened 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.
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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.
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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
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COPRA® Basictools The COPRA® toolbar
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.
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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 ship-
ped with COPRA® are correct as the natural deviations of the coil ma-
terial may be quite high.
After confirmation of the material, additional project information can be entered.

This information is optional and may be left blank.
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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.
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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.
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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 .
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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:
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 a-
vailable 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.
©
COPRA® Basictools The COPRA® Database toolbar
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.
©
COPRA® Basictools The COPRA® Database toolbar
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.
©
COPRA® Basictools The COPRA® Utils toolbar
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.
©
COPRA® Basictools Machine file for bearing seats
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
©
COPRA® Basictools Convert Database
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 ma-
de.
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.
©
COPRA® Round & Rectangular Tubes Archive Files
COPRA® Round & Rectangular Tubes
1. Archive Files
Function:
Important design steps should be saved in archive files
An Archive file has the same file format as the Project file.
The 5 database files *.db are also saved and compressed in the Archive
files, and therefore cannot be modified directly.
In contrast to only one Project file, as many Archive files as necessary 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
Profile, Flower and Rolls modules 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 and its filename
cannot be changed. The user defines the names and location of the Ar-
chive files.
The COPRA® database has changed several times since its first re-
lease, so older versions may have to be converted first. Archive files
of previous releases can always be loaded. Therefore all COPRA® da-
tabase should also be saved as Archive files. Before old Archive files
are loaded a new project should be created with the Project Manager.
©
COPRA® Round & Rectangular Tubes The Flower toolbar
2. The Flower toolbar
The Flower toolbar contains all functions required to create a flower.
2.1. Plane of Unfolding
Function:
Define 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 appears automatically:
Entity Centre:
Allows you to pick the respective entity with the crosshairs. The point of unfolding
is positioned in the middle of the selected entity.
Before Entity:
is positioned at the point of separation from the selected entity. COPRA® direction:
from left to right.
After Entity:
®
is positioned at the point of separation after the selected entity. COPRA direction:
from left to right.
Point picked by Cursor:

Allows you to pick a certain point within an entity. The point of unfolding is at the
defined point. The proposed point, which is marked with a cross, reflects the cen-
tre 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 such 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 are satisfied with the plane of unfolding.
Yes:
If you confirm with Yes, the process is finished and the plane of unfolding 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.
2.2. Unfolding
Function:
Step-by-step unfolding of individual bending steps with user-defined settings
After having selected the icon the system asks you to select the arc to be unfolded
with the help of the crosshairs. Do so and the Interactive Unfolding dialogue box
appears:
Current 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 option, 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.
Join Equal Entities automatically:

All equal entities will be joined automatically.
Calibrating Method:
Allows you to choose from different calibration methods. For detailed information
refer to, Calibration Methods.
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 following is a short description of the differences between the Fold and Un-
fold option.
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.
©
Bending Straights:
For better access to undercut bends it may be necessary to over-bend straights.
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 function from the Profile Utilities toolbar.
2.4. 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 tool is provided by the automatic unfolding command in
COPRA®.
After having selected the icon, the system asks you to select the arc to be un-
folded with the crosshairs. The Automatic Unfolding dialogue box is opened.
Similar to the Interactive Unfolding dialogue box the following functions 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 you to define 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.
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, 2.2 Unfolding.
2.5. Execute Unfolding
Function:
®
Execute the bending parameters entered and save new section in COPRA database
2.6. 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 your information.
View Window:
Displays all entities and their respective values.
Entity Selection:
See chapter, General Information.
Calibration Method:
Allows you to choose from several 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.
2.7. 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 very helpful, for example, for checking accessibility of the rolls.
2.8. 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 very helpful, for example, for checking accessibility of the rolls.
2.9. Symmetrical Profiles
Function:
Split symmetrical sections
Symmetrical sections can be split to make design faster by unfolding only one half
of it. COPRA® automatically recognises whether a certain profile is symmetrical
and loads the required dialogue box.
2.10. 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. Each bend is described by the inner radius Ri, the bend angle α and the
length of neutral line LNL.
©
COPRA® provides 5 different Calibrating Methods:

• Constant radius
• Constant length of neutral line
• Track holding profiling
• Angle/radius profiling
• Tube profiling/power bending
2.10.1. 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 non-bent 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 that
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 possibility 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
2.10.2. 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.
©

Pro: bending areas are not cornered
Cons: higher spring back rate
Characteristics of the Constant Length of Neutral Line Method:

Inner radius: variable
Length of neutral line: constant
Length compensation: no
2.10.3. 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°.

Pro: high accuracy of dimensions
Con: difficult machine set-up
Characteristics of the Constant Length of the Track-holding Method:

Inner radius: constant
2.10.4. 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 0 mm. When modifying the angle as well as the inner radius the length of neu-
®
tral 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 the 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 calcula-
tion 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.

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 cause
minor deviations within the flower. Prerequisite is that the calculated
strip width remains constant.
Restrictions: length compensation pieces cannot be taken from adjacent entities,
if these are bends
Characteristics of the Angle/Radius Method:

2.10.5. 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
can not 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. Selection is
by using the crosshairs.

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:

©
2.11. 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 a section is actually manufactured. But some-
times it is necessary to change the vertical positions of individual sections within a
flower. A typical example is a section with a dovetail.
The vertical position can now be changed with the Move option from the
FLOWER screen menu or with the RefPoint function. Selecting the RefPoint
function will open a new dialogue box.
Fig. 5 Unfolding Reference Point
Fig. 6 Modified Reference Point
©
2.12. The Profile Utilities toolbar
2.12.1. Edit Profile Section
Function:
Modify dimensions and geometries of the section
Normally, it is not necessary to modify a section within a flower. This can be done
®
with the standard COPRA options. This function is only required for a handful of
cases.
This function allows you to modify the calculated length of the neutral
line. Use carefully as improper use may cause 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 an entity is highlighted by selecting 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 the OK will make the changes permanent. The entities at the
section forming point FP are marked with an asterisk.
Radio Button S:
Activated by COPRA®, if only a straight entity in the list is highlighted. A straight
entity 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:
Activated 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.
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.
Profile Entity:
Here the number of entities in a section can be changed. In combination with the
function distribute the length difference to selection it is also possible to separate
entities.
©
% 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.
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 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.

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.
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.

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, in which way the lengths are to be distributed right and 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, closer to the welding point.
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,
further away from 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 can be adjusted to the new length.
Radius:
If required, the radius of an arc entity can be adjusted to the new length.
Length Difference:
After the 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.
2.12.2. Move Profile
Function:
Move section
This function allows you to move a selection of sections by defining reference and
target points. The sections to be moved are displayed in the same colour. Option-
ally, 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 can be saved optionally.
2.12.3. Rotate Profile
Function:
Rotate section
This function allows rotation of 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 can be
saved optionally.
©
2.12.4. Split Entity
Function:
Split one entity into two parts
Sometimes it may be necessary to insert an entity in the same position already
occupied by another entity. In this case the Split entity function can be used to
break an entity in two. The entity to be split has to be selected 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.
2.12.5. 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.
2.12.6. 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.
2.12.7. 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.
©
2.13. The Profil Utils toolbar
2.13.1. Write Part of Profile to File
Function:
Writes a part of a profile for copying purposes to harddisk
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 function and copied
with the Read PP function.
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 for copy.
2.13.2. Read Part of a Profile from File
Function:
Reads a part of a profile from harddisk and inserts it in the current section
Each part of a profile written to harddisk 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 A option causes the profile part 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 E option 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 G option 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 N option 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.
2.13.3. 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.
2.13.4. Read a Sequence of Passes into Flower
Function:
Read flower from file
This function allows you to read a flower or part of a flower from a file.
2.13.5. Material Thickness
Function:
Change material thickness subsequently
This function allows you to subsequently change the sheet thickness for a com-
plete flower. In the occurring dialogue box you can choose between several meth-
ods. After having selected a method, a slide provides a preview of how sheet
thickness will change.
Select:
Select the passes the material thickness of which 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.
©
COPRA® Round & Rectangular Tubes Tubemill map Selection
Outer Radius constantly:

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.
3. Tubemill map Selection
Function:
To manage all created Machines and Machine Data
The Tubemill map Selection dialogue box is divided into the areas Machine, se-
lected Tubemill map, current Machine and a few other options.
Tube Ø:
Shows the finish Tube diameter entered in the Flower.
Stations:
Shows the number of Stations entered in the machine layout.
Comment:
A comment is especially allocated to the selected Tubemill map in order to have
another information possibility.
The Machine definition consists of the name of the machine and an identifi-
cation for the profile.
Machines:
Shows the current and all other available machines. The highlighted Machine is
the one used last.
Profiles:
Shows the current profile and all other available profiles. The highlighted profile is
the one used last, assigned to the selected machine.
©
3.1. Selected Tubemill map
Copy:
To use a machine for another profile, it should be copied and renamed.
The same machine should not be used for different profiles. The original ma-
chine should always be copied and renamed according to the profile. The
reason for this is that if some data in the machine are changed, they will also
be changed in all the profiles for which this machine is used.
Delete:
The DELETE function is used for the deletion of machines.
3.2. Import/Export
Tubemill map:
If selected, the database can be imported. This function is needed e.g. if the
spring-back was calculated in the flower. After selecting this function the Im-
port/Export dialogue box appears:
The dialogue box is divided into the areas Import/Export, import flower database
and further options.
Current Tubemill map:

Shows the current machine name, the final diameter and the pass number.
Import/Export of Tubemill map Data:

Shows the final diameter and the pass number of the machine to which the data
shall be imported or exported.
Import:
If selected, Machine information can be chosen and imported into that being cur-
rently used.
Export:
If selected, Machine information can be chosen and exported into that being cur-
rently used.
Machines:
Shows the current and all other available machines. The highlighted machine is
the one used last.
©
Profiles:
Shows the current profile and all other available profiles. The highlighted profile is
the one used last and is assigned to the highlighted machine.
The Block Import/Export:
Layout:
The layout is imported or exported into or from the selected machine according to
the chosen option.
Flower:
The flower data will be imported into or exported from the selected machine ac-
cording to the chosen option.
Machine:
The machine data will be imported into or exported from the selected machine
according to the chosen option.
Rolls:
The roll data will be imported into or exported from the selected machine accord-
ing to the chosen option.
The Block Import Data Base:
Use Tubemill map Settings:

The settings of the Tubemill map will be used.
Join Entities before Import:

All entities will be joined before the import of the database.
Import Flower from Database:

The database of the modified flower, spring-back, will be imported into the Tube-
mill map.
Import of Data Base in Machine... is allowed :

Shows whether the modified database can be imported into the Tubemill map.
Import of Data Base... finished:

Shows whether the modified database was imported into the Tubemill map.
Old Version:
This is only used for the import of data from the old COPRA® Modules.
©
COPRA® Round & Rectangular Tubes The Tubemill map Layout
4. The Tubemill map Layout
Function:
Defines the machine layout
The layout of an almost arbitrary tube-welding street can be defined quite simply.
The complete machine can be defined by simply selecting the different passes.
To get the dialogue box for designing a flower for a rectangular the last pass
in the machine layout must be a Turk head rectangular or a round rectangu-
lar pass.
Tubemill map:
Shows the selected Tubemill map. The name consists of the chosen machine and
the tube to be manufactured.
Sequence of Stations:
Shows the selected sequence of stations from the first to the last pass.
Modify:
To change the pass type, a dialogue box opens, when selected, with all available
passes. The current pass type is highlighted.
Pass Selection:
All available pass types are shown in slides.
Zoom in by Mouse click:

Clicking on the slide with the right mouse button can enlarge it.
Previous:
The previous macro with pass types will be shown.
Next:
The next macro with pass types will be shown.
Another possibility to select a pass type is to make a double click on the

slide. In this case the Toggle "Zoom in by Mouse click" must not be set.
Add:
This must be selected to add another pass. The added pass is added behind the
highlighted pass.
Remove:
The highlighted pass will be removed from the Tubemill map layout.
©
COPRA® Round & Rectangular Tubes Flower (round Tube)
Split all Top/Bottom Rolls:

When activated, all top and bottom rolls will be split. If it is not set, the bottom rolls
are only split where the vertical adjustment of the shafts is not sufficient for the
assembly of the rolls. In this case the top rolls remain undivided. If the bottom roll
shall not be split, the vertical adjustment of the shafts must be defined bigger.
Tip for the pass types: breakdown pass type 2 should be used only as first
breakdown, since it cannot be used over 90°. The same applies for idler
pass type 3. It can also not be used for more than 90°.
5. Flower (round Tube)
Function:
Calculate the flower automatically
The Tube flower set-up dialogue box is divided into the areas Final section,
Welding section, Wall thickness, Additions, Strip width, Formingsteps and further
options.
To get this dialogue box, a Turkhead round tube must be the last pass in the
Tubemill map layout.
Tubemill map:
Shows the selected Tubemill map.
The Block Final Section:
Tube Diameter:
The final diameter of the round tube is entered here.
Contour Line:
Shows the calculated contour line of the round pipe.
Centre Line:
Shows the calculated centre line of the round tube.
The Block Welding Section:
Weld Diameter:
Shows the welding diameter incl. the calibration addition.
©
Contour Line:
Shows the calculated contour line of the round tube including the calibration addi-
tion.
Centre Line:
Shows the calculated centre line of the round tube including the calibration addi-
tion.
The Block Wall Thickness:
Wall Thickness:
The minimal wall thickness of the round tube to be manufactured is entered here.
Increasing the wall thickness can influence the radius of the top roll.
Max. Wall Thickness:

Entry for the maximum wall thickness of the round tube to be manufactured.
5.1. List of Additions

Entry for the additions to the strip width calculation. The List of additions dia-
logue box is divided into the areas, reduction addition, welding addition, sizing ad-
dition, strip guide addition and further options.
Reduction Addition RA:

This value refers to the strip width and compensates for the material loss caused
by the reduction in the fin passes.
Parameter is Factor:
If set, the factor for the reduction addition is used from parameter.
Factor for Reduction Addition:

The factor can only be entered manually if the additions are not used from the pa-
rameter file (option not set).
Welding Addition WA:

This value refers to the strip width and compensates for material loss cause by
welding. In case there is no material loss in welding the value must be set at 0.
WA (mm):
The value can only be entered manually in millimetres if the additions are not used
from the parameter file (option not set).
©
WA (%):
The value can only be entered manually in percent if the additions are not used
Sizing Addition SA:

This value refers to the tube diameter and compensates for material loss caused
through sizing.
SA (mm):
The value can only be entered manually in millimetres if the additions are not used
Zk (%):
Use Reduction in the driven Stations only:

If set, the reduction is distributed only in the driven stations. The driven stations
are not taken into account here.
Strip Guide Addition GA:

This value refers to the strip width and compensates for material loss caused by
strip guiding into the first station. This value is only actual if a strip guide is used in
the Tubemill map and if there is a reduction happening during this process.
GA (mm):
The value can only be entered manually in millimeters if the additions are not used
GA (%):
Assignment:
The appropriate passes are shown in the list-box by selecting the right addition.
The values can be distributed to the passes in percent.
Uniform:
The addition value is distributed uniformly to all passes in which this value is taken
into account.
Use Parameter:
If set, all additions are used from the parameter file.
©
5.2. Strip Width

The Strip Width dialogue box shows the different methods available for calculata-
tion.
The method which is closer to the results of the strip width hitherto calcu-
lated according to company experience should not be used here. It is impor-
tant to check which factors or additions refer to which value of the profile.
Calculation Method:
The Calculation Method is to determine the strip width, which can be selected.
Calculation Method 0:
This option is for the Strip Width to be entered manually for each pass, and not to
be calculated.
Calculation Method: 1:
In this method the sizing addition is used twice in the bracket and in this case re-
fers to the final radius of the round tube. All other additions are added up on the
result.
In this method the sizing addition is used once in the bracket and in this case re-
fers to the final diameter of the round tube. This means the diameter change cor-
responds to the sizing addition. All other additions are added up on the result.
The reduction addition is used in the bracket. The sizing addition is added up only
after the inquiry of the centre line of the final profile and therefore refers to the
strip width. Then the welding addition (WA) and the wall thickness are added up
on the result.
The centre line is calculated in the bracket without additions. All additions are
added up only after the calculation of the centre line of the final profile and there-
fore refer to the strip width.
Round Strip Width with selected calculation Method:

The calculated strip width can be rounded off.
Round:
The calculated strip width can be rounded up or down. Also the possibility to set a
maximum tolerance for the entered values is given.
©
Compensation in Addition:
The rounded value can be distributed to the appropriate additions.
RA/WA/SA/GA
An addition can be defined by setting one of these options.
The calculated or entered value of the strip width is listed pass by pass. If the cal-
culation method 0 was selected, all values of the strip width can be modified.
5.3. Forming Steps

Here all data are entered to design a tube flower. The Forming Steps dialogue
box is divided into the areas number of arcs, calculations, ovalism, angles, radii,
fin widths, arc lengths, and profile data.
If a star (*) follows a calculated or entered value, it indicates that this entity is
a straight element. The value is the length of the element.
The Block Methods:

The methods can be selected to design the tube flower.
5.3.1. No. of Arcs

Here the Number of Arcs to form the tube are defined. The Number of Arcs dia-
logue box is divided into the areas, sequence of stations, arc selection and num-
ber of arcs.
Sequence of Stations/No. of Arcs:

Shows the sequence of stations and the number of the arcs used in each pass.
Arc Selection:
The number of arcs can be selected by operating the slide. The number of arcs
varies according to the forming strategy of the designer. Maximum 4 arcs can be
used for each symmetrical side.
Number of Arcs:
Single pass types, which shall be formed double symmetrically, can be selected.
The condition for this function is that a double symmetrical profile gets formed.
Only a quarter of the profile will be defined. The values will be mirrored twice.
This method offers the possibility to design with a maximum of 8 arcs per
symmetrical side. The condition is that the final profile is double symmetrical.
©
5.3.2. Calculations
The calculation method of each pass can be defined. The Calculations dialogue
box is divided into the areas sequence of stations, calculation method and factors.
Shows the sequence of stations and the currently selected pass.
Possible Dependencies:
A possible dependence of the previous or following pass can be defined. No val-
ues will be defined here. The actual settings are defined in the Calculation
Method dialogue box.
From previous Station:

If set, the dependency from the previous station will be used.
From next Station:

If this toggle is set the dependency from the next station will be used.
Current Station only:

If set, no dependencies are used.
5.3.2.1. Calculation Method

Shows the used calculation method with the respective slide and formula. Differ-
ent pass types can have also different calculation methods.
Modify:
If selected, the Calculation Method can be changed.
At least one value must be calculated from the strip width and one value
must be set on user-defined.
Modify Station/Calculation Method:

The dialogue box is split into the areas radius, angle and dependencies.
Radius:
Offers different possibilities to determine the radius of the selected arc.
Angle:
Offers different possibilities to determine the angle of the selected arc.
©
Dependencies:
Depending on the selection which was made in the calculation/dependencies
dialogue box, is it now possible to use factors and to enter a dependency on the
previous, the next pass or any pass number.
A calculation of the fin width can be used in the fin passes. In the sizing
passes, only the calculation formula is shown since the profile is already
closed.
In case there are any problems with the inserted values and the calculation
cannot be made an error message will appear.
Factors:
Here the factors will be defined for the dependence of passes for the respective
radii and angles. The values can be adapted depending on the forming strategy.
For example, the welding radius is bent in the first station and kept until the weld-
ing (Weld radius x Factor 1).
5.3.3. Ovalism
The Ovalism can be defined for the passes. The Ovalism dialogue box is split
into the areas, station and form of profile.
An Ovalism can be defined only for a closed pass (fin pass or sizing pass).
Station:
Shows which pass is set on actual, and should be modified.
Form:
Shows which method is used for defining the profile form: calculation or oval
Form of Profile:
Here the form of the profile can be chosen from four different options
Acc. to Calculation:
If an oval form is not to be calculated, this option must be selected.
High:
When using the method high oval, the value for the Ovalism can be entered in
percent. This means that the profile, according to the entered value, is higher than
wider. To determine the oval there is also a possibility to change the angles.
Round:
When selecting this option, the profile is formed round.
©
Flat:
When using the method Flat oval the value for the Ovalism can be entered in
percent. This means that the profile, according to the entered value, is wider than
higher. To determine the oval there is also a possibility to change the angles.
Zoom in by Mouse click:

By selection on the dialogue box with the right mouse button, it will be enlarged.
Total Angle:
Here the formula for the calculation of the total angle is shown.
The Block Values:

The values are entered here to design the tube flower.
5.3.4. Angle
In this dialogue box the angles for each pass can be entered. The condition for
this is that the Calculation Method is set on user-defined. The Angle dialogue
box is split into the areas, station, arc, angle, and end angle.
The total of the arc angle must not be more than 180°.
If an angle is set on zero, a straight element is presumed.
Station:
Shows which pass is set on current and should be modified. The Shift or Ctrl. key
should be used to select and modify more passes simultaneously.
Arc:
Shows the number of arcs and their respective angles.
Angle:
The values for each arc can be entered here. The condition for this is that the cal-
culation method is set on user defined.
Half Angle of the Centre Arc:

Divides the middle arc into two halves and thus simplifies the input for a symmetri-
cal side.
©
5.3.5. Radii
In this dialogue box the radii for each pass can be entered. The condition for this
is that the calculation method is set on user-defined. The Radii dialogue box is
split into the areas, station and radius.
Is a star (*) follows a value it defines a straight element. The value indicates
the length of the element.
Station No.:
should be used to select and modify more passes at a time.
Arc:
Shows the number of arcs and respective radii.
Radii:
The values for each arc can be entered, if the calculation method is set on user-
defined.
Display of Section Radii:

Here it can be selected at which point of the section the radius should be meas-
ured and displayed: on the outside radius, inside radius and in the middle radius.
Outside Radii of Arcs:

Here the radius is measured on the outside of the profile.
Middle Radii of Arcs:

Here the radius is measured on the middle of the profile.
Inside Radii of Arcs:

Here the radius is measured on the inside of the profile.
5.3.6. Fin Width

In this dialogue box the fin width for each pass can be entered if the calculation
method is set on user-defined. The fin width dialogue box is split into the areas,
display in list, location of fin width, station and fin width.
Display in List:
If set, only the fin passes will be shown.
Location of Fin Width:

Here it can be selected at which point the fin width should be measured and dis-
played: on the outside, inside and in the middle of the profile.
©
Station:
Fin Width:
Shows the fin width in each pass.
Input:
The values for each pass can be entered manually here.
From Parameter:
The fin width is taken from the parameter file depending on the tube diameter,
From Formula:
The fin width is calculated by using of a special formula.
5.3.7. Arc Length

In this dialogue box the arc length for each pass can be entered. The calculation
method must be set on user-defined. The Arc Length dialogue box is split into
the areas, Station, strip width, difference, arc and length.
If a star (*) follows a value, it defines a straight element. The value indicates
the length of the element.
Station:
should be used to select and modify more passes simultaneously.
StrWid/2:
Shows half the calculated strip width.
Difference:
Reports if a wrong input was made during the calculation methods thus causing a
different value of the strip width.
Arc:
Shows the value of the arc length in each respective pass and arc.
Length:
The values for each arc can be entered. The calculation method must be set on
user-defined.
©
Const.:
All passes, which are to have a constant arc length, are highlighted here. The de-
sired arc length can be entered and by setting the All, the selected passes get a
constant arc length. For this purpose the calculation method must be set on user-
defined.
Take Reduction into account:

If set the reduction in the passes with reduction are taken into account. The calcu-
lation method must be set on user-defined and the arc length values must be en-
tered.
From the End:

If set, the reduction is taken into account from the end of the sequence of stations.
5.3.8. Profile Data

This dialogue box is a combination of all profile data of the designed flower. All
values can be modified in one dialogue box (angle, radius, arc length calculation
method...). The Profile Data dialogue box is split into the areas, station, arc, an-
gle, radius, length, fin width and calculation method. All profile data are combined
in this dialogue box.
If a star (*) follows a value, it defines a straight element. The value indicates
the length of the element
Station:
Shows which pass is set on current and should be modified. The Shift or Ctrl. key-
StrWid/2:
Shows half the calculated strip width.
Difference:
Reports if a wrong input was made during calculation thus resulting in a difference
of the strip width.
Arc:
Shows the arc length in each respective pass and arc.
Show Angle/Radius/Length:
If the Angle is set all angles are shown in the list box.
©
Angle:
The values for each arc can be entered. For this purpose the calculation method
must be set on User-defined. Detailed information can be found in the document
about the value Angle.
Radii:
The values for each arc can be entered here if the calculation method is set on
user defined. Detailed information can be found in the document about the value
Radii.
Length:
arc Lengths.
Fin Width:
Fin Widths.
Calculation Method:
The calculation method for each pass can be modified here. Detailed information
can be found in the document about the method Calculations.
Half Angle of the Centre Arc:

If set, the values are entered only for one symmetrical side. The result will be mir-
rored.
The Block Display of Section Radii:
Outside Radii of Arc:

If set, the outside radius of the profile will be shown.
Centre Radii of Arc:

If set, the centre radius of the profile will be shown.
Inside Radii of Arc:

If set, the inside radius of the profile will be shown.
Take Reduction into account:

If set, the reduction in the fin passes in the arc lengths is taken into account.
©
From the End:

If set, the reduction in the fin passes starting from the end in the arc lengths is
taken into account
5.4. Use Calculations

If not set, all values can be entered manually. COPRA® does not calculate any
value.
5.5. Parameter
The parameter values for additions and fin width are entered here. The Parame-
ter dialogue box is split into the areas, additions and fin width. A diameter table for
the final tube diameter is entered here. Depending on the diameter the corre-
sponding values for the additions are entered. These values are used if the option
from parameter is selected.
To be able to use the settings of a Tubemill map for further tube diameters,
as many values as possible should be taken from the Parameter file if the
option is possible. For this purpose the parameter file must already have
been completed with values of customer know-how or special literature.
Since the values always refer to the diameter, all data for the rolls are taken
from the parameter file when entering a new tube diameter. This is done with
reference to the diameter. The same is true if the value was entered manu-
ally. The parameters make a highly efficient work with the Tubemill map pos-
sible. The settings are made once and can then be used in a certain diame-
ter area again and again. A complete roll set can be created in a few sec-
onds with the OK. and rolls options.
Addition:
Values for the tube diameter and all additions can be entered.
Ø >=:
The current diameter which is the closest to the designed profile.
RA:
The parameter value for the reduction addition.
WA:
The parameter value for the welding addition.
SA:
The parameter value for the sizing addition.
©
GA:
The parameter value for the strip guiding addition.
Fin Width:
Values for the fin width depending on the diameter table are entered here.
Ø>=:
Shows the existing diameter table.
Fin Width:
The parameter value for the fin width.
Station:
Shows the current station and the used fin width.
Copy:
To complete the parameter file an existing value should be copied and modified.
Remove:
The highlighted value will be deleted.
5.6. Replace Data

Here it can be defined which passes from the flower shall be re-calculated. The
Replace Data dialogue box shows the existing database of the tube flower.
Station:
Shows, the selected stations for the new calculation of the database.
Pass:
Shows the selected stations for the new calculation of the data base.
Created with:
Shows with which module the pass was created, for e.g. Spring-back or downhill
forming.
Select:
Select all stations. Single stations can be selected by using Ctrl and the left mouse
button.
Deselect:
Deselect all selected Stations.
©
COPRA® Round & Rectangular Tubes Flower (rectangular Tube)
5.7. Constant Point of Gravity in sizing Stations

If set, the centre of the profile remains in a constant position from the welding sta-
tion up to the Turkhead.
5.8. OK.
If the dialogue box is left with this option all entered data will be saved. The data-
base shown on the screen will not be updated.
5.9. Flower
If the dialogue box is left with this option all entered data will be saved. The flower
is calculated and unfolded automatically.
5.10. Flower and Rolls

If the dialogue box is left with this option all entered data will be saved. The flower
and rolls are calculated, unfolded and created automatically.
5.11. And Project Slide

If set, a slide is made of the finished flower. This serves for the better identification
of the project in the project manager.
6. Flower (rectangular Tube)
The Tube flower set-up dialogue box is split into the areas, dimension of rectan-
gular, welding section, wall thickness, flower-set and further option.
In order to get this dialogue box either a Turkhead rectangular tube pass or
a round rectangular pass must be positioned at the end of the Tubemill map
layout.
Tubemill map:
Shows the current Tubemill map.
Dimension of Rectangular:
The values for the final profile shape must be entered here.
Rectangular:
If set a real rectangular will be created.
A:
The width of the rectangular.
©
COPRA® Round & Rectangular Tubes Flower (rectangular Tube)
B:
The height of the rectangular.
R2:
The outside radius of the rectangular.
Use:
If set, the centre line of the profile gets predefined. This method is mainly used if
double symmetrical shaped tubes are formed. The strip width is calculated with
the centre line and the additions.
Rectangular/Use not Set:

With the options R1/R2/R3 and ß1/ß2/ß3, a round rectangular or a shaped tube
symmetrical (double symmetrical) can be created just by entering the radii and
angles.
Calculated Tube Ø:
Shows the calculated tube Ø as a result of the values from the rectangular.
Contour Line:
Shows the calculated contour as a result of the values from the rectangular.
Welding Section:
The values for the profile in the welding section are defined here.
Round:
If set, the welding pass is calculated as a round tube.
1x Symmetrical:
If set, the profile in the welding station will be calculated via the entry of angle and
radius values. Only one half of the profile is calculated and mirrored after calcula-
tion.
2x Symmetrical:
If set, the profile in the welding station will be calculated via the entry of the angle
and radius values. Only one quarter of the profile is calculated and mirrored twice
after calculation.
Centre Line:
If set, the centre line of the welding profile gets predefined. To get the option for
entering the value, Use, must also be set.
©
COPRA® Round & Rectangular Tubes Tubemill map Data
Weld Diameter: also

If use additions from parameter, is not set, the value for the tube diameter in the
welding station can be set. The sizing addition should be added also.
Contour Line:
Is the calculated contour of the profile in the welding station.
Centre Line:
If use additions from parameter, is not set, the value for the centre line in the
welding station can be set. The sizing addition should be added also
R1/R2/R3/ß1/ß2/ß3:
The angles and radii from the welding pass can be entered here. Options 1x
symmetrical or 2x symmetrical must be set for this purpose.
Wall Thickness:
Wall thickness: The minimum wall thickness of the profile can be en-
tered.
Maximum wall thickness: The maximum wall thickness of the profile can be en-
tered.
7. Tubemill map Data
The Machine Data dialogue box is split into the areas Machine, Rolls, type of sta-
tion, horizontal distance, axes, root diameter, minimum roll width, diameter de-
faults, roll distance and gaps, width defaults, parameter, round and further op-
tions.
as many values as possible should be set on calculation and not on input or
user defined, if the option is possible. Since the values always refer to the
diameter, all the values get updated according to the tube diameter. In case
the value was inserted manually it will remain the same. The calculation
method makes working with the Tubemill map highly efficient. The settings
are made once and can then be used in a definite diameter area again and
again. A complete roll set can be created in a few seconds with the OK. and
rolls.. options.
If a plus (+) or minus (-) follows a calculated or entered value it indicates that
the minimum or maximum limit is reached.
©
The Block Station Type Selection:
All:
If set, all existing stations will be shown in the list box.
Driven Rolls:
If set, only the existing driven stations will be shown in the list box.
Idler Rolls:
If set, only the existing idler stations will be shown in the list box.
The Block Station Selection:
All:
With this, All passes can be selected. The Shift or Ctrl. key should be used to se-
lect and modify more than one pass at a time.
Previous:
The previous pass selection can be returned.
Station:
Shows the stations in a row.
A slide is listed on the right side to get an overview about the selected station
type and its dimensioning scheme. Zoom in by Mouse click! By clicking on
the slide with the right mouse button it can be extended.
When inserting the values in the passes, the station type selection should
not be set on All. The reason for this is that the dialogue box shows more in-
formation and the slide with the scheme of the pass type is also shown.
Tubemill map:
Shows the currently used Tubemill map.
Tube Diameter:
Shows the final tube diameter.
No. of Stations:
Shows the number of stations used.
©
Top Rolls:
To get the minimum diameter of the top roll, the following values must be entered:
bore Ø, keyway and the min. wall thickness of the roll.
Bottom Rolls:
To get the minimum diameter of the bottom roll, the min. wall thickness of the roll
has to be entered. All other values are used from the top roll.
Side Rolls:
To get the minimum diameter of the side roll, the following values must be en-
tered: bore Ø (bearing seat) and the min. wall thickness of the roll.
7.1. Machine File for Bore Details

All details for the bore, stamping groove and further options are defined in this
function.
These machine files are used in the following modules:

• Standard Roll dimension
• Tube roll dimensioning
• Dimensioned assembly plan
• COPRA® Roll data base
The selection of the machine and modifications of the bore details are possible
after selecting Machine in the main dialogue boxes of those modules.
If a machine is set as current in one module, then this machine is also the
current one in other modules.
Make sure that the settings do not get in conflict with each other. For
example, the diameter of bore must not exceed the inner diameter of
the stamping groove for roll numbers (settings for drawing genera-
tion).
Machine:
All existing machine files are listed here. In order to set the current machine or to
make modifications, the machine has to be highlighted in the list.
Modify:
The settings of the machine selected in the machine list can be modified.
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.
©
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.
Intermediate/Idler Pass:
Analogous to the Breakdown/Fin Pass the values of the side roll borehole details
can be entered here.
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.
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.
Delete:
The machine highlighted in the list will be removed from the list. The correspon-
ding machine file is deleted.
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.
7.1.1. The toggle: Name from Tubemill map

If set, the machine with the bore details gets the same name as the Tubemill map.
7.2. Type of Station

The pass type for the roll design can be changed here. The flower stays the same,
only the roll type changes. The Type of Stations dialogue box is split into the ar-
eas sequence, profile width, height, gap and further options.
Sequence:
Shows the selected sequence of stations.
Profile Width/Height/Gap:
Shows the current data of the profile, calculated from the flower.
©
Modify Type of Station for Roll Design:

The pass type can be changed specifically for the roll design here. The sequence
of stations and the flower remain the same, only the pass type for the roll design
changes. In the slide it is shown which pass type is selected for the roll design.
Type of Station like Profile:

The pass type is set automatically back to the previous setting from the flower and
layout.
7.3. Horizontal Centres

The horizontal pass distance is entered here. The Horizontal Centres dialogue
box is divided into the areas, Station, Selection and Horizontal Centres.
All:
With this, all passes can be selected. The Shift or Ctrl. key should be used to se-
lect and modify more passes simultaneously.
Previous:
The previous pass selection can be fetched back with this button.
Station – Station:
Shows the distance between the station centres.
Distance:
Here the value for the horizontal distance can be entered.
7.4. Axes
The details for the axis are entered here. The Axes dialogue box is split into the
areas, station type selection, roll space, axes bottom, axes top and further op-
tions.
Top Traverse (Mt):

If set, the distance between the machine bed and the top frame can be entered.
not be set on all. The reason for this is that the dialogue box shows more in-
Roll Space A:
The value for the roll space of the horizontal axis.
©
MA1min:
The value for the adjustable distance of the bottom shaft. Measured from the ma-
chine bed up to the centre of the shaft.
MA1max:
The value for the adjustable distance of the bottom shaft. Measured from the ma-
chine bed up to the centre of the shaft.
MPmin:
The value for the adjustable distance of the profile. Measured from the machine
bed up to the point of unfolding.
MPmax:
The value for the adjustable distance of the profile. Measured from the machine
bed up to the point of unfolding.
MA2min:
The value for the adjustable distance of the top shaft. Measured from the machine
bed up to the centre of the shaft.
MA2max:
The value for the adjustable distance of the top shaft. Measured from the machine
bed up to the centre of the shaft.
M-Mt:
The distance between the machine bed and the top frame.
If some of these values are not known they should be entered for maximum
as a very big value and for minimum as a very small value. In this way there
will be no problems caused by limits in the dialogue boxes..
Axis Definition of the Idler Rolls:

The details for the axis are entered here. The Axes dialogue box is split into the
areas, station type selection, roll space and further options.
Roll Space F:
The value for the roll space of the vertical axis.
Offset K:
The value for the offset of the vertical axis.
Hmin:
The value for the adjustable distance of the idler shaft. Measured from the shaft
centre right to the shaft centre left.
©
Hmax:
The value for the adjustable distance of the idler shaft. Measured from the shaft
centre right to the shaft centre left.
If some of these values are not known they should be entered for maximum
as a very big value and for minimum as a very small value. In this way there
will be no problems caused by limits in the dialogue boxes.
7.5. Root Diameter

The Root Diameter for the rolls is entered here. The Root diameter dialogue box
is in split into the areas station type selection, bottom roll Ø, top roll Ø, gear ratio,
vertical centres and further options.
not be set on all. The reason for this is that the dialogue box shows more in-
Root Diameter Top/Bottom Rolls:
Bottom Roll Ø/B:

The value for the root diameter of the bottom roll. Measured from the centre of the
shaft to the lowest point of the profile.
Top Roll Ø/C:

The value for the root diameter of the top roll. Measured from the centre of the
shaft to the lowest point of the profile.
Gear Ratio D:
Shows the gear ratio between lower and top rolls. The top roll should always be
bigger or at least equal than the bottom roll.
Vertical Centres E:
Shows the horizontal distance between the top and bottom shaft.
Angle Bottom Ø b:
Shows, at which point of the profile the driving diameter can be determined most
realistically.
Diff Ø:
Shows the horizontal difference from the point of unfolding after an angle was en-
tered.
©
Fix:
Gives the possibility to set a value to constant depending on the philosophy of the
designer.
Step up Root Diameter:

The step up is the value, which describes the continuous extension of the root di-
ameter from the first to the last station. To reach a pull in the material, this value
should always be used.
Check whether the driving diameter and the gear ratio was entered correctly. Se-
lect only top/bottom rolls in the station type selection. Mark all the stations where
the step up should be taken into account and set the gear ratio on Fix.
Enter the value for the step up and confirm with “Enter”.
The material springs back after the forming in the passes. This causes resis-
tance at the rolls. To compensate for this resistance, the roll-Ø is extended
by the value of the circumference of the rolls. The speed is thus increased
from station to station.
First Station:
The step-up is used from the first station.
Last Station:
The step-up is used from the last station.
Step up:
Shows the value for the step-up.
Max Bottom Roll Ø from PUK:

The value from the maximum bottom roll diameter in reference to the lower edge
of the profile can be entered here.
None:
If set, the value for the bottom roll Ø is taken from the edit box.
LEoP Welding Pass:

If set, the value for the bottom roll Ø is calculated in reference to the lower edge of
the profile in the welding pass.
Point of Gravity:
The value for the point of gravity in the profile.
LEoP by Input:
If set, the value for the bottom roll Ø is calculated in reference to the lower edge of
the profile from the input.
©
Round off:
To round the value LEoP.
Bottom Roll Ø:
If set, the root diameter for the bottom roll is taken from the parameter file.
Top Roll Ø from Parameter:

If set, the root diameter for the top roll is taken from the parameter file.
If some of these values are not known they should be entered for max. as a
very big value and for minimum as a very small value. In this way there will
be no problems with any limits in the dialogue boxes.
Idler Roll Ø:
Shows the calculated value for the root diameter, allocated to the input of the ver-
tical centres in the Axis dialogue box and the current profile width.
Vertical Centres:
Shows the entered value from the Axis dialogue box.
Max Side Roll Ø:

Shows the calculated, side roll Ø. Allocated to the input of the horizontal centres in
the Axis dialogue box and the current profile width.
Side Roll Ø from Parameter:

If set, the value from the side roll Ø is taken from the parameter file.
Round off:
The value for the diameter can be rounded here.
If some of these values are not known they should be entered for max. as a
very big value and for minimum as a very small value. In this way there will
be no problems with any limits in the dialogue boxes.
7.6. Minimum Roll Width

Here a minimum width for the rolls can be entered.
The Minimum Roll Widths dialogue box is split into station type selection, bottom
rolls, top rolls and idler rolls.
©
Bottom Rolls:
The value for the minimum width of the bottom rolls.
Top Rolls:
The value for the minimum width of the top rolls.
Idler Rolls:
The value for the minimum width of the idler rolls.
If these values are not known they should be entered with zero. In this way
there will be no problems with any limits in the dialogue boxes.
7.7. Diameter Defaults

Here the values for the outer roll diameter can be entered. The Diameter Defaults
dialogue box is split into station type selection, ØD1, ØD2 and further options.
user-defined, if the option is possible. Since the values always refer to the
the value was inserted manually it remain the same. The calculation method
gives the possibility of a highly efficient work with the Tubemill map. The set-
tings are made once and then can be used in a definite diameter area again
and again. A complete roll set can be created in a few seconds with the OK.
and rolls options.
Top/Bottom Rolls:
Ø D1:
Shows the calculation method and the value from D1.
Statement:
Shows the formula according to the method for the diameter calculation.
Ø D2:
Shows the calculation method and the value from D2.
©
Ø D3:
Shows the calculation method and the value from D3. Only in closed breakdown
passes (fin pass).
Depending on the pass type there are different calculation methods avail-
able.
Calculation Methods for Diameters from every Roll Type:
the value was inserted manually it will remain the same. The calculation
method makes working with the Tubemill map highly efficient. The settings
are made once and can then be used in a definite diameter area again and
rolls options.
If a plus (+) or a minus (-) follows a calculated or entered value it indicates

that the minimum or maximum limit is reached.
Breakdown Pass:
Input:
For the manual input of the diameter.
Cal.M1 for D1:

ØD1 = F(m), m = PW (previous pass), i. e. the D1 from the bottom roll is calcu-
lated in reference to the profile width from the previous pass in order to guarantee
for a problem-free inflow in the next station.
PW = Profile width
Cal.M2 for D1:

ØD1 = ØB + 2x (PH(PW) + Fd1), i. e. the D1 from the bottom roll is calculated
from the root diameter plus 2 x the profile width measured on the widest point of
the profile, plus factor Fd1, which defines the addition.
ØB = Basic diameter/PH = Profile height/PW = Profile width/Fd1 = Factor

from diameter D1
©
Factor Fd1:
The value for the factor Fd1 used in cal. Method M2 for the addition.
Fd1 = Factor from diameter D1
Cal.M1 for D2:

ØD2 = Dp - 2x dy, i. e. the D2 from the top roll is calculated with the value Dp
(measured from the centre of the top shaft to the highest profile end) minus 2x the
factor dy, which defines the distance between the profile end and D2.
Dp = Diameter profile (measured from the centre of the top shaft to the high-
est profile end)/dy = Factor for the distance between the profile end and D2.
Cal.M2 for D2:

ØD2 = minØ, i. e. the D2 from the top roll is set on the minimum value in reference
to the existing parameters.
Fd2(3):
The value for the factor dy is equal to Fd2(3).
Fin Pass:
Input:
Cal.M1 for D1:

ØD1 = ØB + 2x (Fd1 x PH(PW) ), i. e. the D1 from the bottom roll is calculated
from the root diameter plus 2 x the value from factor Fd1 x profile height meas-
ured on the widest point of the profile.
ØB = Basic diameter/PH = Profile height/PW = Profile width/Fd1 = minus fac-

tor from diameter D1
Factor Fd1:
The value from factor Fd1, used in cal. method M1 (negative distance from the
middle of the profile to the diameter D1).
Fd1 = Factor from diameter D1
©
Cal.M1 for D3:

ØD3 = Dp + 2x dy, iI. e. the D3 from the fin roll is calculated from the value Dp
(measured from the centre of the top shaft to the highest profile end) plus 2x the
factor dy, which defines the distance between the profile end and D3.
Dp = diameter profile measured from the centre of the top shaft to the high-
est profile end)/dy = factor for the distance between the profile end and di-
ameter D2.
Cal.M2 for D3:

ØD3 = Dpi(max) + 2x Fd2(3), i. e. the D3 of the fin roll is calculated from the value
Dpi (measured from the centre of the top shaft to the highest end of the inside of
the profile) plus 2x the factor Fd2(3), which defines the distance between the pro-
file end and D3.
Dp = Diameter Profile (measured from the centre of the top shaft to the high-
est end of the inside of the profile)/Fd2(3) = which defines the distance be-
tween the profile end and D3.
Factor Fd2(3):
The value from Fd2(3), which is used in the calculation method M2. Defines the
distance between the profile end and D3.
Fd2(3) = Factor from Diameter D3
Idler Pass (Side Rolls):
Input D1:
Cal.M1 for D1:

ØD1 = ØG + Fd1 x PW, i. e. the D1 of the side roll is calculated from the root di-
ameter plus factor Fd1 multiplied with the profile width.
ØG = root diameter/PW = Profile width/Fd1 = factor from diameter D1
Input D2:
At the idler pass type1 it can happen that there are 2 points on the roll which
define the inserted diameter. The reason for this is that the profile end angle
is <90°. The 2 diameters are <90° and >90°.
©
Cal.M1 for D2:

ØD2 = ØG + Fd2 x PW, i. e. the D2 of the side roll is calculated from the root di-
ameter plus factor Fd2 x profile width.
ØG = root diameter/PW = Profile width/Fd2 = factor from diameter D2.
Cal.M2 for D2:

ØD2 = ØD1, i. e. the D2 of the side roll is equal to the D1 from the side roll.
Cal.M3 for D2:

ØD2 = ØDp + 2x dx, i. e. the D2 of the side roll is calculated from the value Dp
(measured from the centre point of the idler shaft to the highest profile end) plus
2x the value dx.
Dp = diameter profile (measured from the centre point of the idler shaft to the
highest profile end)/dx = distance from the value Dp to diameter D2.
D2<=D1:
ØD2< = D1, i. e. the D2 of the side roll is smaller or equal to D1 of the side roll.
The Block End of Profile:
Ø Dp:
Shows the diameter of the profile, measured from the centre of the top shaft to the
highest profile end.
Radius:
Shows the calculated radius from the outer profile arc.
Direction:
Is the calculated angle from all profile arcs of one symmetrical axis.
Angle:
Shows the calculated angle of the outer profile arc.
Ø round Ø according to Diameter List:

If set, the value for the diameter is taken from the parameter file dialogue box.
The diameters get rounded according to the diameter list
©
?:
More detailed information about the parameters used in the calculation method.
Idler Rolls
For explanation, see the documentation of the top and bottom rolls.
7.8. Roll Distance and Gaps

The minimum distances between the rolls and between the rolls and the profile
can be entered here.
The Roll Distance and Gaps dialogue box is split into station type selection,
methods, gap and further options.
the value was inserted manually it remains the same. The calculation method
enables you to work with the Tubemill map highly efficiently. The settings are
made once and can then be used in a definite diameter area again and
rolls options.

Method:
Shows the calculation method used.
Gap:
Shows the calculated or entered value for the gap.
Input:
Cal.M1 for Gap:

S = 2x arc radius x sin(F), i. e. the gap is calculated with 2x the arc radius x the
sinus from the factor F. Only for use in idler rolls
F = factor
Cal.M2 for Gap:

S = F x profile width, i. e. the gap is calculated from the factor F x profile width.
©
Factor F:
The value for the factor F is entered here.
The Block Factors for S Rolls and Gap for T/B Rolls:
From Parameter:
If set, the appropriate values are taken from the parameter file.
All rounded off to:

Calculated and entered values in these boxes can be rounded off.
7.9. Width Defaults

Here the width for the rolls can be entered.
The Width Defaults dialogue box is split into station type selection, method and
further options.
user-defined, if this option is possible. Since the values always refer to the
enables you to work with the Tubemill map in a highly efficient way. The set-
tings are made once and can then be used in a definite diameter area again
and rolls options.

Width Top/Bottom Rolls:
Width W1:
Shows the value and used calculation method for the roll width W1.
Statement:
Shows the detailed formula to calculate the roll width W1.
Input:
The value for the roll width can be entered manually.
©
Cal.M1 for W1:

W1 = Rw2 + 2x Fw1, i. e. the width W1 is calculated from Rw2 (inside width of the
top roll) plus 2x the factor Fw1 (roll neck on the side).
W1 = outside width top roll/Fw1 = roll neck at the side/Rw2 = Inside width of
the top roll.
Cal.M2 for W1:

The value for the width W1 can be set equal with the value Rw1.
W1 = Outside width top roll/Rw1 = width of the bottom roll
Factor Fw1:
The value for factor Fw1 used in cal. method M1.
Width Idler Rolls:
PR:
Shows the value of the lower width from the side roll. Measured from the lower
edge of profile to the lower edge of the side roll.
Width W1:
Shows the method and the value for the width W1.
Statement:
PR:
The value for PR can be entered manually.
Symmetrical:
The value PR can set symmetrical, i. e. the width of the side roll is symmetrical on
top and bottom (measure to the profile).
Input:
The value for the roll width W1 can be entered manually.
Cal.M1 for W1:

W1 = Fw1 x TubeØ + PH, i. e. the width W1 is calculated from the factor Fw1 x
the tube Ø plus the profile height.
W1 = width of the side rolls (without the value PR) Fw1=factor from width W1
©
Factor Fw1:
The value for the factor Fw1 can be entered here.
Sizing like Welding:

A pre-requisite for using this option is to make sure that the constant point of
gravity in sizing stations from the Flower dialogue box is set. The value PR is
adapted to the rising lower edge of the profile. Another pre-requisite is that the
vertical axes are set on the same level.
Turk Heads like Welding:

A pre-requisite for using this option is that the constant point of gravity in sizing
stations from the Flower dialogue box must be set.
The value PR is adapted to the rising lower edge of the profile only in the Turk
heads. Another pre-requisite is that the vertical axes are set on the same level.
7.10. Parameter
The parameters for the roll design are entered here.
The Parameter dialogue box is split into station type selection, factors for calcula-
tion of roll widths and diameter and further options.
as many values as possible should, be taken from the parameter file if this
option is possible. One prerequisite for this is that the parameter file has al-
ready been completed with values that either come from customer know-
how or from some special literature. Since the values always refer to the di-
ameter, become at input of a new tube diameter all data for the rolls depend-
ing on the diameter taken from parameter file. In case the value was inserted
manually it remains the same. The parameters give the possibility of working
highly efficiently with the Tubemill map. The settings are made once and can
then be used in a defined diameter area again and again. A complete roll set
can be created in a few seconds with the OK. and rolls options.
Select Pass Type:

The right station type has to be selected before entering the parameters for the
roll design. In the info slide the current station type is always shown.
A pre-requisite for using this parameter input for the factors is that the calcu-
lation method must also be based on a factor.
©
The Block Factors for the Calculation of Roll Widths and Diameter:
Width Bottom:
The value for the factor to calculate the width of the bottom roll.
Width Top:
The value for the factor to calculate the width of the top roll.
Radius Bottom:
The value for the factor to calculate the diameter of the bottom roll.
Radius Top:
The value for the factor to calculate the diameter of the top roll.
Min. Gap:
The value for the minimum gap between top and bottom roll.
Factor Gap Width:

The factor for the gap width calculation of the side rolls.
Ø<=:
The list of the profile diameter.
Bottom Ø:
The parameter for the diameter calculation of the bottom roll.
Top Ø:
The parameter for the diameter calculation of the top roll.
Idler Ø:
The parameter for the diameter calculation of the side roll.
Chamfer Width:
The parameter for chamfer width on the roll end.
Fillet Radius 1:
The parameter for the fillet radius 1 on the roll.
Fillet Radius 2:
©
Fillet Radius 3:
Add:
This is used to add another line (copies an existing line).
Remove:
This is used to remove an existing line.
7.11. The Block round Driven Rolls
Round-off Driven Rolls:

The value for the roll width and diameter can be rounded here.
7.12. The Block round Idler Rolls
Round-off Idler Rolls:

The value for the roll width and diameter can be rounded here.
7.13. The Block min. Gap
Edit Box min. Gap:

The value for the minimum gap between roll and roll and roll and the end of the
profile can be entered here.
©
COPRA® Round & Rectangular Tubes Tubemill map Roll Design Set-up
8. Tubemill map Roll Design Set-up
The Tubemill map Roll Design Set-up dialogue box is split into type of station,
roll width, 4 axes station, relief angles and radii, chamfers and fillet radii, Ø list
blanks, parameter and further options.
and rolls options.

The Block Station Type Selection:
All:
If set, all existing stations will be shown in the list box.
Driven Rolls:
If set, only the existing driven stations will be shown in the list box.
Idler Rolls:
If set, only the existing idler stations will be shown in the list box.
The Block Station Selection:
All:
All passes can be selected. The Shift or Ctrl. key should be used to select and
modify more passes simultaneously.
Previous:
The previous pass selection can be returned.
Station:
Shows the stations in a row.
©
A slide is listed on the right side to get an overview about the selected station
type and its dimensioning scheme. Zoom in by Mouse click! By clicking onto
the slide with the right mouse button, it will be extended.
When inserting the values in the passes, the Station Type Selection should
not be set on All. The reason for this is that the dialogue box shows more in-
Tubemill map:
Shows the currently used Tubemill map.
Tube Diameter:
Shows the final tube diameter.
No. of Stations:
Shows the used number of stations.
8.1. Type of Station

The pass type for the roll design can be changed here. The flower stays the same,
only the roll type changes. The Type of Stations dialogue box is split into se-
quence, profile width, height, gap and further options.
Sequence:
Shows the selected sequence of stations.
Profile Width/Height/Gap:
Shows the current data of the profile, calculated from the flower.
Modify Type of Station for Roll Design:

The pass type can be specifically changed for the roll design here. The sequence
of stations and the flower remain the same, only the pass type for the roll design
changes. In the slide it is shown which pass type is selected for the roll design.
Type of Station like Profile:

The pass type is set back automatically to the previous setting from the flower and
layout.
©
8.2. Roll Widths

The value for the roll widths can be entered here.
Roll Widths:
The Roll Widths dialogue box is split into station type selection, method and fur-
ther options.
and rolls options.

8.2.1. Roll Width Top/Bottom Roll
Roll width Top/Bottom Roll:

The Roll Width dialogue box is split into the areas station type selection, method
Bottom width Rw1:

Shows the value to calculate the roll width Rw1.
Statement:
Top width Rw2:

Shows the value and the calculation method to calculate the roll width Rw2.
Input:
Cal.M1 for Rw1:

Rw1 = Fw1 x TubeØ + PW, i. e. the width Rw1 is calculated from factor Fw1 x the
tube diameter plus the profile width.
Rw1 = outside width bottom roll/Fw1 = factor from roll width 1/PW = profile
width
©
Factor Fw1:
The value for factor Fw1.
All from Parameter:

If set, all factors for the calculation of the roll widths is taken from the parameter
file.
Cal.M1 for Rw2 ( W1 from Dialogue Box width Defaults):

Rw2 = Fw2 x TubeØ + PW, i. e. the width Rw2 (W1) is calculated from factor Fw2
x the tube diameter plus the profile width (PW).
Rw2 = Inside width top roll/Fw2 = factor from roll width 2/PW = profile width
Cal.M2 for Rw2:

The value for width Rw2 (W1) can be set equal with the value Rw1.
Factor Fw2:
All from Parameter:

If set, all roll widths are taken from the parameter file.
8.2.2. Roll Width Side Rolls
Roll Width:
The dialogue box roll width is split into the areas station type selection, method
To be able to use the settings of a Tubemill map for further tube diameters
user defined, if this option is possible. Since the values always refer to the
enables you to work highly efficiently with the Tubemill map. The settings are
made just once and can then be used in a definite diameter area again and
rolls options.

©
Width Rw3:
Shows the value and the calculation method for width Rw3 of the side roll.
Width W1:
Shows the value and the calculation method for width W1 of the side roll.
Statement:
Shows the detailed formula to calculate the roll width Rw3.
Input:
Cal.M1 for Rw3:

Rw3 = Fw3 x TubeØ + PH + PR, i. e. the width Rw3 is calculated form the factor
Fw3 x the TubeØ plus profile height and the value PR (measured from the lower
edge of the roll to the lower edge of the profile).
Rw3 = width side roll/Fw3 = factor from width Rw3/PR = lower width of the
roll (measured from the lower edge of the roll to the lower edge of the pro-
file)/PH = profile height
Factor Fw3:
All from Parameter:

If set, all roll widths are taken from the parameter file.
8.3. 4 Axes Station

This dialogue box is only used for 4 Axes Stations, e.g. Turk heads. The angles
between the rolls are entered here.
4 Axes Station: Angle between Rolls:

The 4 axes Station dialogue box is split into the areas station type selection, an-
gle and further options.
ß1 :
The angle between the bottom shaft and the start of the bottom roll.
ß1a :
The angle between the bottom shaft and the side of the bottom roll, where the gap
is placed.
©
ß2 :
The angle between the top shaft and the start of the top roll.
ß2a :
The angle between the top shaft and the side of the top roll (where the gap is
placed).
ß2 = ß1, ß2a = ß1a:

Gives the option to set the value of the angles ß and ßa equal.
All Angles 45°:

Gives the option to set all angles on 45°. Used for the design of symmetrical rolls.
( ß1_I_ ß1a ), ( ß2_I_ ß2a ):

Gives the option of setting only the 2 angles on ß. The ßa angles are automatically
set on equal.
8.4. Relief Angles and Radii

The relief angles and the radii for the rolls are entered here.
Relief Angles and Radii:

The Relief Angles and Radii dialogue box is split into the areas station type se-
lection, relief angle, radius and further options.
user defined, if this option is possible. Since the values always refer to the
the value was inserted manually it remain the same. The calculation method
enables you to work highly efficiently with the Tubemill map. The settings are
made just once and can then be used in a definite diameter area again and
rolls options.
Relief Radius/Angle:
Shows the selected method, relief radius or relief angle, and whether the value
was calculated or entered manually.
Statement:
Shows the detailed formula to calculate the relief angle or radius.
©
Angle ß:
The value for the relief angle is entered manually. The value is the angle between
the bottom shaft and the inside edge of the roll.
Radius R+ = Arcradius x (/):

The arc radius can be increased by entering a factor. If the factor is 1 there is no
relief radius.
Radius R+ = next Radius x (/):

The arc radius from the next arc can be increased by entering a factor. If the fac-
tor is 1 there is no relief radius.
Radius R+ = Arcradius with Angle ß:

The arc radius can be increased by entering a factor and also a start angle. The
angle defines from which point the relief radius starts.
None:
This must be set if no relief angle or radius is used.
If no relief radius and angle is used, None must be set. Problems in the cal-
culation may occur if the value 0 is used in an edit box.
End Angle of Profile:

Shows the end angle of the profile.
All from Parameter:

If set, all parameters for the calculation of the relief angle or relief radius are used
from the parameter file.
All rounded off to:

The radius can be rounded to get a straight value for the roll design.
8.5. Chamfers and Fillet Radii

The chamfers and the fillet radii for the rolls are entered here.
Chamfer and Radii:

The Chamfer and Radii dialogue box is split into the areas station type selection,
radius, chamfer and further options.
©
The Block Roll Face:
Radius:
If set, a radius is created at the roll end.
Chamfer:
If set, a chamfer is created at the roll end.
Width = Radius:
If set, the radius is centred on the corner. If the toggle is not set, the reference
point of the radius can be defined by entering a width value.
Angle = 45°:
All angles are defined with the value 45°.
The Block Flange of Roll:
Fillet Radius Rf:

The value for the fillet radius between the top roll and the roll flange.
Station:
Shows the selected stations.
When entering the values in the passes, the station type selection should
not be set on All. If so, the dialogue box will show more information and also
a diagram with the scheme of the pass type is shown.
Radius 1:
Bottom roll - radius on the inside of the roll end.
Radius 2:
Bottom roll - inside radius if the roll is split.
To design a bottom roll that is not split, the radius 2 must be set on 0.
Radius 3:
Top roll - inside radius of the top roll.
Radius a:
Bottom roll - radius at the roll end.
©
Wa: Width a:
Bottom roll - width for the radius at the end of the roll.
Radius b :
Top roll - radius at the end of the roll.
Width b:
Top roll - width for the radius at end of the roll end.
If Chamfer at the Roll End is set:
Chamfer a:
Bottom roll - chamfer width at the roll end.
Angle a:
Bottom roll - angle for the chamfer at the roll end.
Wb chamfer b:
Top roll - chamfer width at the roll end.
Angle b:
Top roll - angle for the chamfer at the roll end.
8.5.1. From Parameter

If set, all values for the chamfer and radii of the rolls are taken from the parameter
file.
8.6. Ø List Blanks

A list of roll diameters can be entered here. These diameters will then be used for
the roll design.
Ø List Roller Blanks :

The Ø List Roller Blanks dialogue box is split into the areas list, new and further
options.
List:
Shows the existing list of the roll blanks.
©
New:
This edit box is designed for adding a new blank diameter. The new value is
automatically set on the right position.
Delete:
Used to Delete the highlighted diameter.
8.6.1. RDL
The list with the roll blanks can be called here. Several lists can be created, e. g.
with tolerances depending on the constitution of the roll blanks. These files are
®
automatically saved by COPRA in the installation directory under the SET folder.
8.7. Parameter
The parameters for the roll design are entered here. The Parameter dialogue box
is split into the areas station type selection, factors for calculation of roll widths
and diameter and further options.
as many values as possible should be taken from the parameter file if this
option is possible. A prerequisite for this is that the parameter file is already
complete with values stemming either from customer know-how or from spe-
cial literature. Since the values always refer to the diameter, all data for the
rolls – with reference to their diameters - are taken from parameter file
whenever a new tube diameter is entered. In case the value was entered
manually it remains the same. The parameters make working with the Tube-
mill map highly efficient. The settings are made just once and can then be
used in a defined diameter area again and again. A complete roll set can be
created within a few seconds with the OK. and rolls options.
Select Pass Typ:

The correct station type has to be selected before entering the parameters for the
roll design. In the information slide the actual station type is always shown.
A prerequisite for using the parameter input for the factors is that the calcu-
lation method must also be based on a factor.
The Block Factors for the Calculation of Roll Widths and Diameter:
Width Bottom:
The value for the factor to calculate the width of the bottom roll.
©
Width Top:
The value for the factor to calculate the width of the top roll.
Radius Bottom:
The value for the factor to calculate the diameter of the bottom roll.
Radius Top:
The value for the factor to calculate the diameter of the top roll.
Min. Gap:
The value for the minimum gap between top and bottom roll.
Factor Gap Width:

The factor for the gap width calculation of the side rolls.
Ø<=:
The list of the profile diameter.
Bottom – Ø:
The parameter for the diameter calculation of the bottom roll.
Top – Ø:
The parameter for the diameter calculation of the top roll.
Idler – Ø:
The parameter for the diameter calculation of the side roll.
Chamfer Width:
The parameter for chamfer width on the roll end.
Fillet Radius 1:
Fillet Radius 2:
Fillet Radius 3:
Add:
This is used to add another line (copies an existing line).
©
Remove:
This is used to remove an existing line. The parameters for the roll design are en-
tered here.
8.8. Machine and Roll Data

Shows all dialogue boxes in an overview. This is a combination of all available
dialogue boxes used in the current station.
More detailed information can be found in Tubemill map data and Tubemill map
rolldesign set-up.
8.9. Max. Wall Thickness

The maximum wall thickness for the roll design is entered here.
8.10. Replace Data

Here it is possible to define which passes from the flower shall be calculated
again. The Replace Data dialogue box shows the existing database of the tube
flower.
Station:
Pass:
Created With:
Shows with which module the pass was created, e.g. spring back or downhill form-
ing.
Select:
Select all stations. Single stations can be selected by using Ctrl and the left mouse
button.
Deselect:
Deselect all selected stations.
©
Rolls Data General:
O.K.:
If the dialogue box is closed with this option all data are saved.
O.K. and Rolls:

If the dialogue box is closed with this option all data are saved. The rolls are calcu-
lated automatically for every station. The flower will be not changed.
And Project Slide:

If set, a slide will be created from the last station. The slide is shown in the project
manager.
Show each Station:

If set, every station is shown on the screen during the calculation process.
©
COPRA® Round & Rectangular Tubes Parametric Roll
9. Parametric Roll
The Modify Rolls Interactively dialogue box is split into all dialogue boxes from
machine and rolls setting depending on the current station.
To be able to use the settings of a Tubemill map for other tube diameters, as
many values as possible be set should on calculation and not on input or
make a highly efficient work with the Tubemill map possible. The settings are
made just once and can then be used in a defined diameter area again and
again. A complete roll set can be created within a few seconds with the OK.
and rolls options.
Current:
Shows the current station type.
Create Rolls like:

Shows with which station type the rolls are created.
A slide is shown on the right side to get an overview about the selected sta-
tion type and its dimensioning scheme. Zoom in by Mouse click! By clicking
on the slide with the right mouse button you can extend it.
9.1. Machine Data

All possible settings for the machine set-up are combined here.
A detailed documentation can be found in the paragraph Tubemill map

data.
9.2. Roll Data

All possible settings for the roll design are combined here.
Detailed information can be found in the paragraph Tubemill map

rolldesign set-up.
©
COPRA® Round & Rectangular Tubes Special Solutions in the COPRA® Tubemill map
10. Special Solutions in the COPRA® Tubemill map
10.1. Symmetrical Turk heads

How to design symmetrical Turk head rolls:
1. The value PR in the idler rolls must be set on symmetrical.
2. The option angles 45° in the 4 Axes dialogue box must be set.
3. The roll width RW1 and RW3 must be calculated with the method M1 and the
same factor, e.g. 0,2.
10.2. 4 Axis Sizing Pass

How to get a 4 Axis pass type in the sizing stations:
1. Finish the flower design.
2. Go to Machine or Rolls interactive to type of station.
3. Change the type of station to Turk head round tube and leave the dialogue
box with OK.
Only in the flower is it important to choose the right pass type according to
the additions. During the roll design nothing is changed in the flower design.
You can select almost every pass type for the roll design. All additions such
as the sizing addition are already allocated in the flower.
10.3. Split Bottom Rolls

How to split top and bottom rolls:
1. One possibility is to set Split all Top/Bottom Rolls in the Tubemill map lay-
out dialogue box. All rolls are split if possible.
2. Another possibility is to split single rolls. Set radius 2 in Rolls Interac-
tive/Fillet Radii on any value. If radius 2 is set on zero the rolls are not split.
10.4. Define welding point new

With the function CAD the welding point of a closed profile can be re-defined. This
works in the following way:
After selecting the icon CAD a dialogue box with different options appears. With
the option first element new the first element in the profile can be defined anew.
COPRA® works from the left to the right side. The first element is the element,
which lies at the welding point or at the opening point of the profile. If the profile is
not split the user is asked at which point he wishes to split it. By clicking on the
corresponding element the new first element is defined.
©
10.5. Which Station Types can be used when?

1. Idler pass type 3 is not for use in arcs over 90°. The angle of the profile end is
then negative.
2. Break down type 2 should be not used for arcs over 90°. In this case there is
no safety gap possible.
10.6. Placing the Dependencies for the Forming
Example:
Fold in 1. Break-down depending on the welding radius
1. In the Flower/Forming Steps/Calculation, Calculation Method dialogue
box the dependencies can be set or changed. E.g. from welding radius with
factor 1.
2. The dependencies can be set for any station with any value for the factor.
10.7. How to form a Rectangular Tube?

1. Select a tube mill in the Tubemill map selection.
2. Define the tube mill map layout. It is important that the number of forming
steps from round to shape is included in the layout. The last station must be a
rectangular type.
3. Start the function rectangular tube and enter the values for the rectangular.
4. Select the special shape method.
5. Define the number of the shaping steps.
6. Enter compression factor 10-20% and define the tube Ø (Welding diameter)
Start forming with OK.
7. How to import the database to the Tubemill map: In the Tubemill map selec-
tion under import/export Tubemill map. Start import flower from database.
8. No Ovalism in the flower settings. Everything on Calculation.
9. In the list of additions: distribute the sizing addition uniformly.
10. In forming steps in the Flower radius 1 or 3: dialogue box select calculation
from strip width.
11. Replace data in the Flower dialogue box. Select All. Re-calculate with the
Flower option.
©
10.8. Create Flower new

The flower has to be calculated anew if values change which are in reference to
additions, radii, angle or arc length. Depending on whether rolls already exist or
not the rolls also have to be calculated anew.
10.9. How to design oval Side Rolls in the Forming?

A profile is formed as a high oval before welding:
1. Select a fin pass type 1 or 2 in Tubemill map layout where the idler pass
high oval should be.
2. Select the desired Ovalism for this pass in the Flower/Forming
Steps/Ovalism.
3. Re-calculate the Flower.
4. In Rolls Interactive in station type, enter an idler pass type 1 in exchange for
the fin pass.
10.10. Which Profiles can be designed in the Tubemill map?

All closed profiles which are symmetrical or double symmetrical. One symmetrical
side cannot have more than 4 elements. It does not matter if these elements are
straight or arc entities, e.g. high oval, flat oval or any other kind of shaped tube. In
this context we recommend a COPRA® professional training.
10.11. How to set the Gap between the Turk head rolls on zero?
To set the gap on zero the value for the gap in the Tubemill map data dialogue
box has to be set on zero under minimum gap. This change should be made after
all stations have been designed.
10.12. How to append a Pass ( Straightener )?

In the COPRA® database with the append pass or insert pass options, every
kind of station can be copied and appended. It can also be selected if only the
profile or also the rolls are to be copied.
10.13. How to increase the Forming Radius on the Breakdown Rolls?

To increase the radius the wall thickness in the Rolls Interactive dialogue box
must be increased for just this one station. If the COPRA® module Husk H1 is
also authorised, the rolls can be modified in any way. When re-calculating the
rolls, all modifications made with the Husk H1 are lost.
©
10.14. How to set the Diameters D1 and D2 in the Fin Pass equal?
1. Determine the difference between the 2Ø and split the value.
2. Use the value in the Rolls Interactive dialogue box under Root Diameter.
3. Set bottom roll diameter on Fix.
4. Calculate the total from the vertical centres and the difference value and enter
the result in the vertical centres.
5. OK and back to the dialogue box to check if diameters D1 and D2 are equal.
If D1 is too big, the difference value has to be added to the vertical centres. If
D1 is too small, the difference value has to be subtracted from the vertical
centre.
10.15. Why is there a Gap in the flower when the Roll is closed?
It can happen that no fin roll is used before welding, but a closed roll is used, al-
though the profile still has a gap. In this case, follow the steps described below:
1. For the flower design use a fin pass.
2. Enter all values for the flower in the forming steps.
3. Calculate flower and rolls after entering all values.
4. Select a sizing pass in rolls interactive/type of station. Click OK.
10.16. How to get 4 Axes in Sizing Pass?

1. Create flower with all necessary additions.
2. Calculate flower and rolls after entering all values.
3. Select a Turk head round tube in rolls interactive/type of station. Click OK.
10.17. How to set or change the Gap Width?

In case there are any problems with setting the gap width or with the width of the
rolls in rolls interactive, please check the settings in the Tubemill map data in
the machine data dialogue box.
10.18. Structure of the Tubemill map
Problem Definition:
A new profile should be manufactured on an existing Tubemill.
Each Profile should be assigned to one machine!
It has to be distinguished between two different subjects:

• the designed data in the Project Manager
• the main design data in the Tubemill map Selection
©
10.18.1. Project Manager
The Structure of the Project Manager:

is similar to the structure of Windows Explorer. The only difference is that it is
possible to sort the project according to the project name, time and project group.
Creating a new Project in the Project Manager:

It is important to build a clear and clean structure. The structure can look like the
following example in the Windows Explorer:
1) COPRA® Projects
a) Round tube
b) Ø60x2.0
and so on.
10.18.2. Tubemill map Selection
1. Select the suitable tube mill from the COPRA® Tubemill map selection:
2. Next copy the selected Tubemill and rename it.
You should always create a new definition for every new profile to avoid
overwriting the existing machine and profile settings. Therefore it is im-
portant to select an appropriate Tubemill and assign it to the new profile
by copying and renaming it.
To avoid loss of your design you should make several safety copies of the data,
which you can use again later if necessary. To update your safety copy you
should overwrite them after every modification.
Below is a further explanation of the file structure of the Tubemill data:
There are two different SET directories in COPRA®. One for the setting data of all
existing Tubemills and one for project specific setting data.
The Set register with all existing Tubemills can be found in the main project direc-
®
tory, for example under the directory "COPRA Projects" in the subdirectory
"Tube".
©
In this directory the data files of all created Tubemills are saved. Each Tubemill
consists of 6 data files:
®
• COPRA Ø60x2.0.ARA
• COPRA® Ø60x2.0.ARF
®
• COPRA Ø60x2.0.ARM
• COPRA® Ø60x2.0.ARP
• COPRA® Ø60x2.0.ARR
®
• COPRA Ø60x2.0.PAR
The project specific SET directory exists in the project directory as a subdirectory,
in this example under the directory Ø70x1.8. In this directory only the data of the
currently used, in the project manager selected Tubemill are saved.
If another Tubemill should be used for this particular project, it must be selected in
the Tubemill map. The data of the originally used Mill will be overwritten in the
SET subdirectory under the project directory.
Nevertheless the Tubemill data are still existing in the project directory.
Due to this reason it becomes clear once again how important it is to first
copy and not overwrite a Tubemill if you intend are going to work with an ex-
isting one.
10.19. Which Role does the Writing of an Archive File have?

Another possibility of saving your database, i.e. flower and roll data, you can write
an archive file. If the Tubemill has been erased or destroyed by mistake, you can
at least read the archive file and for example create the roll drawings or NC data.
©
COPRA® Shaped Tubes and Draw-rings The Special Shapes/Draw-rings toolbar
COPRA® Shaped Tubes and Draw-rings
1. The Special Shapes/Draw-rings toolbar
The Special Shapes/Draw-rings toolbar contains a variety of functions for editing

special shapes and draw-rings. They will be described in detail below:
• CAD Profile
• Plane of Unfolding
• Execute Transformation
• Optimise one Pass
• Create 3D Draw-rings
1.1. CAD Profile
Function:
®
Convert a section designed with CAD functions for use with COPRA
After having selected this function, you will be prompted to select the created poly-
line. After selection, the CAD Profile dialogue box is opened:
Material Thickness :
Enter the desired sheet thickness for the section.
Polyline is:
Sets, which contour defines the polyline: centre line or contour line.
Centre of Gravity in 0.0:

Positions the created section to the root co-ordinates.
After having confirmed with OK, you are prompted to define the side, at which
sheet thickness is to be created. Sheet thickness is created according to your set-
tings. If the profile contour is not constant, a dialogue box appears issuing an error
message. You will be asked whether you want to continue. If you confirm with
Yes, COPRA® creates a constant contour. Depending on its deviation, this con-
tour will not exactly equal the predefined polyline. If you select No or if you cancel
the procedure, extrusion will not take place.
©
1.1.1. Redefine welding point

The CAD function allows redefining the welding point for a closed section.
After selecting the CAD icon, a dialogue box appears containing the following fea-
tures: erase database, continue, new first entity, or cancel. The option new fist
entity defines the first section entity. COPRA® works from left to right. The first
entity is the entity positioned at the welding point or at the opening point of the
section. If it is yet not split, the system asks you whether or not it should be split.
After separation, the new first entity is defined by clicking the respective entity.
1.2. Unfolding Plane
Function:
Definition of unfolding plane
Before forming can take place, the plane of unfolding has to be defined. After se-
lecting the Plane of Unfolding function, the defining the point of unfolding dia-
logue box appears:
Entity Centre:
Select the respective entity with the crosshairs. The point of unfolding is in the
centre of the selected entity.
Before Entity:
Pick the respective entity with the crosshairs. The point of unfolding is at the point
of separation in front of the selected entity. COPRA® works from left to right.
After Entity:
Pick the respective entity with the crosshairs. The point of unfolding is at the point
of separation after the selected entity. COPRA® works from left to right.
Point picked by Cursor:

Pick the respective entity with the crosshairs. The point of unfolding is at the de-
fined point. The point proposed by the system is marked with a cross and is ex-
actly in the middle of strip width.
®
COPRA Proposal:
COPRA® proposes to select the point of unfolding on a long straight. The respec-
tive leg is directed upwards.
©
Rotate Profile:
After having defined the point of unfolding, the section can be subsequently ro-
tated by a defined angle. Reference point is the defined point of unfolding. If no
point of unfolding is defined, the middle of the strip width is assumed to be the
reference point.
Mirror Profil:
After having defined the point of unfolding, the section can be subsequently mir-
rored at the selected point. If no point of unfolding is defined, the middle of the
strip width is assumed to be the reference point.
Rotate Profile automatically:

If this function is set and an entity that is not positioned in the horizontal plane is
selected, the section is rotated in a way that the entity is aligned horizontally.
After selection, the point of unfolding is displayed and the following question
appears: Plane of unfolding correct?
Yes:
If you confirm with Yes, the procedure is cancelled, and the plane of unfolding will
be defined.
No:
If you select No, the system will ask you whether the pass is to be recreated. If
you confirm with Yes, a dialogue box appears allowing you to define the plane of
unfolding.
Cancel:
If the procedure is cancelled, no plane of unfolding will be defined.
1.3. Execute Transformation
Function:
Calculates the forming steps
If selected, the Selection of Forming Method dialogue box appears. Two forming
methods are provided, which can be started by clicking the slide. By forming we
understand automatic forming of an original profile (e.g. a tube) to a final profile.
©
1.3.1. Angle Modification

The Angle Modification Method is a linear proportional projection of the final profile
to the target profile. If the target profile is a tube, it will be created automatically.
When using the Angle Modification Method for forming, undesired undercuts
may occur, which can cause problems, especially with the use of drawing
rings.
Undercuts can be partially avoided by using a certain distribution of com-

pression. After forming, these undercuts can possibly be eliminated with the
help of the “Push Profile”, “Turn Profile” and “Change Profile” functions.
After having selected Angle Modification, the Parameter of Shaping Steps
dialogue box is opened.
Numbering according to COPRA® passes is based on the final profile.

The final profile is pass no. 1. Consequently, the final profile is the
source for forming and the original profile (e.g. tube) is the target pro-
file.
1.3.1.1. The Block Shaping Steps

Here, the pass sequence for forming is defined. The new pass sequence is dis-
played in the status line of the dialogue box.
In the Shaped Tube Module, the pass sequence is equal to the station se-
quence, in the Drawing Ring Module it corresponds to section levels through
the drawing ring.
No. of Passes:
Information on the number of profiles currently saved in the database.
Number of Shaping Steps:

Entry of pass number between the source profile (final profile) and the target pro-
file (original profile, e.g. tube).
Pass Number of final Profile:

If only one profile is saved in the database, the source profile is pass no. 1. A tube
is automatically created as target profile (number 2). If several profiles are saved
in the database and the pass number equals the number of passes, the pass
number of the target profile equals the current number of passes +1. A tube is
automatically created as target profile. If several profiles are saved in the data-
base, and the pass number of the source profile is less than the current number of
passes, the existing passes between the pass number of the source profile, and
the pass number of the target profile will be deleted. This will create forming be-
tween the source profiles and the existing target profile. A tube is not created as
target profile.
©
Pass Number of target Profile:

If only one profile is saved in the database, the target profile is pass no. 2. A tube
is automatically created as target profile. If several profiles are saved in the data-
base and the pass number of the target profile equals the number of passes, the
pass number of the target profile automatically equals the number of passes +1. A
tube is automatically created as target profile. If several profiles are saved in the
database, and the pass number of the source profile is less than the current num-
ber of passes, the existing passes between the pass number of the source profile,
and the pass number of the target profile will be deleted. This will create forming
between the source profiles and the existing target profile. A tube is not created as
target profile.
1.3.1.2. Distribution
In case of uniform forming, the arc angles of the shaping steps are exactly within
the angles of the respective entities in the two adjacent passes. Distribution of an-
gle modification can be set in percent.
Distribution of Change of Angle:

The percent distribution of the entire angle modification is listed. Pass assignment
is shown in the status line of the dialogue box. The sum is always 100%.
Factor:
The percent portion of the entire angle modification can be set. As the sum must
always be 100%, the subsequent portion will be adjusted accordingly.
Uniform:
If this toggle is set, the percent portion is equal for all passes and the edit box fac-
tor is blocked.
1.3.1.3. Optimisation Settings

Several methods are available to optimise (close open profile) a profile.
Iteration Condition:
The optimisation methods are numeric iteration methods.
Acceptable Gap Width:

Normally, a gap cannot be closed completely within an acceptable period of time.
The acceptable gap width indicates the acceptable size of the gap after optimisa-
tion.
©
Angle Adjustment:
The angle to be optimised is searched in small angle steps. The higher the value,
the quicker the search, and the higher the probability of errors. Consequently, it is
sometimes impossible to find a result (< acceptable gap width).
We recommend to use the smallest angle that is possible (error tolerance).
Max. Time to Optimize one Pass:

If angle adjustment is very small, optimisation of a profile can be very time-
consuming. After the set maximum optimisation time for a certain profile is ex-
pired, the program cancels optimisation and continues with the next shaping step.
ESC cancels optimisation of all shaping steps.
Percent Range:
The optimised angle of an arc entity is between the angle of the respective arc
entity in the preceding station and the angle of the respective arc entity of the sub-
sequent station. This range is called the 100% range. The angle, which was not
optimised, is exactly in the centre of that range and limited by the angles of the
two adjacent stations. Normally, the optimised angle is within the mean third of
that range.
If a single profile (Close Profile function) is optimised, the 50% and 100%
ranges are not possible.
During forming according to the Angle Modification method, the adjacent
passes of a profile are known. In order to optimise a single profile, the Close
Profile function is used independently of the adjacent passes (the adjacent
passes might have been changed by the user so that any assignment would
be impossible).
50%:
If the 100% range is restricted by 25% to both sides, the centre of the resulting
range is exactly the angle that was not optimised. This is called the 50% range.
100%:
During optimisation an angle is searched in the 100% range.
Angle Range:
The angle range for optimisation can be set absolutely. This method is used for
optimising any pass (Close Profile), independently of the shape of the adjacent
passes.
©
The Block Optimisation Methods:

The optimisation methods available are numeric iteration methods.
No Optimisation:
During forming, the shaping steps will not be optimised (profile is not closed).
Power Fit:
A result is searched for all entities with the help of Angle Modification. Only one
entity serves for the purpose of compensation. The results will be saved and com-
pared. The best result will be taken over.
Best Fit:
A result is searched entity by entity with the help of Angle Modification. Only one
entity serves for the purpose of compensation. As soon as a result is found, it will
be taken over and optimisation is ceased, even if a better result could be pro-
duced by a subsequent entity.
Angle Fit:
A result is searched for all entities with the help of Angle Modification. The com-
pensation is distributed to all other entities. The results will be saved and com-
pared and the best result will be taken over.
Optimise symmetrically:
During optimisation of a symmetrical shaping step, symmetry will normally get lost.
If the Optimise symmetrically option is set, only one symmetrical side of the shap-
ing step will be optimised. The result is applied to the second side.
Symmetrical means that the number of entities, sequence, lengths,

angle and radii at the left and at the right of the point of unfolding are
equal.
Listbox:
List of entities of the current profile. Entities selected in the list will not be changed
during optimisation.
Angle and radii change due to forming.
©
1.3.1.4. Compression
When forming a tube to a final profile, the length of the centre line will be short-
ened due to compression. The shortening factor can be set by a compression fac-
tor given in percent. The compression factor defines the percentage by which the
lengths are shortened. The entire shortening is distributed to the individual shap-
ing steps.
Compression takes place from the original profile (target profile) to the final
profile (source profile). As the target profile is normally not known, the final
profile is used as a reference and compression is calculated.
Reference in Profile:
The set compression can be based on the outer contour of the profile, the centre
line or the neutral line.
When using the Shaped Tube Module, the neutral line should be used as a
reference.
The Drawing Ring Module always uses the outer contour of the profile as
reference line.
Ø of round Tube:
Depending on the selected reference line there is a connection between the Ø of
the original profile and the compression factor.
Compression Factor:
The compression factor can be set in percent of the selected reference line. The
resulting compression factor in millimetres and the Ø of the original profile are
calculated.
Compression total (mm):

The compression factor can be set as an absolute value in millimetres. The result-
ing compression factor as a percentage of the selected reference line as well as
the Ø of the original profile are calculated.
1.3.1.5. Compression settings

The individual compressions between two shaping steps can be set in a percent-
age of the total amount of compression. The total percentage of distribution of to-
tal compression is listed. Pass assignment is shown in the status line of the dia-
logue box. The sum is always 100%. The percentage of total compression can be
set. As the sum must always be 100%, the subsequent value is adjusted accord-
ingly.
If Regular is set, the percentage is equal for all passes and the Edit box factor is
blocked.
©
1.3.1.6. Distribution in Profile

Total compression can be distributed to the profile. An uneven distribution by the
user may give rise to a deviation between the set total compression factor and the
compression factor resulting from distribution. In this case, the total compression
factor or the difference in the list has to be balanced.
Total:
The compression factor can be set as a percentage of the selected reference line.
The resulting compression factor in millimetres is calculated.
The value set here is a reference value for % old.
Total % new:
The compression factor in millimetres possibly resulting by distribution, is dis-
played.
Total mm:
The compression factor can be set as an absolute value in millimetres. The result-
ing compression factor is calculated in percent of the selected reference line. The
value set here is a reference value for % old.
Uniform:
If this toggle is set, total compression is evenly distributed to the profile.
Adjust Compression:
Distribution adjustment by the user may give rise to a deviation between the newly
calculated compression factor and the last set total compression factor. The total
compression factor is adjusted to the new distribution.
Percents to Total %:
Compression of the individual entities is displayed in %. With even distribution,
compression of the individual entities equals total compression in %. The sum
must not necessarily be 100%.
Percents to Total (mm):

Total compression in millimetres is distributed to the individual entities. The sum
referring to the current total compression is 100%.
Percents Distribution:
The standard compression of the individual entities in % is 100%. With even dis-
tribution, compression of the individual entities is 100/number of entities.
Distribute Difference:
Distribution adjustment by the user can give rise to a deviation between the newly
calculated compression factor and the last set total compression factor. The
deviation gives rise to a difference in compression. The difference can be
distributed to the entities selected in the list.
©
Reference:
Reference for set compression can be the outer contour of the profile, the centre
line or the neutral line.
Listbox:
List of entities in the current profile.
1.3.2. Theoretical Basic Knowledge

When forming a tube to a final profile, the entities of the final profile are projected
linearly to the respective entities of the tube. The shaping steps are approximate
sections through a wire model given by the entity points of the tube and the final
®
profile. COPRA profile sections consist of lines and arc entities. However, the
sections of the wire model (given by the tube and the final profile) are different.
These are sections, which consist of curves depending on the final profile geome-
try. The general curves of the shaping steps are approximated by lines and arcs of
a COPRA® profile section.
1.3.3. Entities of shaping Steps

The length of the reference line (contour line, centre line, neutral line) of the tube
equals the length of the reference line of the final profile (if no compression factor
was selected). The diameter of the tube is given by its reference line.
The number of profile entities of the tube and of the shaping steps and their
lengths correspond to the final profile. A line entity with a given length of 100mm is
projected to an arc entity of the tube with a given length of 100mm (if compression
is 0%). The angles of the arc entities of the tubes depend on the lengths of the
profile entities and the diameter of the tubes. With uniform forming, the angle of
an arc entity in a shaping step is exactly between the two angles of the respective
profile entities in the two adjacent stations.
Fig. 7 Angle of one shaping step
90°
L = 2 ∗ 63.66 ∗ Π ∗ = 100mm
360°
180°
L = 2 ∗ 31.83 ∗ Π ∗ = 100mm
360°
©
Example: one shaping step
Final Shaping step 1 Tube

profile
Straight 50° 100°
line
90° 80° 70°
Example: two shaping steps
Final Shaping step 1 Shaping step 2 Tube

profile
Straight 33.3° 66.6° 100°
line
90° 83.3° 76.6° 70°
Example: three shaping steps
Final Shaping step 1 Shaping step 2 Shaping step 3 Tube

profile
Straight 25° 50° 75° 100°
line
90° 85° 80° 75° 70°
The radii of the arc entities in the shaping steps can be calculated from the length
and angles.
1.3.4. Compression Factor

During forming of a tube to a final profile, the length of the centre line is shortened
due to compression. The degree of shortening can be set by a compression factor
in percent. The compression factor defines the total shortening of the length from
the tube to the final profile. The total shortening is distributed to the individual
shaping steps.
Example length of the centre line with a compression factor of 10%:
Tube Shaping step 3 Shaping step 2 Shaping step 1 Final

profile
200mm 195mm 190mm 185mm 180mm
The arc angles in the shaping steps remain constant and the radii will be recalcu-
lated due to the shortened lengths.
©
Optimisation:
The shaping steps of axially and point symmetrical final profiles will be closed
automatically by the angle bisection method. With asymmetrical profiles, on the
contrary, there is a gap and an offset between the first and last profile entities. For
closing this gap there are several optimisation methods, whereby suitability, preci-
sion and speed depend on the final profile and the number of shaping steps.
Acceptable gab width:

Normally, the gap cannot be closed completely within an acceptable period of
time. The acceptable gap width defines the size of the remaining gap after optimi-
sation.
Angle adjustment:
The angle to be optimised is searched in small angle steps. The higher the value,
the quicker the search and the higher the probability of errors. Consequently, it is
sometimes impossible, to find a result (<acceptable gap width). We recommend to
use the smallest angle that is possible (error tolerance).
When reducing the step size, the new step size should be chosen according
to the following formula: old value: new value = integer value. Example: old
size = 1.0°, new size = 0.2° (1.0/0.2 = 5) or 0.5° (1.0/0.5 = 2).
Recommendation: Smallest angle that can be produced (error tolerance).
1.3.5. Optimising Methods
1.3.5.1. Power Fit

A result is searched for all entities with the help of angle modification. Only one
entity serves for the purpose of compensation. The results will be saved and com-
pared. The best result will be taken over.
©
Example for a Result:
Step 1:
The angle of entity 3 is modified and entity 3 is produced. The remaining entities
will not be changed.
Fig. 8 Optimisation of one shaping step, step 1
Step 2:
The angle of entity 4 is modified. The best result is searched in order to close the
gap.
Fig. 9 Optimisation of one shaping step, step 2
©
1.3.5.2. Best Fit

A result is searched entity by entity with the help of angle modification. Only one
entity serves for the purpose of compensation. As soon as a result is found, it will
be taken over and optimisation is ceased, even if a better result could be pro-
duced by a subsequent entity.
1.3.5.3. Angle Fit

A result is searched for all entities with the help of angle modification. The com-
pensation is distributed to all other entities. The results will be saved and com-
pared and the best result will be taken over.
1.3.5.4. Percent Range

The optimised angle of an arc entity is within the angle of the respective arc entity
of the preceding station and the angle of the respective arc entity in the subse-
quent station. This is called the 100% range. The angle, which is not optimised, is
exactly the centre of this range and is limited by the two adjacent stations. Nor-
mally, the optimised angle is within the mean third of this range. If the 100% range
is restricted by 25% each at both ends, the centre of the resulting range equals
exactly the angle, which was not optimised. This is called the 50% range. During
optimisation, an angle is searched in the set range. The search is quicker in the
50% range; however, it may produce no result.
1.3.6. Topographical
The Topographical Method corresponds to an offset of the final profile.
Example: Offset of a polyline with the help of the AutoCAD command 'Offset'.
The Topographical Method does not produce any undercuts.
The Topographical Method is not a proportional projection of the final profile

to the original profile. The lengths of straight lines remain constant whereas
the arc lengths will increase. Profile entities in the offset profiles will be cut
off at dents in the original profile (equals the AutoCAD command 'Trim').
As the Topographical Method is not a proportional projection, it is not

suited for roll forming (Shaped Tube Module). The forming steps are
regarded to be even cuts through a drawing ring.
After selecting Topographical, the Topographical Deformation Method dia-

logue box appears.
No. of Passes:
Information on the current number of profiles saved in the database.
©
Working Pass:
If only one profile is saved in the database, the initial pass will be no. 1. The shap-
ing steps are attached to the database. If several profiles are saved in the data-
base and the pass number of the initial pass equals the number of passes, the
shaping steps are attached to the database. If several profiles are saved in the
database and the pass number of the initial pass is smaller than the number of
passes, the shaping steps will be inserted after the initial pass.
The number of contour lines equals the number of shaping steps.
Total Height H:
Total height of drawing ring.
No. of Contour lines k:

Number of contour lines through the drawing ring.
The number of contour lines equals the number of forming steps.
Distance of Contour lines h:

Distance between two contour lines of the drawing ring.
1.3.6.1. Curve of Contour

The form of the contour of the drawing ring is regarded to be a mathematical func-
tion. The respective displacement ∆r (delta r) between the two shaping steps is
calculated from the contour lines of the drawing ring.
With arc entities, the distance ∆r equals the difference between the radius of
the profile of the initial pass and the displaced profile.
Contour:
Six different contours can be saved which are displayed in the contour list. The
names of the different contours can be adjusted individually. Use the edit box to
do this.
Calculation:
Several methods are available to define the form of the contour.
User Defined:
For each contour line the offset ∆r (from the profile of the initial pass) can be set.
Entry is done in the edit box “∆r” during contour assignment.
The assignment list displays the sums of the distances between the contour
lines h, or the sums of the offset ∆r for the individual levels, i.e. offset refers
to the profile of the initial step.
©
dr(h) = linear Function:

The form of the contour is a straight line.
dr(h) = a*h:
a is the inclination of the straight line.
dr(h) = tan(b)*h:
b is the angle of the straight line.
dr(h) = Exponential Function:

The form of the contour is an exponential curve.
If the form of the contour is used as an exponential curve, the inlet of the
drawing ring is plain and becomes more and more steep in direction to the
outlet. Tangentially, the curve becomes a vertical straight line.
For mathematicians: x and y co-ordinates are exchanged.
Parameter a:
Entry of the linear factor for the selected formula for calculating the offset ∆r.
Parameter b:
According to the formula used to calculate the offset, b is the angle of the contour
line or the exponent of the exponential curve.
Assignment:
Information on the current offset ∆r, which should be calculated on the basis of
the selected formula and parameters. When selecting the entry option, an offset
∆r (from the profile of the initial pass) can be set for each contour line. The value
is entered in the edit box ∆r when assigning the contour.
The assignment list displays the sums of the distances between the contour
lines h, or the sums of the offset ∆r for the individual levels, i.e. offset refers
to the profile of the initial step.
Curve of Contour:
The defined form of the contour is displayed for the purpose of illustration.
The total height of the draw-ring and the total offset are shown for scale as-
signment.
©
1.3.6.2. Fillet Radius

Automatic increase of radii at dents.
At dents, an entity’s radius becomes smaller due to displacement.
At dents in the original profile the profile entities in the displaced pro-
files will be cut (equals the AutoCAD command 'Trim').
Consequently, the radius of an arc entity from the final profile to the
original profile decreases gradually or suddenly. During real forming,
the radius becomes bigger. This effect is not desired in metal forming
and not possible in practice (without pin).
If it is a standardised COPRA® sequence of entities for closed profiles

(clockwise, or positive), the angles of the profile arcs will have a negative
sign at dents.
The 'Change radius tangentially” function allows to manually increase a ra-

dius after forming.
Identifier:
The variable i, defines the current shaping step. The arc angle a (i) is the angle of
an arc entity with a dent. The rounding radius RR(i) is the new radius to be calcu-
lated for an arc entity with a dent.
Radius:
If dents are present in the profile, undercuts may also occur. In this case the
rounding radius to be recalculated is no longer clearly defined and you can choose
between a maximum and minimum radius.
Radius RR(i) round up:

The calculated rounding radius RR(i) can be rounded.
Formulas:
For calculating a new radius for an arc entity with a dent, several methods are
available.
©
No Rounding:
The radius of an arc entity with a dent, which has been produced by displacement,
will not change.
At dents the contour radius decreases with every displacement by the re-
spective value.
If entities have to be trimmed at a dent during displacement, the contour ra-

dius may become 0.0 (inner radius of the profile = sheet thickness). If the “no
rounding” option is turned on, the contour radius remains 0.0.
RR(i) = a+b+RR(i-1):
The contour radius of an arc entity at a dent can be calculated prior to displace-
ment depending on the respective radius of the profile.
Calculation formula: RR(i) = a + b * RR(i-1)
Parameter a/b/c/d:
The parameters of the formula will be set. The parameter b can be entered di-
rectly or can be described as a function depending on the opening angle at the
dent and the parameters c and d.
For mathematicians: Depending on the selection of the parameter b, a linear

or hyperbolic trend of the function can be selected.
Parameter a:
Entry of parameter a.
The parameter a, allows increasing the radius independently of the respec-

tive radius of the profile prior to displacement. Each radius affected is in-
creased by the parameter a.
If the radius is 0 prior to displacement, it can only be increased by the pa-

rameter a. Parameter b will consequently have no influence.
Parameter b:
For parameter b there are two possibilities:
1. Entry of parameter b.
2. Calculation of parameter b according to the formula b = c/a(i-1)+d , depend-
ing on the opening angle a(i-1) at the dent and the parameters c and d.
Parameter b allows increasing the radius depending on the respective radius

of the profile prior to displacement.
©
In the formula for calculation of parameter b, a (i-!) will be divided by the

opening angle. The result is a hyperbolic function. (For mathematicians: y =
1/x). This implies a large increase at a small dent and a small increase at a
large dent.
Opening angles are the angles at individual entities.

A small opening (e.g. 5°) means a small dent whereas a large opening
angle (e.g. 120°) means a large dent.
Parameter c:
Entry of parameter c for calculating parameter b.
Parameter c defines the opening angles for which parameter b = 1 (if d = 0).
Parameter c changes the shape of the hyperbola.
Parameter d:
Entry of parameter d for calculating parameter b.
If parameter d = 0, parameter b is <1, for opening angles smaller than the

reference parameter c. This implies, that the radius will not be increased. By
changing parameter d the position of the hyperbola can be shifted in a way
that parameter b is >1 for all occurring opening angles at dents.
Parameter d changes the position of the hyperbola.
1.3.6.3. Curve Parameter b

The curve of parameter b depending on the opening angle is displayed as a dia-
gram. By selection with the mouse pointer on the diagram, an information box with
a zoomed display of the curve and a list of profile entities is shown.
List of Entities:
All entities with a negative angle (dent) are highlighted in the list. The parameters
a and b as well as the current and the increased contour radius of the displaced
profile are shown as information.
The increased contour radius is rounded, if rounding was agreed.
Diagram Fillet Radius:

Display of curve parameter b depending on apex angle.
©
1.4. Optimise one Pass
Function:
Optimisation of one pass
After automatic forming of an original profile (e.g. tube) to a final profile it might be
necessary to optimise the created shaping steps.
Subsequent modification is often necessary to:
• Close a profile
• Eliminate undercuts
• Increase radii of an arc entity from the final profile to the original profile.
By clicking the respective slide, a method for optimisation is selected.
1.4.1. Close Section

The Close Section function tries to close an open profile with several numeric op-
timising methods.
The shaping steps of axially and point-symmetrical final profiles will be auto-
matically closed by the Angle Bisection Method. In asymmetrical profiles
there is a gap and an offset between the first and last profile entity.
For closing this gap there are several numeric optimisation methods whose
suitability, precision and speed depend on the final profile and the number of
shaping steps.
1.4.2. Optimisation Settings

The functions of this dialogue box are described under Forming - Angle modifi-
cation – Optimisation settings.
1.4.3. Modify Section

Normally, a profile within a flower has not to be changed. For this purpose stan-
®
dardised COPRA options are available. This option will only rarely be used. The
option changes the calculated length of the neutral line, which can give rise to
problems. You should therefore use this command carefully.
Pass Data:
Information on current flower
• Number of passes in the database
• Current pass number to be changed
• Number of entities in the current profile
• Sheet thickness
©
Flower Data:
A list of the data of all profiles within a flower is displayed. For further information,
®
refer to ProfList option in the COPRA DB page menu.
Strip Width:
Information on changes of the original strip width
• Original (old) strip width at the left of the profile forming point
• Original (old) strip width at the right of the profile forming point
• Current strip width at the left of the profile forming point
• Current strip width at the right of the profile forming point
• Difference between the original and the current strip width at the left of the
profile forming point
• Difference between the original and the current strip width at the right of the
profile forming point
• Original (old) sum of the single percentages referred to the entire original
strip width
• Current sum of the single percentages referred to the entire original strip
width
• Difference between the original and the current sum of the single percent-
ages referred to the entire original strip width
List Box:
If an entity is identified with the help of the crosshair cursor, its geometry data will
be displayed in the edit boxes at the bottom of the window. The values can be
changed. By clicking OK, the changes will be saved permanently. An asterisk
marks the entities at the point of unfolding, AP.
Radio Button S:
®
Is activated by COPRA if only straight entities are highlighted in the list. A straight
line can be changed in an arc with the help of B. The data of the straight line will
be saved. If the arc entity is again changed in a straight line, the previous data will
be restored.
Radio Button B:
Is activated by COPRA® if only an arc entity is highlighted in the list. An arc entity
can be changed in a straight line with the help of G. The data of the arc will be
saved. If the straight line will again be changed in an arc, the previous data will be
restored.
Edit box Angle:

The angles of the entities selected in the list are set to the displayed value. Ac-
cording to the respective method, the radii and lengths of the entities will be ad-
justed (length compensation).
©
Edit box Inner Radius:

The inner radius of the entities selected in the list is set to the displayed value.
According to the respective method, the radii and lengths of the entities will be
adjusted (length compensation).
Edit box Contour Radius:

The contour radius of the entities selected in the list is set to the displayed value.
Length:
The length of the neutral line of the entities selected in the list is set to the dis-
played value. According to the respective method, the radii and lengths of the enti-
ties will be adjusted (length compensation).
% new:
The percentage of the neutral line referred to the entire original strip width of the
entities selected in the list is set to the displayed value. The length of the neutral
line is recalculated. According to the respective method, the radii and lengths of
the entities will be adjusted (length compensation).
For a description of entity selection refer to General Information.
Profile Entity:
Here the number of entities of the profile can be modified. In combination with the
Distribute length difference to function, it is also possible to separate entities.
Add:
If only one entity is highlighted in the list, it can be copied with the Add! option.
The new entity is inserted after the selected entity. If the copied entity is a straight
line, it can be changed in an arc, provided that the radio button B is selected. If the
copied entity is an arc, it can be converted to a straight line.
The new entity has the same data as the copied entity. Strip width differs by
the length of the copied entity.
Remove:
All entities highlighted will be deleted from the list.
Modify Methods:
The different methods have different effects on the profile if angle, radius or length
of an entity is changed. Different types of length compensation are possible.
©
Free:
This method equals the COPRA® Angle/Radii Calibration Method.
Modification Angle Radius Length Length compensation

Angle Remains equal Is adjusted None
Radius Is adjusted Is adjusted none
Length Adjust Option Adjust Option none
Neutral line Constant/Adapt:

This method equals the COPRA® Arc Calibration Method. The length of the neu-
tral line is constant. If the arc angle is changed, the inner radius will have to be
recalculated and vice versa. You can apply the same options as for unfolding ac-
cording to the Arc Method.

Angle Is adjusted Remains equal none
Length Adjust Option Adjust Option None
Compensation only in straight Entities:

®
This method equals the COPRA Finished Radii Calibration Method. Length is
only compensated in straight entities. If an adjacent entity of the modified entity is
not a straight entity, a new straight entity will automatically be produced.

Angle Remains equal Is adjusted Only in straight entities
Radius Remains equal Is adjusted In straight entities only
Length Adjust Option Adjust Option In straight entities only
Compensation in Adjacent Entities:

This method equals the COPRA® Tube Profiling Calibration Method. Length is
only compensated in the adjacent entities of the modified entities, no matter
whether the adjacent entities are straight or arc entities.

Angle Remains equal Is adjusted Adjacent entities
Radius Remains equal Is adjusted Adjacent entities
Length Adjust Option Adjust Option Adjacent entities
©
Length Compensation:
If a method is chosen that is based on direct length compensation, the distribution
of the lengths at the left and at the right of the entity can be set.
Outside:
The entity next to the modified entity, which is more distant from the point of un-
folding and more close to the end of the profile or, in closed profiles, more close to
the point of welding, is outside.
Inside:
The entity next to the modified entity which is more distant from the point of un-
the point of welding, is inside.
Adapt:
When changing the length of an arc or in case of an arc as a length compensation
entity either the radius or the angle can be adjusted to the new length.
Angle:
The angle of an arc entity is adjusted to the new length, if needed.
Radius:
The radius of an arc entity is adjusted to the new length, if needed.
Length Difference:
During user-specific editing of the profile data a difference between the original
strip width and the new current strip width can occur.
This difference can be distributed to the entities selected in the list.
Distribute on Selection uniform:

The number of the selected entities divides the difference. The resulting value is
applied to each entity.
Distribute on Selection percentage:

Depending on the entity length, the difference is distributed in percent. The longer
the entity the higher the compensation.
©
1.4.4. Change Bend

The Change Bend function corresponds to the Unfold and Unbend functions
(contained in the Flower Module) with the Tube Profiling Calibration Method.
Radius and angle of an arc entity can be changed individually. Length is either
compensated in the two adjacent entities or in an individual profile entity.
The 'Change Profile' function also allows for the Tube Profiling Calibration
Method. An arc entity can be modified independently. Length can be com-
pensated in several different entities.
1.4.5. Change Radius tangentially

This function allows increasing the radius of an arc entity. Geometry and position
of the entire profile remains unchanged. The new arc entity is inserted tangentially
in the profile. In general, the angle of the modified arc entity is thereby adjusted.
Adjacent entities will be trimmed.
A tangential increase of a radius gives rise to a change in strip width (length

of neutral line). Length will not be compensated.
After identification of an arc entity, the Change radius tangentially dialogue box
appears.
Entity No.:
Entity number of the identified arc entity in the current profile.
Angle:
Current angle of the identified arc entity in the current profile.
Radius of Outside Contour:

By default, the edit box displays the current radius of the outer contour of the iden-
tified arc entity. The new radius can be entered.
The radius can only be increased.
1.5. Create 3D Draw-ring
Function:
Creates a 3D volume model from the values of the draw-ring
©
COPRA® Shaped Tubes and Draw-rings The Profile Utilities toolbar
2. The Profile Utilities toolbar
2.1. Edit Profile
Function:
Change all dimensions and geometry data 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 com-
mand is required.
This function can change the calculated length of the neutral line. Be
careful with this function as otherwise problems can occur.
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:
A list of the data of all profiles within a flower is displayed.
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 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:
Is activated by COPRA®, if only a straight entity is highlighted in the list. A straight
entity can be changed into an arc entity by A. 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:
®
Is activated by COPRA , if only an arc entity is highlighted in the list. An arc entity
can be changed into a straight entity by 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.
Angle:
The angles of the entities selected in the list are set to the displayed value. Ac-
cording to the respective method, the radii and lengths of the entities will be ad-
justed (length compensation).
Inner Radius:
The inner radius of the entities selected in the list is set to the displayed value.
Contour Radius:
The contour radius of the entities selected in the list is set to the displayed value.
Length:
The length of the neutral line of the entities selected in the list is set to the dis-
played value. According to the respective method, the radii and lengths of the enti-
ties will be adjusted (length compensation).
% new:
The percentage of the neutral line referred to the entire original strip width of the
entities selected in the list is set to the displayed value. The length of the neutral
line is recalculated. According to the respective method, the radii and lengths of
the entities will be adjusted (length compensation).
For a description of how to select entities refer to General Functions.
©
Profile Entity:
Here, the number of entities of the profile can be modified. In combination with the
Distribute length difference to function, it is also possible to separate entities.
Add:
If only one entity is highlighted in the list, it can be copied with the Add! option.
The new entity is inserted after the selected entity. If the copied entity is a straight
line, it can be changed in an arc, provided that B is selected. If the copied entity is
an arc, it can be converted to a straight line.
The new entity has the same data as the copied entity. Strip width differs by
the length of the copied entity.
Remove:
All entities highlighted will be deleted from the list.
Modify Methods:
The different methods have different effects on the profile if angle, radius or length
of an entity is changed. Different types of length compensation are possible.
Free:
®
This method equals the COPRA Angle/Radii Calibration Method.

Angle Remains equal Is adjusted None
Radius Is adjusted Is adjusted none
Length Adjust Option Adjust Option none
Neutral line constant/adapt:

This method equals the COPRA® Arc Calibration Method. The length of the neu-
tral line is constant. If the arc angle is changed, the inner radius will have to be
recalculated and vice versa. You can apply the same options as for unfolding ac-
cording to the Arc Method.

Angle Is adjusted Remains equal none
Length Adjust Option Adjust Option None
©
Compensation only in straight entities:

This method equals the COPRA® Finished Radii Calibration Method. Length is
only compensated in straight entities. If an adjacent entity of the modified entity is
not a straight entity, a new straight entity will automatically be produced.

Angle Remains equal Is adjusted Only in straight entities
Radius Remains equal Is adjusted In straight entities only
Length Adjust Option Adjust Option In straight entities only
Compensation in adjacent entities:

This method equals the COPRA® Tube Profiling Calibration Method. Length is
only compensated in the adjacent entities of the modified entities, no matter
whether the adjacent entities are straight or arc entities.

Angle Remains equal Is adjusted Adjacent entities
Radius Remains equal Is adjusted Adjacent entities
Length Adjust Option Adjust Option Adjacent entities
Length compensation:
If a method is chosen that is based on direct length compensation, the distribution
of the lengths at the left and at the right of the entity can be set.
Outside:
The entity next to the modified entity, which is more distant from the point of un-
the point of welding, is outside.
Inside:
The entity next to the modified entity which, is more distant from the point of un-
the point of welding, is inside.
Adapt:
When changing the length of an arc or in case of an arc as a length compensation
entity either the radius or the angle can be adjusted to the new length.
Angle:
The angle of an arc entity is adjusted to the new length, if needed.
©
Radius:
The radius of an arc entity is adjusted to the new length, if needed.
Length difference:
During user-specific editing of the profile data, a difference between the original
strip width and the new current strip width can occur.
This difference can be distributed to the entities selected in the list.
Distribute on selection uniform:

The number of the selected entities divides the difference. The resulting value is
applied to each entity.
Distribute on selection percentage:

Depending on the entities’ length, the difference is distributed in percent. The
longer the entity the higher the compensation.
2.2. Move Profile
Function:
Move section
This function allows moving a selection of sections by defining source and target
points. The sections to be moved will be displayed in the same colour. Optionally,
additional sections can be displayed in a different colour. The modifications will
automatically be saved in the database. If only one section is moved, it can be
saved optionally.
2.3. Rotate Profile
Function:
Rotate section
This function allows rotating a section by defining reference points. The sections
to be rotated are displayed in the same colour. Optionally, further sections can be
displayed in a different colour. The modifications will automatically be saved in the
database. If only one section is moved, this will be saved optionally.
©
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
separate 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.
2.5. Join Entities
Function:
Join split entities
If selected, two equal adjacent entities can be connected.
To do so, pick the entities with the crosshairs. All entities in between will be auto-
matically connected with the same geometrical values. In case of arcs, the inner
radii have to be equal.
2.6. Join all Entities
Function:
Connect split entities
If selected, all equal adjacent entities are connected. In case of arcs the inner radii
have to be equal.
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 of a second pass is adjusted. The
second pass has to be selected in the appearing dialogue box.
©
Index
A
Acceptable gab width 118
Angle 58
Angle adjustment 118
Angle Modification Method 110
Arc Length 60
Archive-Files 4
Assembly Plan Dimensioning 23
Axes 71
B
Bend Angle 40
Bending Sequence 32
Bending Sequence Trapezoidal 33
Bending Straights 32
Breakdown Pass 77
Breakdown/Fin Pass 24, 70
C
CADFinder 5
Calculation Method 56, 62
Calculation Methods for Diameters from every Roll Typ 77
Calculations 56
Calibrating Methods 35, 36, 37
Calibration Method 33
Angle/Radii 129, 134
Centre of Gravity in 0,0 107
Chamfer at the Roll End 95
Change all dimensions and geometry data of the section 132
Change material thickness 46
Clear also COPRA® help layers when updating screen 13
Clear only COPRA® Layers when updating Screen 13
Compression 114
Computer RAM 3
Contour as a polyline 19
Contour Radius 40
Convert a section designed with CAD-functions 107
COPRA® Paths 13
COPRA® Proposal 29, 108
Copy 10, 25, 48, 70
CPM-File 3
Create 3D Drawring 131
Create new, display or update existing projects 8
D
Define plane of unfolding 29
Delete 25, 48, 70
Display of Section Radii 62
Display rolls for a station 21
Distribution 115
document management system 5
Drawrings 107
E
End of Profile 80
©
Index
F
Factors for S-Rolls 82
Factors for the Calculation of Roll Widths and Diameter 85, 96
Fin Pass 78
Fin Width 59
Final Profile 110
Final Section 51
Flange of Roll 94
Flower ( rectangular Tube ) 65
Flower (round Tube) 51
Flower Data 39, 127, 132
Folding with Angle/Radius Calibrating Method 31
G
Gap for T/B Rolls 82
H
Horizontal Centres 71
I
Identifications 70
Idler Pass 79
Import / Export 49
Import / Export of Tubemill map Data 48
Import Data Base 49
Initialize the COPRA® Rollform Software 8
Insert Part of Profile at a Location defined by an Entity Number 46
Insert Part of Profile at a Location picked by Crosshairs 45
Insert Part of Profile at the Beginning of the Section 45
Insert Part of Profile at the End of the Section 45
Inserted station 15
Inside Radius 40
Intermediate/Idler Pass 24, 70
J
Join Equal Entities automatically 31
Join split entities 44
L
List of Additions 52, 53
Load of COPRA® Set 25
M
Machine data 67
Machine layout 50
Machines 47
Material Thickness 107
Methods 55
Minimum Roll Width 75
Mirror Profil 109
Mirror Profile 30
Modification of Entities 2
Modification Procedures 41, 42, 43
Modify 10
Modify dimensions and geometries of the section 39
Modify Machine 23
©
Index
Modify Methods 128, 129, 134, 135

Modify the vertical position of a flower 38
Move section 43, 136
N
Numbering of the different Stations: 12
Numbering with Machine 15
O
Optimisation 111, 112, 118
Optimisation Methods 113
Optimisation of one pass 126
Optimising Methods 118
Ovalism 57
P
Parameter 63, 64
Pass Data 33, 39, 126, 132
Pass sequence 110
Profiles 47
Project Mainfolder 9
R
Radii 59
Reactivate changes 22
Relief Angles and Radii 92
Remove 10, 41, 50, 64
Replace Data 64
Reset commands 21
Roll Face 94
roll information 14
Roll numbering 16
roll numbers will not be changed 15
Roll Width 90
Rolls Data General 99
Root Diameter Top- / Bottom Rolls 73
Rotate Profile 29, 109
Rotate section 43, 136
S
Save 10
Save the design data of the current project 18
Save to COPRA® Set 25
Settings 11
Shortcuts 1
Special Shapes 107
Split all Top/Bottom Rolls 51
Split one entity into two parts 44
Split symmetrical sections 34
Splitting Straights for Overbending Purposes 32
Station attributes 15
Station numbering with COPRA® 15
Station Selection 68
Station Type Selection 68, 87
Stations 47
Strip Width 39, 54, 55, 127, 132
©
Index
T
Take Reduction into account 61
Top-/ Bottom Rolls 76
Tubemill map 48
Tube-Ø 47
U
Unfolding plane 108
V
Values 58
W
Wall Thickness 52
Welding Section 51
Width Top- / Bottom Rolls 82
Write flower to file 46
Z
Zoom in by Mouse click 50
©

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COPRA® RF Software

User Manual . General Functions

Round Tubes & Rectangular Tubes

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

4. The COPRA® Explorer with CADFinder 5

1.3.2. Material Choice 14

1.3.3. Station Attributes 15

1.3.4. Roll numbering 16

2. The COPRA® Database toolbar 19

2.6. Insert Pass 20

COPRA® Round & Rectangular Tubes 28

2.12.6. Join All Entities 44

3. Tubemill map Selection 47

8.2. Roll Widths 89

COPRA® Shaped Tubes and Draw-rings 107

1.3.1.6. Distribution in Profile 115

Under the star symbol you find useful tips.

3.1. COPRA® Database

The database consists of the following files:

3.2. Computer RAM

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

3.3. The CPM File

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

3.4. Archive Files

4. The COPRA® Explorer with CADFinder

4.1. CADFinder/The box Project data

What are the features of this solution?

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

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

4.2.1. Flower data

4.2.2. Pass (x)

4.3.3. Roll Data and Attributes

1. The COPRA® toolbar

1.1. Starting COPRA®

1.2. Project Manager – Please do no longer use

One directory may contain one project only.

1.2.1. Dialogue box: Project Manager

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

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

1.3. The Base Functions toolbar

Split Lines in Profile:

Fade out Plane of Unfolding:

Fade in next Section:

Fade in previous Section:

Pass and Roll Numbers:

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

Numbering of the different Stations:

Use COPRA® Numbering:

The resp. stations separated:

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

Attach stationtype to profilenumber:

Clear only COPRA® Layers when updating Screen:

Clear also COPRA® help layers when updating screen:

Automatic redraw when changing project:

The dialog box roll information:

Show info in Rolls:

1.3.2. Material Choice

1.3.3. Station Attributes

Station sub type:

1.3.4. Roll numbering

A dialogue opens if you click the icon Roll numbering.

The column Selection:

The column Format: