Home

PROFIL User Manual

1. elofolnjoujajejolo Only with option Database Afterwards the manufacturing of a profile has been finished the roll tools are removed from the roll former and are taken to the roll stock so the roll former can be set up for the next project This is the right time to transfer the rolls from the project to the roll database The roll database gives information about the rolls in the roll stock This helps while designing a new profile project if you want to re use existing rolls for reducing the costs The roll database performs quick filter and search functions To transfer the rolls from and to the database the clipboard can be used All rolls of a shaft a stand or of the complete project can be stored directly Also a roll drawn in CAD can be stored Rolls from the database can be transferred directly to CAD If only a paper drawing of old rolls is avallable the data can be entered directly into the database Calling the function Before you call this function select the View Roll Tools This prepares opening the roll stock management for the button in the top button bar Call this function optionally by e Main menu Rolls Stock Management o a Button Roll Stock Management in the Button Key Bar Stock Management Open After calling this function the window Roll Stock Management appears which contains 4 areas e Roll Table lower area This is the real roll database each ro
2. EN From Layer To Layer In Output FEA LS Dyna page Profile Meshing in Sheet Running Direction Analysis Count is defined how many layers in longitudinal direction are simulated Copyright 2015 by UBECO GmbH Iserlohn 144 UBECO PROFIL Rollform Design Software select which layers should be displayed pa E Time Interval In Output FEA LS Dyna page Meshing Long Temporally Intervals Count is defined how many time intervals should be saved into the results file Select which time interval should be displayed Il 2D Rolls on off This button can be used to switch on off the 2D drawing of the designed rolls within the 3D drawing of the FEA result pe 3D Rolls on off This button can be used to switch on off the 3D models of the designed rolls within the 3D drawing of the FEA result One layer only Use this button to reduce the FEA result to one layer only see also From Layer To Layer Either layer 1 is shown or if you have selected a stand in the Profile Explorer previously the layer that is between the rolls of the selected stand see also Press again this button to show all layers again el Graph This button opens the Graph window that shows the stress strain and thickness dependant on the position of the sheet in the machine in sheet running direction LI y a ery 4 Tube3Dx2 Ol fA LOG Show layer between the rolls By selecting a stand entry in the
3. Calling the function Before you call this function identify the roll by clicking the previous Roll Corner Point of the roll Relevant is the order in the Roll Tool Window Call this function optionally by e Main menu Rolls Corner Append e Context menu right mouse button click on the certain corner point of the desired roll in the Drawing Area Corner Append Principle of operation CA a Give Width for the New Corner 2 000 12 000 PANTI X Cancel Help The input window appears with the question Give width for the new corner and an admissible range of values for the input which begins at the end of the last fillet and ends at the beginning of the next fillet The width is related to the Roll Reference Point In the input field appears the rounded mean value as a proposal You can modify this proposal or overwrite it Principle of operation The new roll corner point is appended at the given position If two fillets touch one another the new corner point will be inserted at the point of tangency and the input window will not appear Copyright 2015 by UBECO GmbH Iserlohn Reference 125 Hint e f you want to undo a this function use the function Corner Remove 3 1 4 23 2 Remove 3 1 5 3 1 5 1 Use this function to remove a Roll Corner Point Calling the function Before you call this function identify the Roll Corner Point for removing Call this function optionally
4. Meshing Transv Meshing Lona Files Machine Material Contact Others Roll Tool Contact Use General Contact instead of individual contact settings in the roll data window Touching the Profile at Top Bottom Side Edge Self Contact Check contact sheet with sheet Check contact left and right sheet side only for General Contact only Friction coefficient p MContact pressure reduction factor for thin sheet Reduction Factor 1 00 Recommended 1 0 for normal sheet 0 1 for sheet thickness lt 0 3 mm 1x Cancel 7 Hilfe Roll Tool Contact Use General Contact The General Contact is an improved time saving alternative to the individual contact definition in the Expanded Roll Tool Window Touching the Profile at ABAQUS Rel 6 8 is necessary for this option When this box is checked the settings in the roll tool window are ignored Self Contact Check contact sheet with sheet If the profile touches itself e g if edges are fold this option can be set This avoids unwanted self penetration of the sheet If no self contact is possible the checkbox should keep unchecked in order to reduce the computing time Check contact left and right sheet side only This option can be set alternatively for e g tubes or tubular profiles This also reduces the computing time For this option General Contact is necessary Friction coefficient u To consider the friction between sheet and sheet
5. Before you call this function select the profile element with the 180 degree arc which should be opened Call this function optionally by e Main menu Profile Element Open Fold e Context menu right mouse button click on the arc element for opening in the Drawing Area Profile Element Open Fold CA al Open Fold give new inner radius 0 000 0 700 I Cancel Help The input window appears with the question Open fold give new inner radius Enter the new radius that should be in the range 0 4 0 8 x sheet thickness empirical value Principle of operation After confirming with the Ok button the fold is opened as described Precondition is The previous and the next elements are lines and they have sufficient material that they can be shortened to move the material into the arc Copyright 2015 by UBECO GmbH Iserlohn Reference 101 Any arc angle is possible So the function also can be used e g if a symmetrical profile starts with a 90 degree arc 3 1 3 16 3 Convert L to A1 TS a Convert L to 41 new arc angle 0 000 180 000 10 000 x Cancel Hilfe Use this function to convert a profile element of type L Line to a profile element of type A1 with the same developed length This is used if first an arc is formed into the flat strip which is pressed to flat again in one of the last stands Application spectrum e Compensating the spring back in case the
6. Express Language 51 Roll Stock Management 255 Extension Filter Create from Clipboard 255 Filter On Off Copyright 2015 by UBECO GmbH Iserlohn 268 UBECO PROFIL Rollform Design Software Filter On Off Profile Catalogue 250 Roll Stock Management 255 FinPass 218 Profile 160 Side Rolls 166 Top Roll 163 Fin Pass Bottom Roll Bottom Roll 164 Finite Element Analysis Output FEA ABAQUS 194 Output FEA LS Dyna 185 Quality Management 28 Simulation Rollforming Process 29 Fit 204 FKD File 230 Flower Automatic Flower Creation 37 Designing 34 View Flower 3D 139 View Flower Nested 138 View Flower Separated 139 Flower Pattern Development Table 96 Folded Band Edge 99 Folded Edges 141 Forming Rolls Renumber 117 Forming Stand 218 Frame 232 Friction 114 Friction Coefficient 194 Function Keys 81 sts Gap 114 116 Gear Ratio 219 General Contact 194 Graph for Stress Strain Sheet Thickness 146 Graphical method for Designing the Profile 33 Grid Options Drawing 62 View Show 150 Grid Lines Color 64 Guidance 193 Guided Nodes 194 H Hardlock 259 Hat Profile 157 Help 201 Help Assistant 201 Hem 99 Hewlett Packard ME10 261 Hole Cut Out FEA LS Dyna Definition 185 LS Dyna Meshing 189 Options Profile List 65 Position 238 Profile List 240 Size 237 Hookean Line 199 Horizontal Dimension 172 How to Work 27 Identification Groove Expanded Roll Tool Window 211 Groove File 213
7. Idle Roll 212 IGES Export 51 Options Files 75 Imperial System 66 Import 50 Machine File 230 Import Stress Strain Curve LS Dyna 191 Output FEA ABAQUS 194 In Principal Axes 126 Inactive Color 64 Inch 66 Inclination Angle 225 Increment 67 Options Spacer Rolls 68 Inertial Radii 128 Input Output Path LS Dyna 190 Output FEA ABAQUS 194 Insert Element 103 Profile List 91 Inspect 203 Installation Copyright 2015 by UBECO GmbH Iserlohn Index 269 Installation Contents of the Disks 259 Driver USB Hardlock 259 Interface AutoCAD SolidWorks 260 Interface ME10 261 Interface to other CAD Systems 262 PROFIL 259 Integer Places 66 Interface to ABAQUS Explicit 194 to AutoCAD SolidWorks BricsCAD 260 to CAD 257 to CNC Lathe Control 73 to LS Dyna 185 to ME10 261 to MS Excel 70 to MS Word MS Paint and others 58 to other CAD Systems 262 Introduction to PROFIL 27 J Join Profile Element 102 Rolls 119 K K1 K10 Spring Back Factors 210 230 Keyboard 81 Keyway 212 KTR Contour File KTR Format 231 Import 50 Options Files 75 e Layer 143 145 Layer Numbers 75 Layer Select 226 Layout of Profile List Window 65 lb 66 lead 222 Leg Height 85 License 13 Line Join 102 Profile Element 236 Split 102 Toolbox Profile Design 151 Line to Arc Conversion 101 Linear Course of Band Edge 133 Lnn File 233 Loaded Profile List 94 Radius Angle 237 Lowering the
8. Moments of Inertia The moments of inertia will be calculated as well as for the coordinate system of the drawing as for the In principal Axes system Moments of inertia in the In principal axes system represent the maximum x and the minimum y moment See also Statics Moments of Resistance By using of moments of resistance it is possible to calculate the effect of stress in the material based on the cause of bending stress applied torque el gt y The profile will not be deformed if appearing stress is lower than safe bending load get from material tables Based on the moments of inertia the moments of resistance are calculated from the outside distance For the worst case lowest moments of resistance use the maximum distance J max W PROFIL calculates the moments of resistance related on the In Principal Axes system which are the axes of minimum and maximum loading See also Statics Max Distance Because bending will cause maximum stress at the outside of strip the maximum distance in x and y direction is important It will be used to calculate the moments of resistance based on the moments of inertia The drawing displays the maximum distance as the length of the red axis system See also Statics Copyright 2015 by UBECO GmbH Iserlohn 128 UBECO PROFIL Rollform Design Software 3 1 5 1 8 Inertial Radii The inertial radius is the radius of a imaginary round
9. Reverse Zoom Reverse Zoom Use this check box to change the zoom direction when spinning the wheel mouse So you can adapt it to the zoom direction of your CAD system Step interval Step Interval for Toolbox Modif Angle 1 000 Radius 0 200 Length 1 000 Select the step interval for changing the values in the input fields for Angle Radius and Length in the profile list and roll tool window by using the Up Down buttons of the Toolbox Modify also for the Pg Up Dn keys of the keyboard Profile Read CAD Contour Use this function to import a contour which you have prepared in your CAD system into PROFIL in order to generate a Profile list Whether a Contour File KTR format or a Contour File DXF format is being read you select in Options Files from CAD If you want to read files with frequent varying file names instead of a temporary file with a constant file name better use the Import Function Calling the function Previously select in the Profile List Window the Profile Element which should be the start point for inserting the read data The start point normally is element 1 except you read the 2nd half of an asymmetrical profile then the start point is the next element behind element P Call this function optionally by e Main menu Profile Read CAD Contour o Button Read CAD Contour in the Button Key Bar If you have enabled the ActiveX Input from CAD in Options ActiveX the drawing is directly re
10. bottom rolls appear with count 2 correctly the side rolls however not What is wrong Count 2 appears if and only if the parts list rows are fully identic also in the column Designation Please check Options Parts List Set Up Columns Designation if the designation for left and right side rolls are identic Alternative Remove the column Designation Then the designation is not checked for identity How can install a PROFIL update without loosing my settings Do not uninstall the old release Simply install the new release by overwriting the old one then the settings from the Windows system registry keep alive Alternatively export the setting from the old release into an INI file Options General Save INI file settings and reload it in the new release Why do the short keys Ctrl C and Ctrl V for Copy and Paste not work in the PROFIL input fields as in other Windows programs By default these short keys are assigned to Roll Copy and Roll Paste Simply remove the assignment in Options Keyboard then you can use the short keys Ctrl C and Ctrl V in input fields as usual Alternatively open the context menu by right mouse click in the input field The functions Copy and Paste work independent on the assignment Why is it not possible to dimension the distance between top and bottom roll The dimensioning works object orientated and associatively in contrast to many CAD systems This is why both d
11. 3 1 7 1 3 Partial Ellipse 3 1 7 1 4 This function is a part of the Toolbox Profile Design and generates a set of arc elements that approximate a partial ellipse Calling the function Call this function by e E Button Partial Ellipse from the Toolbox Profile Design The window Partial Ellipse is opened Enter the half Major Axis Length B and the half Minor Axis Length H The major axis length always must be larger than the minor axis length In case of H gt 0 A counter clockwise partial ellipse is created H lt 0 A clockwise partial ellipse is created Enter the Start Angle AO and the Apex Angle A of the partial ellipse In case of AO 0 or 180 The partial ellipse starts at the minor axis AO 90 or 270 The partial ellipse starts at the major axis Principle of operation If you have selected a Profile Element previously the new profile element will be appended to the selected one Otherwise it will be appended to the end of the profile Arc lt 90 Line This function is a part of the Toolbox Profile Design and generates a new element of type arc and a new element of type line The dimension reference point is the intersection point of the tangents to the arc so this function is useful for arcs until 90 Calling the function Call this function by e A Button Arc lt 90 Line from the Toolbox Profile Design The window Arc lt 90 Line is opened Copyright 2015 by UBECO GmbH Iserl
12. Hints e The function Rolls Spacer Rolls Create fills a gap between rolls automatically with a spacer roll e f you want to undo a moving move again in the opposite direction 3 1 4 17 Mirror Copyright 2015 by UBECO GmbH Iserlohn Reference 121 3 1 4 18 Top bottom roll Use this function to mirror a roll at the right or left outer edge of a roll set This is useful for easier designing of rolls for symmetrical profiles create the rolls for one half only and mirror them afterwards IHd tor SLON NO75 1101 Ps r Ol Side roll This function creates a mirrored side roll on the opposite side This means a left side roll will be mirrored to a right side roll and vice versa This simplifies designing rolls for symmetrical profiles Calling the function Top bottom roll Before you call this function identify the roll by clicking a Roll Corner Point of the roll that should be mirrored It is important which corner is selected the mirrored roll will be created at the right or left outer edge of the roll set dependent on if you select a corner on the right or left Side roll Before you call this function identify the roll by clicking any corner of the roll that should be mirrored Check previously if no roll exist on the opposite side in the corresponding height If more than one roll should be mirrored use this function for each roll successively Call this function optionally by e Main menu Ro
13. Profile e Element Separator Lines In Options Drawing Profile you can switch off the Element Separator Lines between line and arc segments Hints e The Navigator helps you to zoom to move and to fit the drawing e Use the Toolbox Modify to bend the profile up and down and to modify the size of the profile e With the function Output Drawing gt CAD you can transfer the drawing to your CAD System Copyright 2015 by UBECO GmbH Iserlohn Reference 137 3 1 6 2 Statics Centroid N Principal Axes Reference Point Shear Center Point Statics Related to x y Centroid of an Area Ref Point xO yO 0 799 10 138 mm Shear Center Point Ref Point xO yO 2 469 7 581 mm Moment of Inertia xy in Centroid 1 078 aro cm4 Moment of Inertia in Principal Axes 3 806 1 023 cm4 Moment of Resistan xAyin Centroid 0 777 1 576 cm3 Moment of Resistan In Principal Axes 1 624 0 882 cm3 Max Distance In Principal Axes 1 159 2 344 cm Inertial Radius In Principal Axes 1 473 0 764 cm Area of Cross Sec 1 753 cm2 Weight without Hole 1 376 kg m Princip Axes Angle Axis in Centroid 98 074 deg Vault Resistance Shear Center Point 1 662 cm6 Torsion Moment Centroid 0 023 cm4 Use this function to display the profile discharged in the Drawing Area In addition the drawing will be enhanced with the static parameters T
14. This function enables the ActiveX output and switches the function Output Drawing gt CAD and the matching button on the Button Key Bar to ActiveX Furthermore the function 3D Stand gt AutoCAD will be enabled At the same time the file output see Options Files will be disabled Peculiarity of the SolidWorks interface Since PROFIL Rel 4 0 and SolidWorks 2003 this interface has been provided to transfer profile and roll tools drawings from PROFIL to a SolidWorks drawing and to transfer profile and roll contours from a SolidWorks drawing to PROFIL Peculiarity of the SolidEdge interface Since PROFIL Rel 4 3 and SolidEdge Rel ST7 this interface has been provided to transfer profile and roll tools drawings from PROFIL to SolidEdge and to transfer profile and roll contours from SolidEdge to PROFIL preliminary only for 2D drawings The extension to 3D models is planned for a later release Peculiarity of the BricsCAD interface Since PROFIL Rel 4 3 and BricsCAD Rel 15 this interface has been provided to transfer profile and roll tools drawings from PROFIL to BricsCAD and to transfer profile and roll contours from BricsCAD to PROFIL preliminary only for 2D drawings The extension to 3D models is planned for a later release Interface to ME10 gt previously Hewlett Packard ME10 and CoCreate OneSpace Drafting now PTC Creo Elements Direct Drafting After you have performed the Installation PROFIL and the ME10 installation
15. Type A1 4 Arc The angle of the marked arc will be modified Behind the marked item a new arc will be appended with the residual angle The Strip Width will keep constant if the Calculation Method DIN 3965 is selected It will change marginally if Oehler is selected because the straight length calculated by the Oehler method is dependent on the arc angle Hint Redo splitting by the function Profile Element Join 3 1 3 16 5 Join This function joins the marked Profile Elements of type Line L or Arc A1 4 together with the next profile element in the Profile List Calling the function Before you call this function select the profile element type L line or A arc that should be joined with the next one e f the marked element is a Line type L the next element must be a line too e f the marked element is an Arc type A1 4 the next element must be of the same Arc Type and must have the same Arc Direction and Radius Call this function optionally by e Main menu Profile Element Join Copyright 2015 by UBECO GmbH Iserlohn Reference 103 e Context menu right mouse button click on the profile element in the Drawing Area Profile Element Join Principle of operation The selected profile element is joined with the next profile element For arcs is effective The Strip Width will keep constant if the Calculation Method DIN 3965 is selected It will change marginally if Oehler is selec
16. preferably at the utmost 5 Start the solver and the profile is simulated with holes cut outs Hints e Before you create the FEA simulation model you should use the function Calculate Plausibility Check to check the whole profile project on errors e In order to get a good simulation result the maximum aspect ratio of the shell or solid elements of the flat sheet should preferably not exceed 3 After pressing the Ok button the status bar at the bottom of the main window shows the maximum aspect ratio of the profile and the rolls the aspect ratio is saved in the lt project name gt txt file too If the aspect ratio exceed 10 a message window opens and shows the corresponding profile element number In case the sheet has bore holes cut outs the maximum aspect ratio should not exceed 5 This is why the automesh function of the solver should be able to remesh the surrounding sheet mesh correctly e The maximum aspect ratio of the shell elements of the rolls should not exceed 20 Also this ratio is shown in the status bar and is saved in the lt project name gt ixt file e Rolls should not have sharp edges e in the cross section should not touch two contour lines each other with an angle The reason is The surface normals of two adjoining surfaces change the direction abruptly Because of the discontinuous function the numeric solver cannot consider the boundary conditions correctly It is recommended to create a small fillet radius a
17. COMA dci 192 S ac coe eee ere aE IE E EAR AEE EEE E AEEA E EOE SORE SER TERT 193 ABAQUSS da 194 Cure o AA A 199 O NO 201 ASA A A ts N s 201 Sie a A A Awana O CO seed ee sees 201 2 BUT OWS ira 202 04 cacedeuusanaucantels actus tisgennsaal aa e Ea a aE 202 Dimensions OO ito 203 se necaccnestantersies 203 Navigatora e ae OaE os secasueuddacen wane aaea aa EEEa E 204 Navigator 3D A ia 204 a Oa Poara a A edn thaccenacecsaue E aeeai 205 3 WINdOWS 1 205 ProM 4D do lo 1 enra aaa e a aa ea a a a E EES ES aE E Eee E 205 Project DAA A Ea Er eaaa A E SEEE Aa E EOE EE 206 EEOAE EEIN AE E IAES E ES T S SPEE EE EE N A SAE E Se EEEIEE E eT 207 DCS Ci OU ON ae neria S a te eat aera 207 Drawing NUM Dacia AAA AAA AAA 207 Matera lanceros arar DA NEO O O 207 MAIS Nac 207 DATE ooo 208 A O O 208 REVISION O rte vaiie 208 A ON 208 Caladan Melod oaea todas 208 Protile D EOE E aio 209 PPOB AOK eaa a tars sec Bececcdecae ect arieaneerers 210 BR ON IP E E aan P EPE EE EEE O A E E A ETT A T I A E E A 211 Expanded Roll Tool Widow ssssssssnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn nnn enana nnana 211 BEE e So NE i E E ES E E E AE da AA EE E AE T 212 DIVO O auto 212 A tuipsce se acd cid a A esas coterie 212 BUSHIDO saree ceesiecatestec vied usc Paae tenner nance tach ae lacus ame sees crease we uta eneet pone net e 213 ISRATITICATION RGR OOV Saa A icine a AAA AAA AA Aoi 213 Matet larisa on E O e AO 213 Treating Surface Addition REM ee ee od
18. Height 3 000 Select the text height in Options Drawing Text Copyright 2015 by UBECO GmbH Iserlohn 216 UBECO PROFIL Rollform Design Software 3 3 8 f 1 200 y 0 800 Select in Options Drawing Grid the grid lines distance and if the grid lines should be visible on the screen or not Color of Grid Lines Diff to Background Color fio Select in Options Drawing how much the color of the grid lines should differ from the background color Use the function Drawing CAD to transfer the drawing which is displayed in the Drawing Area to your CAD System Machine PEI Machine Rollformer T300 i l Machine File Stand F Forming Stand C Calibration St E Rollformer T300 f Machine Ralltarmer T300 E Prie st Transm Ratio B T Roll 1 000 z 1 400 Dz working Width 250 000 ee a 70 000 Materia 2080 Stand Final St Dist to Next Stand 300 000 Calibration Factor H Deform Deg Append Right Side Shaft rs Remove Shaft cer 000 50 000 52 000 32 000 Th Inci Amate 80 000 The machine window shows the machine date of the current Project It is opened and closed again by the menu function Edit Machine or with the button H in the top Button Key Bar The machine window works together with the Drawing Area and the Profile Explorer fully interactively This means after clicking on an item the corresponding objects in the other two partitions are
19. Iserlohn Reference 73 3 1 2 8 11 NC Use this settings for the NC output as NC program and DXF file Output NC Program Output HC Frogram Build Program Number from F Rall No e Part Mo Create Separate Files Integer Decimal Places Hi Path for Entire File CAPROFIL D ata Eng Path for Separate Files CAPROFIL Data Eng Use the left side of this window to set the parameters for creating the NC programs of the rolls for the CNC lathe by the function Output Create NC The file is in text format it contains NC commands according to DIN 66025 The roll contour is described in form of G01 G02 G03 commands and can be transferred to any machine control that is able to read an external program Afterwards the program can be completed on the shop floor e g by rough cutting cycles tool selection etc Build Program Number from Every NC program starts in the first line with 0 and a following program number Select if this program number should be created from Roll No or from Part No If you check both boxes Roll No and Part No will be combined If you do not check both the NC programs will be numbered starting with 001 If you check Modus Separate Files the file names become the program number Create Separate Files The function Output Create NC creates a NC file which contains the NC programs of all rolls of the profile project If you check the box Create Separate Files you get a set of files
20. LO2 Lnn are emptied in which the rolls are preserved and all passes LO2 Lnn are created newly for the new sheet thickness from the development table In doing so all arc angles and all arc bending methods are taken into account from the origin flower pattern in order to create the new flower pattern for the new sheet thickness As a result the strip width in all passes is the same and all rolls from the origin project are preserved as designed for the old sheet thickness The described steps also can be proceeded manually by calling the development table from the profile menu and applying it to the project This enables the user to make more modifications in the development table in addition to the thickness change Copyright 2015 by UBECO GmbH Iserlohn Reference 89 3 1 3 7 Principle of operation selection Use existing rolls The settings in the dialog window have influence on all passes LO1 Lnn As a result the sheet thickness in all passes is unequal In order to get equal strip widths in all passes the following method is applied on the passes L02 Lnn For each pass the difference between the strip width and the one of pass L01 is determined Then the profile elements at the bad edge are corrected in the following way e Is the profile element at the band edge a line L it is lengthened or shortened e Is the profile element at the band edge an arc A the angle is increased or decreased by keeping the radiu
21. Large Arc Seg 4 000 mm Def Lange Arc Radius gt Thickness x 2 0 Line Segments select the desired length of the shell elements for Profile Elements of type Line Since the divisor must be a whole number the effective length will be approximate to the setting Small Arc Seg select the desired length of the shell elements for Profile Elements of type Arc The arc angle is divided Regards the whole number divisor see above Large Arc Seg select the desired length of the shell elements for Profile Elements of type Arc The arc developed length is divided Regards the whole number divisor see above Def Large Arc enter the limit between large and small arcs A large arc is detected when the radius of the centerline of the sheet is larger than the sheet thickness multiplied by the preset factor Meshing Long Meshing Long Length 8 000 mm Length select the desired length of the shell segments in longitudinal direction Initial Passes Count Initial Passes Count E Select how many passes should be displayed when the profile stress analysis is called for the first time Later you can modify the analysis range by using the From Pass and To Pass selectors Copyright 2015 by UBECO GmbH Iserlohn Reference 81 Color Assign select by moving the tabs which relative stresses should be assigned to the colors blue and red The stresses are related to the yield point of the selected material 0
22. Le peH O a A gt a a i D Xr F p p y P id P a 4 HHH Buanna Dy SHR b A _ P a cer ee O A a Please note e Define holes as CIRCLES in color RED or in the color that is preset in Holes Cut Outs Colors DXF file Holes Cut Outs respectively e Define cut outs as closed POLYLINES in color RED or in the color that is preset in Holes Cut Outs Colors DXF file Holes Cut Outs respectively The polylines can consist of line and bulged arc segments e Position the circles and polylines by orienting to the sheet corners or the mesh lines Another method Define Holes Cut outs in the Profile List L01 of the Profile List Window Previously extend the profile list window in Options Profile List to layout With Holes Cut Outs The center lines in the developed sheet in the DXF file are useful for positioning e Save the drawing in AutoCAD 2000 DXF format Press the Ok button again PROFIL extracts the attached holes and cut outs from the DXF file only circles and polylines in color RED and copies them to the trimming file lt project name gt trm The meshing of the holes cut outs is done automatically by the solver see Profile Adaptive refinement Automatic remesh In order to enable the Solver s Automesh function to do this correctly select Profile Meshing in Sheet Running Direction with an aspect ration of 1
23. PASS a 233 RR o A EA 234 Stip Width A a 234 Reference Point KO VO a ca 234 O 235 Profile Elements ioscan cs evens iccsdncasdsccccanncsataceatcncasmunesetsesvasvancaateacaasaucsavescdmvaseasssneucesmacstabuneseucseesecaeice 236 A A eee ere Ime Smee Te Rea Sn Se te LS ae eee een 236 TYDE A A A bec dea ane wey sare A A is 236 DIFECUOrerarara raro a ran ta waaie 237 Radiis Angle DISCM Ane daa acid 237 Radius Arg Edad do aint adidas tas 237 O 237 FeO Sill Srta ea a ena 238 A T eR ene 238 US Ss puma etico ee ee cence ieee 238 RE Seder t A A A ae tt et ied ied Re athe eae et ce 2 hs 238 DEO UV OCS hci ash este sie a aa eE E aE a cecaseocuaanagesenasues sassaasacsxsecceesencuseasteenmmes 238 FIOIES C tH OS O EAE E AS E petielvelixdeluavactsnuscueal aa cauuanssaaueuacasainetessaeinceaesesiupeeseluneys 240 CaleCulation Methods a ee 240 User Defined Calculation Methods 000oncccccccononccnnncccoccccooccnnnncnnoncnnnnnnnnnn nn cnn rn nnnnnnnnn nn nen rr nnnnnnnnn nn nr rr nnmnnn nnne 242 Factor Method sacs ii 242 A ERa E AA AANA 243 0 FROW o CA O 243 A OS 243 PATADA deis 244 Classical Mia A o 244 Wis ui a a 244 Max DiaMeter inician A AAA da da 245 Spacer ao 245 Gorner ROM buin AAA AA AAA ii 245 A stacey heck seen a ieee ee oe Sans Gog ae Ne BS aa cS ha ea hes aN cae oh sa lle Sten ala 246 e o e a ae ees 246 RAS e oe 246 ANGIE a a a tes 246 T Protle CAtAlO GUC arcilla 247 Prole Table AAA A canta ladee eanecsecctca decals pdedus
24. Scanning the profile bottom side the sheet center line and the profile top side Optionally scanning the profile bottom side the sheet center line or the profile top side bottom and top related to the reference point is possible In case profile legs touch each other and have common lines it can be valuable to scan the opposite side lt _ O Q A y Symmetrical profile Asymmetrical profile You have called this window with the function Profile Read CAD Contour If you design a symmetrical profile left picture set both the marker Reference Point x0 y0 blue and the marker Contour Start Point green to the Reference Point X0 YO of the profile If you design an asymmetrical profile right picture set the marker Contour Start Point green to the left corner of the profile and the marker Reference Point x0 y0 blue to the Reference Point X0 Y0 of the profile For both set the marker Contour End Point red to the right corner of the profile The color change to the mark color light blue by default must mark the lower contour line in the reference point of the profile Otherwise see topic Controlling the contour tracking manually In case of a symmetrical profile you only need to append a Profile Element PS for Point S ymmetrical to the end of the profile list This mirrors the right side to the left Snap points for setting the profile reference point By clicking on a drawing element
25. Select among 3 possible layouts of the Profile List Window Normal is the smallest window without spring back and holes cut outs With Spring Back displays the Spring Back this means besides the discharged state and the loaded state too With Holes Cut Outs displays the Holes Cut Outs Modify Strip Width Sheet Thickness Modity Stip Width Sheet Thickness Corr sheet width right side 50 When the functions Profile Modify Sheet Thickness and Profile Modify Strip Width are applied on a asymmetrical profile the partition of the strip width modification to the left and right band edge can be preset Corr sheet width right side Enter a value between 0 and 100 that assigns the percentage of the modification to the right band edge The difference to 100 is assigned to the left band edge The entry 50 means Both band edges are modified in equal measure Copyright 2015 by UBECO GmbH Iserlohn 66 UBECO PROFIL Rollform Design Software 3 1 2 8 5 Calculate Use this function to set the parameters for the calculation of the profile Paths to System Files Paths to System File Material Data CAPROFIL D ata Profil wkd Edit User Def Calc Methods CAPROFIL Data Profil fkd Edit Material data Use the Edit button to call the text editor set in Options General with the Material File This file contains a set of sheet materials with according data You can modify or enhance the file to your own needs Pa
26. SldWorks Application 14 SolidWorks 2007 SldWorks Application 15 SolidWorks 2008 SldWorks Application 16 SolidWorks 2009 SldWorks Application 17 SolidWorks 2010 SldWorks Application 18 SolidWorks 2011 SldWorks Application 19 SolidWorks 2012 SldWorks Application 20 Copyright 2015 by UBECO GmbH Iserlohn Installation 261 4 9 SolidWorks 2013 SldWorks Application 21 SolidWorks 2014 SldWorks Application 22 SolidWorks 2015 SldWorks Application 23 etc e SldWorks Application Connects to the current SolidWorks release this is the last installed one SolidEdge Application Connects to the current SolidEdge release this is the last installed one e BricscadApp AcadApplication nn Connects to BricscadApp release nn Use this Program ID if you have installed more than one BricscadApp release and you want to select a special one BricsCAD Release 15 BricscadApp AcadApplication 15 0 e BricscadApp AcadApplication Connects to the current BricscadApp release this is the last installed one If the drop down list is empty no AutoCAD or SolidWorks or SolidEdge or BricsCAD release is installed on your computer Enable ActiveX Input from CAD This function enables the ActiveX input and switches the function Profile Read CAD Contour and Roll Read CAD Contour and the matching button on the Button Key Bar to Activex At the same time the file input see Options Files will be disabled Enable ActiveX Output to CAD
27. T600 19 07 00 Brandear 19 07 00 120 081 72 162 4 000 436 495 CAPROFIL3A Metal Fo Shaped Tube Q 60 45 3 st224 T600 18 03 02 Brandegc 01 04 2002 34 000 22 000 3 000 91 881 CAPROFIL32 Metal Fo Shaped Tube 60 4500 a st14 T300 25 02 00 28 02 2003 63 856 10 000 2 000 89 917 CAPROFIL32 Only with option Database While dealing with an inquiry the designer needs calculation data from similar profiles that are produced in the past Designing new roll form projects should consider experience from earlier projects The profile catalogue gives a quick overview of all produced roll formed parts Any filters can be defined named saved and reloaded by the user for selecting the desired profiles The profile catalogue contains the Profile List of the final pass LO1 each and the project data of the Profile Project The belonging drawing of the final pass is quickly generated and displayed while browsing through the database A special button in the profile window enables quick access to the project file 3 different user defined views with desired columns are displayed by key stroke Calling the function Before you call this function select one of the views View Pass View Statics View Flower Nested View Flower Separated View Flower 3D This prepares opening the profile catalogue for the button in the top button bar Call this function optionally by e Main menu Profile Profile Cat
28. The status of the switch is displayed by a coloured background of the table fields in the Profile List Window possibly select with spring back in Options Profile List Calling the function Before reading the contour select one of the center lines for defining whether a bottom a top or a side roll should be created The center lines are visible in the Drawing Area if you have selected View Rolls and the Machine Window contains machine data In case of rolls already exist on the shaft select any roll in order to mark the shaft Call this function optionally by e Main menu Rolls Scan Profile Drawing o Y Button Scan Profile Drawing in the Button Key Bar ST The Window Scan Profile Drawing appears and you define the start green and end point red of the contour Principle of operation After confirmation by pressing the Ok button in the Window Scan Profile Drawing the position on the shaft is checked first e The position is free the new roll is inserted at the defined position The user has to check if there are remaining gaps between the rolls e A roll yet exists with same width and position the existing roll is replaced by The new one if the user agrees e An overlap occurs between an existing roll and the new one The existing rolls are moved by the overlap width if the user agrees A roll is created that matches the scanned profile contour Afterwards you can modify the roll for your own needs by using
29. The width is related to the left edge of the roll unlike to the rolls in the profile project i e the width of the first corner is always 0 The field Angle is not an input field the angle will be calculated automatically Save every record by using the button Post edit Saving a roll from a CAD drawing Press the button Insert Roll from CAD in the top bar of the Roll Table Copyright 2015 by UBECO GmbH Iserlohn Tutorial 43 2 2 7 1 Machine New Handling Of Machine Data us Machine Rollformer T300 j 3 x Machine File Stand F Forming Stand C Calibration St ollformer T300 Machine Rolltormer T300 E Final SE Transm Ratio B T Roll 1 000 1 400 PoE T Working Width 250 000 Input from file Export to file 3 11 Spacers A 70 000 Materia 2080 Additional side shafts w AY Stand Final Sk Dist to Next Stand 300 000 A po Calibratian Factor Deform Deg 1 th k Append Right Side Shaft oe Remove Shat y vame p Sooo 50 000 52 000 Ma context menu tor u Workina B ll ane Ei IM ine Incl Arale O aoo Old handling until PROFIL Rel 4 6 Machine data are saved in the Machine File m01 The profile project contains a link to the machine file only When additional machine data are needed e g during designing new rolls they are auto loaded from the machine file If machine data are modified in the project e g fr
30. X Cancel Help In the dialog window FEA Parameters LS Dyna is opened These settings are necessary for the FEA simulation e Profile Meshing in profile cross section and in in sheet running direction element type Rolls Meshing rolls axial and radial Holes Cut Outs Meshing the roll tools and holes cut outs Start FEA input output path start and restart start position Material Material properties stress strain curve import Contact Roll tool contact scale factor for sliding interface penalties Others Time step size mass scaling guiding Principle of operation After pressing the Ok button these file are created lt project name gt dyn Main file that is opened by the LS Dyna solver lt project name gt trm Trimming file contains holes cut outs if defined lt project name gt _op05 dyn File for trimming the sheet lt project name gt _op10 dyn File for the first stand in sheet running direction lt project name gt _op10 bnd File for guiding the first row of nodes if parameterized lt project name gt _op20 dyn File for the second stand in sheet running direction lt project name gt _op20 bnd File for guiding the first row of nodes if parameterized ES etc lt project name gt blk Geometry of the blank sheet lt project name gt mod Geometry of the rolls and the support lt project name gt dxf contains the blank sheet for defining the holes cut outs lt project name gt txt for documentation contai
31. e To insert a list before the current one use Profile Insert e To remove a list use the function Profile Remove 3 1 3 11 Remove E L U30x20 LJ LO SU U30x20 LJ L0 Use this function to remove a Profile List from the set of lists Calling the function Before you call this function select the pass that should be removed Call this function optionally by e Main menu Profile Remove e Context menu right mouse button click on any profile element of the desired pass in the Drawing Area Profile Remove Principle of operation The profile list is removed irretrievably The numbers of all following lists will be decreased by 1 Hints e To insert or append a profile list use the functions Profile Insert and Profile Append e To delete all profile elements without removing the profile list use the function Profile Empty Copyright 2015 by UBECO GmbH Iserlohn 94 UBECO PROFIL Rollform Design Software 3 1 3 12 Loaded LO ye L02 Pass x0 200 000 Dist Stand 300 000 y0 150 000 Strp width 105 456 Direc i Radius dis ch nale Radiusloa ded nale StLenath St ___ 6 000 1 500 75 000 1 466 76 142 2 553 51 30 000 1 000 75 000 0 974 76 142 1 898 Pl y 5 000 1 000 90 000 0 974 91 371 2 278 5 000 The fields with the yellow background in the profile list window left cause if in the d
32. each of them contains one NC program only The file name is the same as the program number PROFIL avoids double file names and with it overwriting existing files by attaching 1 2 etc to the file name if necessary In a first step after calling this function all existing NC program files that belong to the project are deleted before they are created newly So the function can be called repeatedly Decimal Places Set the precision of the coordinates in the NC program The default is 3 decimal places Path for Entire File Separate Files Enter the path for the NC files if necessary also with a drive letter e g c NC You can select the path for Entire File and for Separate Files separately After clicking into the input field the Explorer appears Output DXF File Copyright 2015 by UBECO GmbH Iserlohn 74 UBECO PROFIL Rollform Design Software Output DF File Whole Project in Sep Files Bund Filename from F Rall Hie Part Hic Turm over Aol Filename for Entire File CAPROFIL D atas E ngs Protil DF Path for Separate Files CNPROFIL DatasE ng Use the right side of the window to set the parameters for creating the DXF files of the rolls by function Drawing gt NC which you want to transfer to a NC programming system The used file format is DXF format rel 12 file format defined by Autodesk Nearly all NC systems are able to read files in this format
33. has a crucial influence on the quality of the product On the one hand the course must be as short as possible in order to form the band edge elastically only The shortest connection between two points is the straight line but the band edge Is creased both at the machine entrance and exit This is why the second important point of view for choosing the right band edge course is the tangential transition at entrance and exit In practise a linear function with fillet radii is often used or a cosine function PROFIL is able to create the flower pattern for trapezoidal profile automatically E Ss Sa AE UE AR a Ne The function can be used for the forming of corrugated sheet too see Hint Calling the function Before you call this function define the final trapezoidal profile by the function Trapeziodal Profile from the Toolbox Profile Design or by CAD drawing see Graphical Method Select the pass that should be handled as the final pass normally LO1 Call this function by e Main menu Calculate Trapezoidal Profile Forming Trapezoidal Profile Forming ajx Band edge course with tangential connections according to cosine function linear function with fillet radius at machine entrance 5000 at machine exit oga Unbend trap flank simultaneously instead of trapezoid X Cancel Help A dialog window is opened with the question Band edge course with tangential connections according to o 00 N
34. line or arc the desired point contour start point reference point or contour end point will be set to the nearest end point of the drawing element UVA In case of Reference Point you can use further snap points by opening the context menu right mouse button click if the imported CAD contour has no element breakup at the desired position Line Center Point left Arc Quad Point 270 center and Arc Quad Point 90 right The picture shows the typical applications If the reference point should be set to another point that does not exist in the drawing it is recommended to proceed like this Split the element in CAD at the desired position Then also the window Read CAD Contour contains split elements and the reference point can be set by direct mouse click Designing a roll set by using the CAD system or by scanning the profile drawing ST _ gt Copyright 2015 by UBECO GmbH Iserlohn 228 UBECO PROFIL Rollform Design Software 3 4 3 4 1 You have called this window with the function Roll Read CAD Contour or Roll Scan Profile Drawing Set the marker Contour Start Point green to the left corner of the roll and the marker Contour End Point red to the right corner of the roll The color change to the mark color light blue by default must mark the roll contour without the edges see picture Rounding radii can be attached later in the roll list Otherwise see topic Controlling the
35. machine data first or import an existing machine file When machine data are modified in the machine data window the modifications are shown in the project immediately It is not necessary to save the machine data or to close the machine data window Thereby interactive modifications are possible similar to the profile list window and the result is shown in the drawing area at once Compatibility Old and new Project Files are fully compatible However if an old project file is opened with the new PROFIL release the machine window is filled out partly only with machine data that could be extracted from the project Then the appropriate machine file should be imported once and the project has to be saved with the machine data Afterwards the machine file in principle is not needed anymore for this project The old PROFIL release also is able to open a new project file with machine data However the machine data from the file are ignored Copyright 2015 by UBECO GmbH Iserlohn 44 UBECO PROFIL Rollform Design Software 2 1 2 H Working Instructions The new button Machine in the top button bar opens and closes the machine data window This window shows the machine data of the currently opened project Entered values take affect on the project immediately After closing the machine data window the machine data keep alive When an older project has been opened that does not contain machine data the machine windo
36. the hint will appear again UBECO PROFIL Help Assistant repeat last hint mark all hints as read mark all hinta as unread show all hints w show unread hints only show no hinta By right click on the PROFIL symbol the assistant menu is shown Select if you want to see all or no hints or if only unread hints should be shown In the last case each hint appears only once Furthermore you can mark all hints as read or unread 3 1 9 2 Check for Update Your PROFIL Release is 4 8 DB FEA Check if it is still up to date You need online access to the internet Select Check Now Check for Update Your PROFIL release is up to date The next release will be available in Dec 2012 Please check again later Planned new features in the next version not yet defined The new release will be presented Euro BLECH Oct 23 27 2012 in Hannover Germany JD More Info E Mail X Cancel 7 Help Use this function to check whether your PROFIL release still is up to date or if a new release is available in the mean time For this you need online access to the internet Calling the function Call this function by e Main menu Help Check for Update Principle of operation The window Check for Update is opened and you can select Check Now PROFIL checks the UBECO website if an update is available More Info The Web browser opens the web site http www ubeco com E Mail A new mail is created and the
37. the roll tools without a CAD system Calling the function Call this function optionally by e Main menu Toolbox Tube Design 2 Button Toolbox Tube Design in the Button Key Bar Content Section 1 contains functions for creating the different passes for tube forming and for tube calibrating A Shaped Tube Calibration Welding Pass a Fin Pass Break Down Pass Break Down Pass W Forming Section 2 contains functions for generating the rolls for tube forming E Fin Pass Top Roll isl Fin Pass Bottom Roll U Break Down Pass Top Roll Break Down Pass Bottom Roll 2 Fin Pass Side Rolls Copyright 2015 by UBECO GmbH Iserlohn 36 UBECO PROFIL Rollform Design Software a Break Down Pass Side Rolls Principle of operation e Preparing Create a new profile project by using File New Open the Machine Window and enter the machine data or import a Machine File that you exported from a previous project If the welded tube should be formed to a shaped tube the machine must contain calibrating stands e Defining the tube dimensions round tube Call the function Welding Pass of the Toolbox Tube Design and enter the diameter the sheet thickness and the necessary addition for welding e Defining the tube dimensions shaped tube Use the Toolbox Profile Design the Graphical Method or the Numerical Method to define the cross section of the shaped tube Afterw
38. the sheet top or bottom surface but only the undesirable deformation of the sheet center In case of a symmetrical profile only one half is simulated for optimizing the calculation time Select if the result should be mirrored automatically Mirror Symm Autom i ps 2 From Layer To Layer In Output FEA ABAQUS page Meshing Long Analysis Count is defined how many layers in longitudinal direction are simulated Select which layers should be displayed JE Time Interval In Output FEA ABAQUS page Meshing Long Temporally Intervals Count is defined how many time intervals should be saved into the results file Select which time interval should be displayed iml 2p Rolls on off This button can be used to switch on off the 2D drawing of the designed rolls within the 3D drawing of the FEA result 2 AVI File like Video Start Stop but in addition the video is saved into an AVI file Afterwards the WINDOWS Media Player is started to run the video Remark Both for creating and for running the video a compression method is used that is available in newer WINDOWS versions only gt a Video Start Stop The time intervals are displayed sequential this means the FEA simulation result is shown like a video as desired with or without rolls After a short waiting period the video is repeated automatically until the stop button is pressed By selecting a stand entry in the Profile Explorer the selector From Layer To Layer is set aut
39. to transfer the drawing to CAD or to print the drawing without spacers Output of the Manufacturing Data Profile and Roll Tool Drawings Assembly Drawings Use the Toolbox Dimensioning to dimension the profile and roll tool drawings either manually or automatically Use the function Output Drawing gt CAD to transfer the desired drawings to the CAD System After completion of the drawings use the CAD system functions to plot out or print out the drawing Or use the function File Print to print the drawings directly By using the function File Plot you get a standardized assembly drawing with frame and title block Parts List Sawing List Use the function Output Create Parts List to create a text file which contains the parts list of all rolls of the project You can print the text file or transfer it to a soread sheet Or use the same function to transfer the parts list directly into a predefined work sheet of MS Excel Copyright 2015 by UBECO GmbH Iserlohn 42 UBECO PROFIL Rollform Design Software NC Programs Use the function Output Create NC to create a text file which contains the NC programs Contour data of all rolls of the project You can split the file into separate files for each roll NC Drawing If you use a NC programming system and it needs DXF files use the function Output Drawing gt NC to create these files Programming the CNC Lathe manually If the machine control does not support im
40. 00 y 00 00 00 J YN y NES RS e Cosine function The cosine band edge course left creates a sine course of the stress of band edge right The advantage of this method is the very smooth transition both from the entering flat sheet and to the ready product leaving the machine Copyright 2015 by UBECO GmbH Iserlohn 134 UBECO PROFIL Rollform Design Software e Linear function with fillet radius The linear band edge course left creates a linear course of the stress of band edge right and with it the smallest count of roll forming stands Fillet radii at the machine entrance and exit prevent creases e Unbend trap flank simultaneously instead of trapezoid can be selected both for cosine and linear function The roll forming process always starts with the inner trapezoids This is why the material should be able to flow to the inside during bending The user can select if the entire trapezoid or the trapezoid s flank is formed simultaneously J Ls Sf NS A SL NY The trapezoid is formed simultaneously fewer stands are needed Problem when the material is impeded to flow to the inside this may cause deep drawing effects J Js Y f M AU The trapezoid s flank is formed simultaneously more stands are necessary the material can better flow to the inside Problem the band edge moves up and down this causes higher stress The stress can be
41. 1 i i Radius dis ch nale Radiusloa ded nale StLenath St 6 000 1 500 75 000 1 466 76 142 2553 51 30 000 _ 1 000 75 000 0 974 76 142 1 898 A o 5 000 1 000 90 000 0 974 91 371 2 278 5 000 For designing the roll tools for the finishing stand you have to use the geometry of the profile in the loaded state The spring back of a profile is automatically calculated if you define a profile by function Profile Read CAD Contour or you modify a pass in the Profile List Window or in the drawing Precondition is that you have selected a material in the Project Data Window The calculation of the spring back uses the factors K1 and K10 of the Material File These two factors are used as supporting values for an e function for interpolation The spring back is shown if you select With Spring Back in Options Profile List You can define by using the menu switch Profile Loaded whether the discharged or the loaded state should be used for display design and for calculation PROFIL uses the Oehler method for getting the over bend angle This method is valid from the ratio radius thickness 1 until 100 If in case of very large radii the ratio 100 is exceeded a warning message comes Calculation of spring back not possible at ratio radius thickness gt 100 Otherwise a loaded angle is suggested and displayed nevertheless This value comes from extrapolating the e
42. 109 Partial Ellipse 153 Partial Project Add On 48 Save as 50 Partition of the strip width modification 65 Parts List 71 Create 181 Edit 183 Export 51 Options Parts List 70 Set Up Columns 71 Pass Count 135 Profile List 233 View 136 Paste Roll 122 Path Options Database 69 System Files 66 PC DRAFT 257 PE 238 Peripheral Velocity 219 Perspective Angle 62 Photo Realistic Image 179 Plausibility Check 135 Plot 55 Plot To Scale 55 Point 236 Poisson Ratio LS Dyna 191 Output FEA ABAQUS 194 POLYLINE Contour File 231 Position Hole Cut Out 238 Pound 66 Predecessor Count 194 Preview Open Project 47 Print 54 Preview Pictures Explorer 205 Open Project 47 Options General 61 Previous Pass 148 Principal Axes Angle 128 Print 54 Print Preview 53 PROFIL Story 13 Profile Catalogue Drawing Area 250 Filter 250 General 97 247 Profile Element Table 249 Profile Table 248 Profile Design 151 Profile Element Abs Angle 98 Append 103 Convert Lto A1 101 Copy 104 Insert 103 Join 102 Open Fold 99 Remove 104 Split 102 Profile Element Table 249 Profile Elements Direction 237 Copyright 2015 by UBECO GmbH Iserlohn 272 UBECO PROFIL Rollform Design Software Profile Elements General 236 Number 236 PE 238 Position 238 Radius Angle Discharged 237 Radius Angle Loaded 237 Size 237 Straight Length 238 Stress 238 Type 236 Profile Explorer 205 Profile
43. 120 MS DOS Release Export 51 Import 50 Multi Axles 44 N Name 208 Name Filter Profile Catalogue 250 Roll Stock Management 255 Natural Forming 95 Navigator 2D 204 3D 204 NG Create 183 Edit 184 Export 51 Options NC 73 Nested 138 New Handling Of Machine Data 43 New Project 47 NextPass 148 No of Profile List Windows 65 Nominal Strain 199 Number Drawing No 207 Profile List 236 Number Keys 117 Multi Axles 44 Options Rolls 67 Options Spacer Rolls 68 Roll Mirror 120 Numerical Method for Designing the Profile 31 O ODB File 194 Oehler Method Calculation Methods 240 Oehler Method Spring Back 210 OLE Automation 77 OneSpace Designer Drafting CAD Systems 257 Interface ME10 261 Open Fold 99 Partial Project 48 Project 4 7 61 Roll Stock Management 123 251 Options ActiveX 77 Colors 64 Database 69 Drawing 62 Files 75 General 61 Copyright 2015 by UBECO GmbH Iserlohn Index 271 Options Keyboard 81 LS Dyna 185 Mouse 82 NC 73 Options 66 Parts List 70 Profile List 65 PSA 80 Rolls 67 Set Up Parts List Columns 71 Spacer Rolls 68 Window 61 Output 41 3D Model gt CAD 179 Create NC 183 Create Parts List 181 Drawing gt CAD 177 Drawing gt NC 178 Edit NC 184 Edit Parts List 183 FEA ABAQUS 194 FEA LS Dyna 185 Overbend Angle 210 Parallel Dimension 173 Part Number Options Rolls 67 Options Spacer Rolls 68 Roll Tool Window 244 Spacer Rolls
44. 214 TOUCHING the PLOTS atan tia abados 214 DAW ate FBC eons A AA A A E A Se a asa ere ena ek tte 214 AG ING cc cee cence este scnene snes con nvacuonvacniecs O secuaceccuruuccenrecuusyen 216 MACIIMGEX DIOKET ks A E EE aa iaa 218 MACHE cheeses cies me sie sac tito 219 Transmission AMD SAA A AS AAA AAA AA dota 219 A WIO zeccaserczssessateconsctavter a A a stontasaaataneepaneeasseanenenahenamaneaamatedt 220 nS t eRe ee Er N cr on OE eve eee ee eee ere 220 lat NANG cece ede did ica adds 220 DISTANCE TO Next Sta A A earns ta teeth eee At atc 221 Alo 221 Deformation Degree n ina e 221 Damer olaa tea cr cds 222 Working DIAN A AAA AA AO ii 222 Copyright 2015 by UBECO GmbH Iserlohn UBECO PROFIL Rollform Design Software Reference PO lbn manita dad iaa 223 lc a suse E 225 Read CAD Contour Scan Profile Drawing cccccccccccccononncnnncnncnnannnnn conc nrnnnnnnnrnnrrrnrnrnnnennnnnnnnnnnnnnnnaananas 226 ATEOS ua cosa vanedeseue aessecewenaes ait neen sedecnecaubi we E ROE 228 Prole Proein lar ai aeaieneines 228 Material Fille cil isos 229 AA eek trie cocci uc cen tus Laden ts audantewieadesaniudie auc tuutewsabances a Ti 230 Machine File ca tarece cote cues tee ecnatcctea ws cae soseuetcuae a ER 230 Contour File KTR Format is 231 Contour File DXF Format erian naea a 231 Additions Fle nirea a A OAE AA AAAA 232 Drawmg Template iii a EE A ses eee unten ca AAE AORE a e E E naani 232 F PTOS EIST oaa a d do 233
45. A1 L If you press Yes all profile elements from the clipboard are pasted Otherwise an empty line is appended Hints e To insert a profile element at the current position use the function Element Insert e To remove a profile element from the profile list use the function Element Remove e To copy profile elements to the clipboard use the function Element Copy 3 1 3 16 8 Remove 77 U30x20 L01 ax P u30x20 L01 ax Pass Pass x0 xD 200 000 Dist Stand 300 000 y0 150 000 Strip width 62 007 Direc No Typ Di Radius dis Anale dis StLenath Str Lomo 11 000 L 2000 90 000 E PS Dist Stand 300 000 yO 200 000 150 000 Strip width 54 000 Direc No Typ Di Radius dis Angle dis StLenath Str L 11 000 16 000 PS Use this function to remove the current Profile Element from the profile list Numbers of the following elements will be decreased by 1 2 4444 61 3 16 000 4 Calling the function Before you call this function select the profile element Call this function optionally by e Main menu Profile Element Remove e Context menu right mouse button click on the profile element in the Drawing Area Profile Element Remove Principle of operation The profile element is removed irretrievably The numbers of all following elements will be decreased by 1 Hints
46. A11 format file format defined by ISD for the CAD system PC DRAFT DXF format file format defined by Autodesk Nearly all CAD systems are able to read files in this format Mi format file format defined by Hewlett Packard CoCreate for the CAD system ME10 OneSpace Designer Drafting or PTC Creo Elements Direct Drafting respectively IGES format file format defined by the Initial Graphics Exchange Specification Copyright 2015 by UBECO GmbH Iserlohn 76 UBECO PROFIL Rollform Design Software STEP AP214 3D file format in accordance with DIN ISO 10303 Product data representation and exchange EXPRESS language If you have selected the DXF format you can preset With Blocks Please select this option if the objects passes rolls should not only organized on layers but the layers should also converted to blocks Hint In AutoCAD blocks are handled easier in all e g moving the whole block For modifying however blocks have to be exploded If you have selected the STEP format you can preset Profile built from separate bodies Each Profile Element becomes a separate 3D body Otherwise the whole profile becomes one entire 3D body The setting Separate Bodies is useful if the CAD system is not able to represent a profile with self contact i e one part of the profile touches another part If your CAD System is running under other operating systems Umlaute and special letters must be converted WI
47. Dyna or Output FEA ABAQUS e Proceed the FEA simulation by using LS DYNA Solver or ABAQUS Explicit Solver e Check the result of the simulation by using the function View FEA Result or with LS PrePost see picture or with ABAQUS CAE see picture The result of the FEA calculation is the a CAD drawing of the profile which can be dimensioned and checked if the deformation is within the allowances If not the design has to be modified All this happens before the rolls are manufactured Profile Designing the Profile 46 30 Create a new empty profile list by using the function File New enter a suitable file name that allows easy identification of the project Enter the project data into the Project Data Window Select among 3 different methods the toolbox the graphical or the numerical method for data input e Use the Toolbox Profile Design for quick and easy design of standard profiles like U C Hat etc without CAD or for applying extensions to them e Use the Graphical Method to design a more complicated profile which is better to be drawn in CAD e Use the Numerical Method to design a simple rectangular profile or a tube Because in this case you know all input data or you easily can calculate them which are directly entered into the profile list If after defining the profile cross section modifications in the profile list should be necessary toggle to the Draft Modus You can modify angles and radii of arc seg
48. GmbH Iserlohn 84 UBECO PROFIL Rollform Design Software 3 1 3 2 3 1 3 3 in Options Profile List If the CAD drawing contains partial ellipses they are converted to arcs approximately only DXF input and ActiveX Input One arc with small radius is created at the major axis of the ellipse another arc with large radius at the minor axis Between both an arc with medium radius is created There is exact correlation in the quadrant points of the ellipse intersection points with major and minor axis i e the contour tracking finds connection to other elements As a result of the approximation procedure there is small deviation between the ellipse and the arcs in the other parts except the quadrant points This is why the contour tracking does not find the connection We recommend to proceed like this first transfer the ellipse to PROFIL and afterwards transfer the created arcs back again to CAD Then create the connection elements in CAD and transfer the whole drawing to PROFIL Hints Further function for creating the profile list are e The Toolbox Profile Design for simple profiles like U C Hat etc e The Numerical Method for simple rectangular profiles Empty Use this function to empty the profile list i e to delete all Profile Elements Calling the function Before you call this function select the pass whose profile list should be emptied Call this function optionally by e Main menu Profile
49. KTR Format and for reading a MI file Please contact your dealer CAD system PC DRAFT Macros are available for generating a Contour file KTR Format and for reading a A11 file Please contact your dealer Others Please create macros by your own for quick data exchange via DXF In order to transfer 3D models use the STEP format If you do not know the drive path and file format for data exchange file files please ask your system administrator If the used CAD system is running under the operating system UNIX it is possible to exchange data via a network server lt does not matter if the generated files have the UNIX file format only LF at the end of a line PROFIL is able to read them In the other direction PROFIL generates files with CR LF at the end of a line UNIX systems should be able to read them Copyright 2015 by UBECO GmbH Iserlohn Installation 259 4 2 4 3 Installation Contents of the Disks Dependent on the different operating system and CAD systems the following files are necessary If a necessary file is absent please order it or download it from the web site http www ubeco com e profil32 exe Setup procedure for the demo version 32 bit for WINDOWS Contains the ActiveX interface to AutoCAD SolidWorks SolidEdge and BricsCAD and any the file interface to any CAD system e ProfilMe zip Interface to CoCreate ME10 or OneSpace Designer Drafting or Creo Elements Direct Drafting respectiv
50. List Radius Angle Discharged Radius and angle discharged are columns of the table of Profile Elements of the Profile List and describe the inner radius and bending angle of a bent part in discharged state this means after the profile has left the roll tools and has sprung back So the profile list LO1 discharged describes the geometry of the desired profile See also Radius Angle Loaded See also Profile List Radius Angle Loaded Radius and angle loaded are columns of the table of Profile Elements of the Profile List and describe the inner radius and bending angle of a bent part in loaded state this means while the profile is in contact with the roll tools For compensating the Spring Back this angle must be larger and the radius must be smaller than in discharged state The loaded state is automatically calculated out of the discharged state if you have selected a Material in the Project Data Window and the Material File contains the factors k1 and k10 for spring back for this material Otherwise also the calculation of the discharged state out of the loaded state is possible Radius and angle are shown in the Profile List Window if you have selected the layout With Spring Back in Options Profile List See also Radius Angle Discharged See also Profile List Size The size is a column of the table of the Profile Element of the Profile List and defines the diameter of a hole or the width of a cut out Holes Cut Outs are all
51. Machine Data Keep Roll Data in Options Rolls is shown and can be modified Lead Strip tension It s a common practice to keep the strip under tension by gradually increasing the roll pitch diameters Thus also the circumferential speed of the rolls is increased from stand to stand This causes strip tension in sheet running direction and prevents vertical buckling Also the spring back of the profile legs is reduced between the stands In the Machine Window enter the desired working diameter and call the function Copy To All of the context menu right mouse button ax Increase Working diameter per stand by 1 000 X Cancel Help A window opens and asks Increase working diameter per stand by The diameters of all previous stands are decreased by the given value thus the diameter increase in sheet running direction Reference Point Pic 1 The roll reference point is identical to the profile reference The roll reference point PO with the drawing coordinates X0 and YO is a part of the machine data and is displayed for each shaft in the bottom part of the Machine Window The Working Diameter pitch diameter DO 2x working radius RO is related to this reference point The reference point of the machine is the connection to the profile and is measured in the drawing s coordinates Mostly it is identical to the Reference Point X0 Y0 of the profile list see pic 1 In this case the Copyrigh
52. Main menu Calculate Shaped Tube Calibration e Button Shaped Tube Calibration in the Toolbox Tube Design Confirm xl Pies ES Current pass is a shaped tube Create all calibrating stands now sy During this process in designing direction against the sheet running direction 7 the shaped tube should be formed to a round tube f the shaped tube should be formed to an elliptic tube 7 the cross section of the shaped tube should keep unchanged After checking if the given cross section is a closed shaped tube a dialog window Is opened with the question Current pass is a shaped tube Create all calibrating passes now During this process in designing direction against the sheet running direction You can select between three items see also the drawing above e the shaped tube should be formed to a round tube The calibrating passes are created dependent on calibration factor and deformation degree Finally a round tube is created at the stand that has the deformation degree zero for the first occurrence normally the welding station a calibrating stand is possible however Because there are many possible cross Copyright 2015 by UBECO GmbH Iserlohn 132 UBECO PROFIL Rollform Design Software section patterns for the calibrating stands PROFIL has a built in random generator that calculates 10 various solutions for the problem 9 of them are thrown away and the best with the minimum horizonta
53. Modifications by hand or be the Toolbox Modify are allowed however e The function Shaped Tube Calibration needs a closed cross section pattern which can be symmetrical or unsymmetrical with any count and type of profile elements Before using the Toolbox Tube Design it is recommended to prepare the machine data in the Machine Window Copyright 2015 by UBECO GmbH Iserlohn 160 UBECO PROFIL Rollform Design Software 3 1 7 2 1 3 1 7 2 2 Welding Pass This function is a part of the Toolbox Tube Design and creates the tube profile for the welding pass Calling the function Call this function by Q Button Welding Pass from the Toolbox Tube Design The window Welding Pass is opened Enter these parameters into the input fields e tube diameter D e sheet thickness s e addition for welding A Principle of operation After pressing the Ok button the tube profile for the welding pass is entered into the profile list If the profile was not empty the contents will be replaced Hint e For creating the rolls for the welding pass use the function Fin Pass Side Rolls Fin Pass This function is a part of the Toolbox Tube Design and creates the tube profile for a Fin Pass Calling the function Before calling this function you should have created a Welding Pass and afterwards by using the function Profile Append have appended a profile list for the new fin pass Call this function by 0 Butt
54. Modify Reference Point e Some Statics are related on the reference point Centroid The centroid is the centroid of the area of the profile Inside the drawing the centroid is the origin of the principal axes red axis system Cold roll former often lower the web of the profile from one stand to another to reduce the stress of the band edge Center Line Forming also called downhill forming or natural forming Usually this is done by placing the centroid of all passes to the same level See also Statics In Principal Axes The In principal axes is an axis system for maximum bend round the X main axis and minimum bend round the Y main axis load of the profile The origin of axis system is the Centroid Inside the drawing principal axes are displayed in red color The angle between the X axis of principal axes and the horizontal X axis is the Principal Axes Angle See also Statics Copyright 2015 by UBECO GmbH Iserlohn Reference 127 3 1 5 1 4 3 1 5 1 5 3 1 5 1 6 3 1 5 1 7 Shear Center Point The shear center point is the optimal point of application of load in case of bending without shearing force i e bending stress without torsion Inside the drawing the shear center point is displayed as a small red cross For U type profiles the shear center point will be mostly outside the profile Then a welded on bracket may allow application of load in the shear center point See also Statics
55. Pr a F mn AS TH ee ed ae eee AAA pe LoL or al E Ae I bru Cees Ferd Py pri iiy To 11 454 i kiram mo r eT iHi il a 1 Tad F Gii ia ra Tir i AA Raat ay r Cup H im i PE LIE E m mart 1P 5 mn tre mr hi E ja bn Ta Hin an F 3 AF ELE T T 3 A hn E 1 a ll 4 ies Pra Ti s mH Pme a PA Ee PROFIL is the roll design software for every manufacturer of cold roll formed profiles or seamed tubes from sheet metal and for designers of rollformers and tube forming machines PROFIL enables quicker working and cost reductions in planning design calculation and drawing of the profile the flower pattern bending steps and the roll tooling PROFIL is running under all WINDOWS platforms and has an easy to use WINDOWS based user interface which enables experienced WINDOWS users to learn through self tuition PROFIL has built in CAD interfaces DXF IGES and MI which can be used for generating drawings in any CAD system For AutoCAD SolidWorks SolidEdge and BricsCAD the very Copyright 2015 by UBECO GmbH Iserlohn 12 UBECO PROFIL Rollform Design Software 1 3 1 4 1 5 comfortable ActiveX interface is used 3D models can be transferred to any 3D CAD system via the STEP format in accordance with DIN ISO 10303 What are the aims of PROFIL PROFIL will not replace the engineer This is not possible But it will give him practical help for a quicke
56. Printer Plotter Parts List and NC Program If the spacer rolls are switched off they are switched on automatically by Creating Spacer Rolls Hint The difference between automatic spacers and spacer rolls is discussed in Tutorial Roll Tools Creating Spacer Rolls Copyright 2015 by UBECO GmbH Iserlohn 150 UBECO PROFIL Rollform Design Software 3 1 6 9 3 3 1 6 9 4 Dimensioning In case the dimensioning should be not visible it can be switched off Calling the function Call this function by e Main menu View Show Dimensioning Principle of operation This function switches all dimensions temporarily off and on again In position switched off the dimensions are not displayed in the Drawing Area not transferred to CAD Drawing gt CAD not printed Print and not plotted Plot Grid In order to have a better overview of the size proportion during profile and roll design it is helpful to have a graph paper in the background of the Drawing Area Example While choosing the width of side extensions at rolls Grid lines distance and color can be preset by the user Calling the function Call this function by e Main menu View Show Grid Button Grid on off in the Button Key Bar Principle of operation This function switches the grid lines on and off After switching on the dialog line at the bottom of the screen shows which grid lines distance currently is preset Hi
57. Reference Point 126 Shear Center Point 127 Torsion Moment 129 Vault Resistance 128 Weight 128 Station 233 STEP CAD Systems 257 STEP AP214 Export 51 Options Files 75 Output 3D Model gt CAD 179 Step Interval 82 Stock Management Stock Position 252 Straight Length Addition Method 243 Factor Method 242 General 238 User Defined Calculation Methods 242 Straight Length Calculation 240 Strain 123 251 275 Index True 199 Stress fracture 238 Nominal 199 Profile Stress Analysis 141 Stress of Band Edge Calculate 129 Quality Management 28 Stress Strain Curve LS Dyna 191 Output FEA ABAQUS 194 Strip Tension 222 Strip Width Modify 89 Profile List 234 Subset of Passes 50 Successor Count 194 Support 13 Surface Expanded Roll Tool Window 211 Option Rolls 214 Switching Roll Corners Projects 253 Symmetrical Point 236 Sytem Files 66 T Table of Filter Conditions Profile Catalogue 250 Roll Stock Management 255 Table of Profile Elements 249 Table of Profiles 248 Table of Projects 254 Table of Roll Corners 253 Table of Shims 68 Template 232 Tensile Breaking Stress 199 Tensile Strain 146 Tensile Stress 146 Tensile Test 199 Text Color 64 Text Editor 61 Thickness 208 Modify Sheet Thickness 87 Project Data 208 Three Step Concept for Quality Management Time Interval LS Dyna 187 Output FEA ABAQUS 194 28 Copyright 2015 by UBECO GmbH Iserlohn 276 UBECO PROFIL R
58. Rollform Design Software importing check the stress strain curve graphically by opening the Curve Generator Curve Generator In case the stress strain curve of the used sheet material is not available and you nevertheless want to proceed a FEA simulation with approximate values you quickly can create a curve by the Curve Generator by defining three characteristic curve points Hints e In a roll forming process also larger strain sometimes occurs either desirably or undesirably During simulating also for larger strain the belonging stress must be found So it is recommended to extend the stress strain curve to strain 1 at least better strain 2 e Take care that the stress strain curve increases continuously at the end this means the stress must be related the current area not to the original area of the tensile test soecimen 3 1 8 8 1 6 Contact This dialog window is called by Output FEA LS Dyna is used for set up of the roll tool contact and the scale factor for sliding interface penalties a 2x LS Dyna Profile Scale factor for sliding interface penalties Rolls CONTROL_CONTACT SLSFAC 0 50 Holes Cut Out Start Self Contact ares Check contact sheet with sheet liters starting from stand in sheet running direction X Cancel Help Scale factor for sliding interface penalties CONTROL_CONTACT SLSFAC This factor determines how deep the sheet is allowed to pen
59. S90 AS Bite ashes EEEE AA EERTE TA ay E T AE E E ima cease alavdae ob civ 154 AA Pe Ee ee ee 155 Trapezlodal Prolene riales 155 RONE OT 156 C PONE rae e o eee 156 Ha ROM san 157 nn veterans E aa at tava 157 TUDES DESI OM ats ccp ence Eos 158 Welding BRASS ads liada as 160 A O O ON 160 Break DOWA a Sismo aida daba da ibn 161 Break Down Pass W EO Mia 162 Hn Fass TOD Roll dd i cee ese 163 El Pass Boton Roland ada 164 Beak Down Pass Top Rol ostia dia pierde Geta aE 165 Break DOWN Pass DOOM daa 166 lil ode RONG tached accaeetat evade tacetniad Gants eae eae A EE natasha anes 166 Break Down Pass o deso linia iia 167 A O oO idee deedeavetsosseives 168 DIMAS Pa 169 MESSI ida as 171 HOrzZO Mal DUM StS OW titan 172 Verica DIMENSION sissien diari dit 172 A OT 173 Diameter DiM ensiONe caia dina dali 173 Radius DIMenSOn zasa n a a A N AA 174 Andle DIMENSION cercanias 174 AULOMAtic Roll DiIMCASIONAG ie 175 Move DIMENSION a da 177 PISTOLS POSTS OM adas 177 QUIPDUES ses einai cunt ar dite A ess did A ADA A bd AAA AA ARA ADA AER ARA A 177 Drawings AD Ie 177 Drawing NG issn r e Aa 178 30 Modal CAD nado 179 ee PS NS Ease a a E dota a S 181 ERAS Sd anaa A O A A saw aa tan paeetamiandacensaaeasneet 183 AN a to a A 183 A eu O 184 FER us aio dd 185 cio 185 Copyright 2015 by UBECO GmbH Iserlohn A II e AEA 187 OS Seo aa EE E 189 Holes CUr OU a aa ue 189 A hes Soa A neat aoe dee ena a 190 Matetlalta inside 191
60. SHELL With it also simulation of roll formed processes are possible that contain massive forming either wanted or unwanted Output FEA LS Dyna Output of a logfile for documentation of the FEA settings Output FEA LS Dyna Start Configurable FEA project name Options ActiveX New ActiveX interface to SolidEdge and BricsCAD Options General Preview pictures can be switched off this causes faster screen refresh for larger projects Partial Project Add On Roll number and part number are locked against renumbering Bugfixes File New In the path name also a dot is allowed now Print directly without preview No form feed anymore behind each line Profile List Window Strip Width is now also updated if the window is not active Output FEA LS Dyna Round off error in CONSTRAINED_ GLOBAL z Position is now fixed This causes correct sheet movement Profile Read CAD Contour Invisible colors now are replaced by visible colors Profile Read CAD Contour Also arcs with reverse rotation now are imported correctly PROFIL Rel 5 2 1 01 Mar 2015 New features Output FEA LS Dyna Others Guiding the first node row at the profile lead and tail end forces safe threading of the profile into the next roller stands and prevents up and down oscillation Output FEA LS Dyna Contact Check self contact starting with a preset stand number This is useful to avoid penetration in case the profile touches Itself Par
61. Simulation e With flat sheet Select this option if you want to analyse a project for the first time i e a result from earlier simulation does not exist e Restart behind stand If you detect after proceeding the simulation that a roll stand does not produce the desired result you can restart the simulation after modifying the rolls based on the result of the correct predecessor stand This saves computation time because successful simulated stands do not need to be repeated LOG LO5 L04 LO3 a LO1 case10 case20 case30 case40 case50 case60 Example Your project Example pro consist of 6 stands L01 LO6 and LO7 flat sheet additionally The first simulation starting with the flat sheet produces the files Example_case10 dynain correspondents to L06 until Example_case60 dynain Copyright 2015 by UBECO GmbH Iserlohn Reference 191 correspondents to L01 Hint In PROFIL the stands are numbered in designing direction in LS Dyna in sheet running direction Now you detect an error in stand L02 i e the simulation result Example_case50 dynain and all successive have to be repeated after modifying the roll of L02 Select in the file selection field Example_case40 dynain i e the simulation result that still was correct The following simulation will base on this result Start position in front of a stand in of the largest roll radius The simulation of a stand is finished if the front end of the sheet is just
62. Spacer Rolls 68 Shortcut Keys 81 Side Roll Mirror 120 Side Rolls Break Down Pass 167 Fin Pass 166 Similar Profiles Automatic Flower Creation 37 Searching for 33 Simulation of the Rollforming Process 29 Size Hole Cut Out 237 Slenderness 128 Sliding Interface Penalties 193 Small Shims Outside 68 Snapshot 146 Solid Elements 187 SolidEdge CAD Systems 257 Interface by ActiveX 260 Options ActiveX 77 Output 3D Model gt CAD 179 SolidWorks CAD Systems 257 Interface by ActiveX 260 Options ActiveX 77 Output 3D Model gt CAD 179 Space Mouse 204 Spacer Roll Roll Tool Window 245 Spacer Rolls Create 109 Creating 40 Options 68 Remove 110 Renumber 117 Splitting to Shims 40 View Show 149 Spacers Creating 40 Machine Window 220 Working Width 220 Spacers Autom Creating 40 Spacers automatic Options Drawing 62 Specific Weight 229 Speech Balloon Help 201 Copyright 2015 by UBECO GmbH Iserlohn Split Profile Element 102 Roll at Corner 117 Roll between Corners 118 Spring Back Arc Types 238 Profile List Window 210 St Venant s Drill Resistance 129 Stage 155 Stand 233 Append 92 Insert 91 Remove 93 Stand Name 220 Start Direction 226 Start Point 226 Start Positiont LS Dyna 190 Start LS Dyna 185 Statics Areaof Cross 128 Centroid 126 General 125 In Principal Axes 126 Inertial Radii 128 Max Distance 127 Moments of Inertia 127 Moments of Resistance 127 Principal Axes Angle 128
63. Width 10 000 Key Height 6 000 Key Depth of keyway in shaft 3 400 Key Depth of keyway in hub To assign a bore hole to a roll click with the mouse cursor into the input field Select the desired bore hole file within the file select window Copyright 2015 by UBECO GmbH Iserlohn Reference 213 3 3 6 4 3 3 6 5 3 3 6 6 If you want to create new bore hole files press Edit in the Expanded Roll Tool Window and select File Save as The data in the file currently are not yet utilized The bore hole file name can be used as a column of the Roll Parts List Furthermore the name is displayed in the Roll Tool Drawing within the bore hole Bushing Bushing belongs to the roll data and is displayed in the Expanded Roll Tool Window Bushing is the name of a file that e g contains these data BUSHFILE Bushing 80 000 Outer Diameter H7 Fit Roll E Fit Bushing To assign a bushing to a roll click with the mouse cursor into the input field Select the desired bushing file within the file select window Bushing is often used for idle rolls this means the roll is not driven This is why the mark Driven is removed when you select a bushing If you want to create new bushing files press Edit in the Expanded Roll Tool Window and select File Save as Bushing are separate entries is the Roll Parts List if this is set in Options Parts List Furthermore belonging bushing can be displayed i
64. a roll by using the function Roll Read CAD Contour or Roll Scan Profile Drawing The roll number can be incremented automatically when you split a roll by using the function Roll Split at Corner or Roll Split between Corners Select the Automatic Increment in Options Rolls for Copyright 2015 by UBECO GmbH Iserlohn 244 UBECO PROFIL Rollform Design Software 3 6 2 3 6 3 3 6 4 the roll number The roll number should not be engraved into the roll because later the roll could be installed in another stand if you want to re use the roll For engraving use the Part Number The roll number appears in the drawing in the Drawing Area and in the CAD output file which you generate with function Drawing CAD and determines the layer name Furthermore the roll number is inserted in the Parts List and determines the program number of the NC Program Part Number The part number belongs to the roll data and is displayed in the header of the Roll Tool Window For the part number all numbers and characters included special character are allowed If the rolls should be re used and the part number is engraved into the roll it is recommended not to code the profile project and the install location into the part number Pay attention that the part number is unambiguous this means allocate each part number only once The part number can be created automatically if you enter a number key into the dialog Options
65. and the strip width e Outer radii Inner radii are changed dependent on the new sheet thickness as well as the strip width because the straight lengths are changed e Radii on the reference point side The Reference Point always is on the sheet metal s bottom side near the profile s web center point By selecting this item the inner or outer radii keep constant that are on the same side as the reference point e Radii opposite the reference point side By selecting this item the inner or outer radii keep constant that are on the opposite side as the reference point If the selection Keeping constant sheet metal s line is applied on all passes different strip widths will result in the passes inevitably In order to avoid this select between two different methods for Keeping constant strip width by No rolls existing Check this item if no rolls exist or existing rolls should not be considered for the profile with new sheet thickness The selection which line should keep constant is applied on the final pass LO1 only All other passes are created newly by presetting the arc angles and arc bending methods from the origin flower pattern Thus all passes get the same strip width however the radii in passes L02 Lnn will differ from the constant line setting above If rolls exist they will not fit to the new profile contour This is why this setting makes sense only during flower design if rolls not yet exist Use existing rolls Select t
66. are set to the start point of the contour If you have selected another element the new profile elements will be appended to the existing ones without changing the reference point So you can append the second half of an asymmetrical profile behind the point P e Selection discharged or loaded by using the menu switch Profile List Loaded just as you have drawn the contour e Call the function Profile Read CAD Contour The window Window Read CAD Contour Copyright 2015 by UBECO GmbH Iserlohn 232 UBECO PROFIL Rollform Design Software 3 4 7 3 4 8 appears and you define the desired profile contour in this window Afterwards you get the profile list for the contour Check the profile list by using the function View Pass For generating a roll tool proceed the same steps but e Draw the contour by using and modifying the drawing of the profile which you have transferred by using the function Drawing gt CAD e Read the contour file by using the function Roll Read CAD Contour The window Window Read CAD Contour appears and you define the desired roll contour in this window The result is the roll tool with the desired roll contour Additions File The additions file contains the additions for diameter and width which are necessary for the calculation of the blank sizes out of the finished sizes The file is utilized when you call the function Output Create Parts List Section Roll Diameter The fi
67. be noticed easily if the running in profile is shown Calling the function Call this function optionally by e Main menu View Show Previous Pass or View Show Next Pass e Function key F6 for previous pass The function key assignment can be modified in Options Keyboard Shortcut Key Assignment Principle of operation By using this function the drawing of the previous and next pass can be inserted in the drawing of the Roll Tools of the current stand or in the drawing of the current Pass The previous and next passes always are displayed in the Inactive Color Setup in Options Drawing Colors of drawing area Printing and transfer to CAD is not possible Spacer Rolls Sp20x60 Sp10x60 SpSxttull Sp10x60 2402 SpSxtSp10x60 Sp20x60 Ps Ps1u 02 Spacer rolls are objects in the PROFIL object hierarchy like forming rolls and can be output dimensioned and modified as well They are necessary to fix the horizontal position of the forming rolls in case the whole working width of the machine is not used for forming rolls Because spacer rolls often are not manufactured but taken from a spacer stock the spacer rolls can be switched off for output as desired Calling the function Call this function by e Main menu View Show Spacer Rolls Principle of operation By using this switch you can switch off the spacer rolls temporarily in order not to display them in the Drawing Area and not to output them to CAD
68. before the next stand This is the start position for the simulation of the next stand as well Because the contact definitions for the next stand still are not effective the profile can penetrate the rolls is the front end is too close to the rolls and the simulation cannot be continued Enter the start position in of the maximum roll diameter 100 means maximum safety the front end never can touch any roll The simulation time however increases because for the first interval a lower velocity is set e In front of the 1st stand in sheet running direction In case Guiding the nodes of the profile reference point is selected see Others the sheet can start closer recommended is 50 In case is Guiding the node at the profile lead end selected see Others a larger distance must be selected e g 200 This is why the guide curves must start at zero displacement e In front of all other stands Recommended is 80 that prevents penetration If Guiding the first node row at the profile front see Others is used the profile can start closer to the rolls e g at 30 3 1 8 8 1 5 Material This dialog window is called by Output FEA LS Dyna is used for parameterizing the material properties the stress strain curve and for importing curves LT x LS D yna Profile Rolls Material File Ic PROFIL324ST14 mat Holes Cut Out Material Name sT1 4 Start Materia Description Bemerkungen Contact Young s Modulus 207000 N mm Othe
69. before you bend up the arc Q Bottom and top rolls are combined in one parts list row left and right side rolls however not Why A Also left and right side rolls are combined in case of equal values in all visible columns Check if they have the same designation Set Up in Options Parts List Set Up Columns Designation Copyright 2015 by UBECO GmbH Iserlohn 24 UBECO PROFIL Rollform Design Software want to use Docol DP1200 for roll forming Do you have the specifications for the material file I m sorry not If you want to calculate the stress of band edge or the PSA you only need to select a similar material from the material file Check and modify the yield stress dependent on the supplier s specifications If you want to calculate the spring back more effort is necessary You need the spring back factors from two bending experiments with two different inner radii More see PROFIL user manual Although checked Spacers in Options Drawing the spaces are not shown in the drawing Why not You probably forgot to fill out Working Width or Spacer Diameter in the machine window Without these data the spacers cannot be shown The window Options Files is disabled Why You have enabled ActiveX Uncheck the boxes in Options ActiveX Then you can set up the file interface In Options Rolls selected Keep Roll Part No for mirroring In the parts list the top and
70. body contains the serial and release number of your PROFIL version You can use it to ask for the price of the update Copyright 2015 by UBECO GmbH Iserlohn 202 UBECO PROFIL Rollform Design Software 3 2 Buttons 3 2 1 Button Key Bar Use the button key bar for quicker working So you do not need to open the pull down menus E New Project Open Project lan Save Project 2 Print i Profile Read CAD Contour or Roll Read CAD Contour q Roll Scan Profile Drawing 6 Profile Append Pa Machine Hd Window Visible Hidden A Statics Stress of Edge P Profile Catalogue or Roll Stock Management KA Undo C Redo ET Options Help Toolbox Profile Design 2 Toolbox Tube Design ES Toolbox Modify Toolbox Dimensioning Z Grid on off pg Dimensions on off Copyright 2015 by UBECO GmbH Iserlohn Reference 203 3 2 2 3 2 3 ory Inspect B View Pass A View Statics aE View Flower Nested H View Flower Separated View Flower 3D IT View Roll Tools PSA Profile Stress Analysis FEA View FEA Result ca QQ 0 Drawing gt CAD NE Drawing gt NC Dimensions on off This function switches all dimensions temporarily off and on again Calling the function Call this function by e Main menu Output Drawing gt CAD pg Button Dimensions on off in the Button Key Bar Principle of operation In position switched off the dimensions are no
71. button The columns of the material file are No Identification number of the material Material Name of the material K1 K10 Factors of spring back for inner radius thickness of sheet respectively 10 thickness of sheet c0 5 c1 c2 c3 c6 Critical minimum bending factors for the thickness of sheet 0 5 6 mm which are the base for calculating the minimum bending radius cn thickness of sheet In the Imperial System the critical minimum bending factors are called c0 02 c0 04 c0 08 c0 12 c0 24 and are valid for the thickness 0 02 0 24 in Re Stress at the yield point in N mm2 This size is used for calculating the relative stress of the band edge corresponding to the yield point from the strain of the band edge In the Imperial System the yield point has the unit psi pounds per square inch lb in2 E Young s modulus in 1000 N mm2 It is used for calculating the stress of the band edge from the strain of the band edge In the Imperial System the Young s modulus has the unit kips kilo pounds per square inch 1000 Ib in2 rho Density of the material in kg dm3 In the Imperial System the density has the unit pci pounds per cubic inch b in3 View the material file with the function Options Calculate Edit and select the desired material The same function can be used to enhance the file with new materials Be sure to use ascending numbering If the material file does not contain your desired material y
72. can compress the drawing in z direction sheet running direction for a better overview 1 0 means not compressed 0 2 means compressed to 20 z Scaling Text Height Tex Height 3 000 Select the text height for the table of statics the roll numbering and the dimension texts on the Drawing Area Profile Profile e Element Separator Lines select if the Profile Drawing should contain the following information e Element Separator Lines mark start and end of a Profile Element type L or A They are shown in Auxiliary Line Color Rolls Falls e Revolution Lines I Bore Lines Text Aligam Center select if the Roll Tool Drawing should contain the following information e Revolution Lines are the imagined lines to the Roll Corner Points These lines are useful for selecting a roll corner point by mouse click They are shown in Auxiliary Line Color e Bore Lines are displayed with the Diameter Shaft e Automatic Spacers are for fixing the horizontal position of the forming rolls PROFIL creates them automatically by filling the distance between forming rolls and the Working Width of the machine e Text Alignment Center The texts for Roll No Part No and Bore Hole can be aligned center instead of left Hint The difference between Automatic Spacers and Spacer Rolls is described in Creating Spacers Grid f 1 200 y 0 800 Select the grid lines distance and if the gri
73. causes an additional shearing stress of the profile Based on the vault resistance it is possible to calculate this composite stress See also Statics Copyright 2015 by UBECO GmbH Iserlohn Reference 129 3 1 5 1 13 Torsion moment 3 1 5 2 The torsion moment has for torsion stress a similar meaning as the moment of inertia for bending lt allows to calculate the effect of torsion shear stress from the cause of torsion applying torque M Mt max OWS M applied torque Jt torsion moment max maximum distance The profile will not be deformed if the appearing shearing stress is lower than safe working stress for torsion get values from material tables For exact interpretation the torsion moment is only defined for circular or similar profiles For thin walled profiles with any design the torsion moment can be replaced with proper accuracy by the St Venant s drill resistance PROFIL does it provided that the profile is open See also Statics Stress of Edge Stress of Band Edge Material 3 FE P02 G 275 NA Re 380 N mm2 Center Line Forming Ps Re osm eo co Calculation of stress of edge is step 1 of the three step concept for quality management This function calculates approximately the strain of the band edge and the resulting relative stress related to the yield point of the used material Thus you can check quickly whether the edge keeps or excee
74. center point and the radius keeps constant the angle will be increased or decreased The extension can be negative in order to get a smaller roll You define the amount either or e by width relative e to width absolute e to diameter absolute Y If the roll ends with a line an arched extension can be added with a selectable radius In this case the arched extension always is convex this means it points to the centerline of the roll Calling the function Before you call this function activate either the left or the right corner of the roll to define whether the extension should be left or right Call this function optionally by e Main menu Rolls Arched Extension e Context menu right mouse button click on the left or right corner of the desired roll in the Drawing Area Arched Extension The input window appears and asks Give width for the arched extension or Give diameter for the arched extension In case of Width you can select between relative By Width and absolute To Width In case of By Width the input can be negative in order to get a smaller roll Input a Give Width for the Arched Extenzion 4 000 f By Width relative f To Width absolute 3 Cancel Help If the roll ends with a line an additional input window appears and asks Give radius for the Copyright 2015 by UBECO GmbH Iserlohn Reference 113 arched extension Principle of operation The a
75. dependent on the selected width e Width gt 1 5mm 0 075in Large radius 8mm 0 4in small radius 0 5mm 0 025in e Width lt 1 5mm 0 075in Large radius 5mm 0 25in small radius 0 3mm 0 015in Hints If the message appears Double fillet not possible for this roll geometry the reason is e The distance to the neighboring roll corner point or to arc start point of this corner point is too small Copyright 2015 by UBECO GmbH Iserlohn 114 UBECO PROFIL Rollform Design Software 3 1 4 9 e In case of conical rolls the angle from the selected to the neighboring roll corner point is too large Clearance Angle Clearance Angle What is a clearance angle Clearance angle means the inclined flank of a roll top roll in the picture above is rotated by a small angle normally 1 2 degree around the Roll Corner Point Thereby an acute gap opens between roll and sheet The more the circumferential soeeds of top and bottom rolls differ the larger is the gap width What a clearance angle is required for There a two reasons why a clearance angle should be provided e Balancing of different circumferential speeds in case of the roll diameter ratio does not fit to the gear transmission ratio e Avoiding wedging thereby better flowing transversal moving of the profile legs into the stand We will discuss these two reasons now Balancing of different circumferential speeds Each r
76. drawing is plotted by using the selected Scale If the plot range of your output device is smaller than the drawing only the center part is plotted Better use Scaled To Fit instead Scaled To Fit The size of the drawing is reduced or extended in order to fit the maximum plot range of the output device Scale The drawing can be sent to the output device by using one of the following fixed scales 20 1 0 1 J 5 1 2 1 Copyright 2015 by UBECO GmbH Iserlohn Reference 57 3 1 1 12 3 1 2 3 1 2 1 a ee 1 2 5 1 10 1 20 Select the scale from the drop down list so that the drawing fits the sheet If you don t find a practical scale select User and enter the desired scale into the input window e g 3 000for scale 3 1 0 250for scale 1 4 EA Drawing gt CAD Use this button to transfer the assembly drawing to the CAD system The settings of the function Drawing gt CAD in the PROFIL main window are used as well If you do not want to transfer a drawing template use an empty DXF file as template fi ii Plot The Windows print dialog opens and you can select the desired output device e amp Reset Use this button to undo all modifications and to start newly e x Cancel Closes the window Hints e The functions File Print Preview or File Print can be used to print the drawing and further information e The function Edit Copy can be used to copy the drawing that is displayed
77. e g in case of complicated profiles use the function View Flower separated Copyright 2015 by UBECO GmbH Iserlohn Reference 139 3 1 6 4 3 1 6 5 Flower Separated AA me Use this function to display the flower pattern separated of the profile project in the Drawing Area Separated means the webs of all passes have different y coordinates Calling the function Call this function optionally by e Main menu View Flower Separated L e Button View Flower Separated in the Button Key Bar Principle of operation The flower pattern of the project is displayed separately in the Drawing Area This kind of display has the advantage that the flower pattern is shown more clearly in case of complicated profiles Settings are the same as described in View Pass Hints e The Navigator helps you to zoom to move and to fit the drawing e Use the Toolbox Modify to bend the profile up and down and to modify the size of the profile e With the function Output Drawing gt CAD you can transfer the drawing to your CAD System e Another kind of displaying the flower pattern is View Flower Nested View Flower 3D Flower 3D Use this function to display the flower pattern 3D of the profile project in the Drawing Area The passes are displayed in a perspective view So you are able to examine if the course of the band edge is smoothly without detou
78. filter conditions If no roll is displayed no suited roll exists or the allowance is too small Now browse through the rolls and select a suited one Press the button Copy Roll to Clipboard and change to the main window Select the shaft and insert the roll from the clipboard by using the function Roll Insert Move the roll to the correct position function Roll Move If you observe however that the roll is not suited delete it again function Roll Delete and search for a better one Adapting the Roll Tools If necessary you can modify the roll by using the functions of the pull down menu Roll Conical Extension Cylindrical Extension Arched Extension Split at Corner Split between Corners Join Turn Move Mirror Cut Copy Paste Delete To modify single roll corner points use the Toolbox Modify After selecting the desired roll corner point select Width Diameter or Radius in the toolbox and click on the arrow buttons for stepping the value up or down A Clearance Angle is used to reduce wear out of rolls if the rolls have different circumference speeds because of the different heights of the legs of the profile By using the function Gap the clearance angle can be continued in the successive profile segments Check by using the function View Show Previous Pass if the profile is treated correctly by the rolls and if no conflict occurs Creating Spacer Rolls Spacers red see picture are bushings that are mount
79. filter is switched off or a subset of the profiles if the filter is switched on Each row of the table displays the project data of the Profile Project Customer Date Description Name Drawing No Revision Material Thickness Machine Further columns contain the profile data of the Profile List Strip width Direction From the profile geometry are calculated e Width Total width of the profile e Height Total height of the profile Furthermore are displayed e Project Path This entry is used for quick access to the project by button Open Profile Project The maximum field length is 40 Please consider that quick access only works if the path length does not exceed the maximum length Columns for manual input are e Classification Organize the profiles in user defined groups dependent on the geometry Assign a classification key to each group This is useful for searching for special kind of profiles User def col of the profile catalogue Title of column 1 User 1 Tithe of column 2 User 2 Title of column 3 User 3 e User 1 3 Define the meaning of these columns by yourself Enter suitable titles for these columns in Options Database Filtering for these columns is possible too The belonging profile elements of the selected profile are displayed in the Profile Element Table Use a Filter to reduce the amount of displayed profiles The drawing of the selected profile is not stored in the database while browsing t
80. from Options Spacer Rolls button More is the input field Material inactive Enter the material in then Machine Window Spacers instead The material file name can be used as a column of the Roll Parts List Treating Surface Addition Remark Treating Surface Addition Remark are additional data the field names of which can be defined by the user in Options Rolls Button More They belong to the roll data and are displayed in the Expanded Roll Tool Window PROFIL remembers new entries into these data fields later you can recall them from a drop down box by mouse click on the arrow symbol If you want to remove an entry from the drop down box recall the entry and press Del on the keyboard Touching the Profile at This switch belongs to the roll data and is displayed in the Expanded Roll Tool Window The information is needed when you call the FEA simulation by using the function Output FEA and is used for optimizing the computation time of the simulation Top Bottom Side If this switch is set the FEA system checks the contact between the roll and the top bottom side of the strip Edge With this information the FEA system checks the contact with the edge of the strip sheet thickness If there is contact at the top bottom side AND the edge both switches can be set in principle To optimize the computing time it is a good idea to split the roll in that way that each partial roll has either contact at top bottom side OR at edg
81. g 111 5 x 56 0 52 0 4 3 2 0 RightRol 401 A4865 RO1 R1 2080 g 111 5 x 56 0 52 0 4 3 2 0 RightRol 401 A4865 R02 R1 2080 116 5 x 47 0 52 0 3 9 1 7 LeftRoll 301 A4865 R02 L1 2080 BD 116 5 x 47 0 52 0 ETRS 1 7 BottomRol 102 A4865 R04 U2 2080 BD 126 5 x 41 0 50 0 4 0 2 8 BottomRoll 101 A4865 R05 U1 2080 BD 126 52 x 70 0 50 0 6 9 4 7 BottomRoll 102 A4865 R05 U2 2080 BD 126 52 x 70 0 50 0 6 9 4 7 BottomRoll 102 A4865 R03 U2 2080 131 5 x 43 0 50 0 4 6 Sl BottomRol 101 A4865 R01 U1 2080 131 59 x 65 0 50 0 6 9 Syl BottomRoll 101 A4865 R02 U1 2080 T3175 x 65 0 50 0 6 9 5 0 TopRol 202 A4865 R01 02 2080 162 0 x 23 0 50 0 St Jeo BottomRoll 103 A4865 R04 U3 2080 172 0 x 68 0 50 0 12 4 I9 BottomRol 101 A4865 R04 U1 2080 172 0 x 68 0 50 0 12 4 IO TopRol 202 A4865 R02 02 2080 182 0 x 44 0 50 0 9 0 6 7 TopRol 201 A4865 R03 01 2080 VD 182 0 x 55 0 50 0 11 2 54D TopRol 202 A4865 R03 02 2080 VD 182 0 x 55 0 50 0 11 2 579 TopRol 202 A4865 R04 02 2080 VD 182 0 x 65 0 50 0 1343 7 4 TopRol 201 A4865 R04 01 2080 YD 182 0 x 65 0 50 0 1373 7 4 TopRol 201 A4865 R05 01 2080 VD 182 0 x 70 0 50 0 14 3 99 TopRol 202 A4865 R05 02 2080 g 182 0 x 70 0 50 0 14 3 9 9 LeftRoll 301 A5865 R05 L1 2080 BD 202 0 x 36 0 52 0 9 1 6 5 RightRol 401 A5865 R05 R1 2080 BD 202 0 x 36 0 52 0 9 1 6 5 BottomRoll 101 A4865 R03 U1 2080 BD 202 0 x 57 0 50 0 14 3 9 4 BottomRoll 103 A4865 R03 U3 2080 BD 202 0 x 57 0 50 0 14 3 9 4 53 395 1 23 6 5 Use this function to g
82. has enough space for all fillet radii The result is rounded to 10 mm or 1 in e Fillet Radii R1 R2 Select a fillet radius at the inside at the tube and a fillet radius at the outside at the roll edges e Shoulder Height SH Enter the height of the shoulder which should lead the edge of the sheet Working diameter and reference point are taken from the Machine Data Copyright 2015 by UBECO GmbH Iserlohn 168 UBECO PROFIL Rollform Design Software 3 1 7 3 Principle of operation After pressing the Ok button the roll is generated If a roll is yet existing it will be replaced Modify Use the Toolbox Modify to bend the profile up and down to modify the size of the profile and to modify the corner points of the rolls Calling the function Call this function optionally by e Main menu Toolbox Modify e L Button Toolbox Modify in the Button Key Bar One of these buttons are shown at the right screen edge dependant on you just are designing the profile the flower pattern or the rolls Content o RL L AY Y Angle Radius Length These switches are visible in the left column of the Toolbox Modify if you have selected a single pass or a pass of the flower You can modify the Angle the Radius or the Length of a Profile Element To modify an angle or radius you must have selected an arc either by clicking into the Drawing Area or in the Profile List Window The profile element will be bent
83. if the bottom shafts are not adjustable Calling the function Change Machine Data When you are going to modify the working diameter select in Options Rolls Changing Machine Data Keep Roll Data if the rolls or if the roll contour only should keep unchanged during this operation Modify the reference point optionally by e EE Machine Window Working Enter the new working diameter for the selected stand and shaft type e Context menu right mouse button click on a roll or shaft dash dot centerline in the Drawing Area Modify working diameter if you wan to enter a new working diameter e Context menu right mouse button click on a roll or shaft dash dot centerline in the Drawing Area Calculate working diameter from transm ratio if the new diameter should be calculated from the Transmission Ratio and the working diameter of the opposite roll Copyright 2015 by UBECO GmbH Iserlohn Reference 223 3 3 8 12 TS as New Working Diameter Bottom Aall 120 000 Keep Rall Data f Adapt rolls by keeping working contour x Cancel Help After calling the function the input window appears with the question New Working Diameter In case of Modify working diameter the topic working diameter is shown and can be modified In case of Calculate working diameter from transm ratio the result of the calculation is shown and can be confirmed or modified Furthermore the topic setting of the switch Changing
84. in an input field activate it and press the Pg Up Dn keys on the keyboard If you have opened further windows e g statics window or stress of band edge window the contents will simultaneously be updated Also the drawing will be updated Set the step interval for the modification in Options Mouse Click into a row of the table and the corresponding profile element in the Drawing Area will be highlighted in the predefined mark color Vice versa if you identify a roll corner point in the drawing the corresponding row of the table in the profile list window will be activated Copyright 2015 by UBECO GmbH Iserlohn 210 UBECO PROFIL Rollform Design Software 3 3 4 All values are shown in mm if you have selected in Options Profile List the representation of values Metric If you have selected Imperial they are shown in inch Hint In certain input fields further functions are available from the context menu right mouse button e Cut Copy Paste Delete Enables transfer of parameters via the clipboard e Copy To All Copies the selected parameter to the corresponding input field in all other profile lists e Calculator Opens the Calculator and copies the selected parameter to it s display After closing the calculator the result is transferred back to the input field Press the Enter or Tab key afterwards Spring Back AE 02 Pass 0 200 000 Dist Stand 300 000 y0 150 000 Strp Width 105 456 Direc
85. in the Button Key Bar Principle of operation If the box Separate Files in Options NC is not checked always the same temporal file is created Otherwise a file with all rolls of a stand is created Afterwards you have to load the file into your NC system Copyright 2015 by UBECO GmbH Iserlohn Reference 179 Setup Output DF File Whole Project in Sep Files Build Filename from Rall He fi Part Hic Jum over Aol Filename for Entire File CAPROFIL D ataEngsProfil DF Path for Separate Files CAPROFIL D ata Eng Which filename and which path are to be used select in Options NC Hints e In order to create a set of different files sequentially better use the Export function e Select by View Show Spacer Rolls whether the NC output should contain spacer rolls 3 1 8 3 3D Model gt CAD Example 3D model in SolidEdge transfer by STEP file This function creates the 3D model of the current profile pass the roll of the stand that is shown in Copyright 2015 by UBECO GmbH Iserlohn 180 UBECO PROFIL Rollform Design Software the Drawing Area or of all stands of the whole project The model is transferred to AutoCAD or SolidWorks via ActiveX The function needs AutoCAD R14 or higher or SolidWorks 2003 or higher respectively The ActiveX interface must be enabled in Options ActiveX Alternatively a STEP file in accordance with DIN ISO 1030
86. increment it is necessary that the last digit or last two digits are numeric Enter a fixed term e g b01 for the first roll of the bottom shaft or a combination of a Variable and a fixed term e g PLb01 Example If you enter PSb01 into the input field Bottom Roll Roll No the first bottom roll of the 7th pass will get the roll number 7b01 Scan Profile Drawir Edge rounding 0 500 Edge rounding Enter the radius fillet for the first and the last corner of a roll when you create a roll automatically by using the function Roll Scan Profile Drawing Scan Profile Drawing Change Machine Data Copyright 2015 by UBECO GmbH Iserlohn 68 UBECO PROFIL Rollform Design Software 3 1 2 8 7 Change Machine Data Keep Roll Data Select what should happen with the rolls of your current project when you modify the Machine Data working diameter reference point inclination angle or if you select another machine e If checked the roll data keep unchanged but the position of the rolls will change dependent on the new machine data Possibly the rolls do not touch the profile anymore e f not checked the working contour of the rolls will be retained but the center line and the sides of the rolls will change This means the rolls touch the profile at the same points as previously but the size of the rolls is changed Mirror Copy Rolls e Keep Aoll Part No Keep Roll Part No If checked the rol
87. is guided straightaway with constant intersection point of the tangents Select if the intersection point of the tangents inside or outside of the arc should be constant Addition Part Previous Segment Select how much of the length should be added to the previous segment The remainder is added to the next segment If Track Holding is set this input field is not active Modify angle constant radius With this setting A4 works like A2 and A3 by keeping the radius constant if a new angle is entered Modify angle and radius For special needs an arc can be bent open by entering a new angle and a new radius see Arc Types Case of application is to compensate the springback and to minimize the end flare effect Calc M DIN 6935 Calc M DIN 6935 f by table E by formula In DIN 6935 a method defined by a table and a method defined by formula is described Select if you want to use the method by table or by formula The setting will take effect when you select the calculation method DIN 6935 in the Project Window Copyright 2015 by UBECO GmbH Iserlohn Reference 67 Representation of values Representation of Values Integer Decimal Places fa a e Metric N mm f Imperial Ib ir Integer Decimal Places Set the number of integer places digits left of the decimal separator and the decimal places digits right of the decimal separator for the representation of values in the data windows For normal
88. means no stress and 100 means the yield point stress is reached 3 1 2 8 15 Keyboard Use this window to assign shortcut keys to any menu item Assigning Shortcut Keys Assigning Shortcut Keys File Open Project FileSave Project F2 Ple Save as FilePartial Project4dd On FilePartial Project Save as File riport File Esport FilePrint Preview m mI A Menu ltem Shortcut Kep File Print Fs Assign Remove All menu item are listed behind the equal sign the currently assigned shortcut is displayed If you select an entry menu item and shortcut are copied to the fields below for modifying the assignment Menu Item This field shows the selected menu item Shortcut Key This field shows the shortcut key that is currently assigned to the selected menu item To enter a new shortcut set the cursor into this field and press the desired shortcut on the keyboard These shortcuts are possible F2 F12 F1 is reserved for the context sensitive help Shift any character Ctrl any character Alt any character Alt Gr any character Assign Assigns the new shortcut key to the selected menu item If the shortcut is yet assigned to another menu item a message is displayed Remove Removes the shortcut from the selected menu item Copyright 2015 by UBECO GmbH Iserlohn 82 UBECO PROFIL Rollform Design Software 3 1 2 8 16 Mouse 3 1 3 3 1 3 1 Wheel Mouse Wheel Mouse
89. modified mutually independently Calling the function Call this function optionally by e Main menu Edit Draft Modus Principle of operation Draft Modus checked Use this setting while Designing the Profile if modifications of the Profile List are necessary You can modify angles and radii of Arc Segments without changing the corresponding other value and without changing neighboring segments this means the Bending Methods A1 A4 are not considered The straight length and with it the strip width is changed necessarily The switched on draft modus is displayed by a changed background color The draft modus is switched off again automatically if you select another view or if you open another project The picture shows an example wherein inner radii and angles has been modified mutually independently in the top cross section The bottom cross section shows the result Draft Modus unchecked Use this setting for Designing the Flower Pattern after Designing the Profile is finished By modifying angles and radii of arc segments the arc is bent or unbent dependent on the Bending Methods A1 A4 During this operation the Strip Width the sum of the straight Lengths of all profile segments keeps unchanged The background of the Drawing Area has the color that is selected in Options Drawing Colors of Drawing Area Background 3 1 2 7 Explorer E Or E E Or Fin Ses 3 ad Pass 7 al Fin Pass 2 a Pass 6 Fin Pass 1 E 4 LOS ad
90. new projects If a file is opened that was created from another project possibly bending angles appear in a column whose header entry is not an arc This is why the structure of the current project shown in the header row does not fit to the structure of the development table from the file shown by the bending angle sequence in the table In this case it is necessary to adapt the structure of the table by using the functions Development Table Column Development Table Create from current project The Angle sequence of the currently opened project is inserted to the table the angles are in degree first Furthermore the Bending Methods are inserted toggle by Development Table View Bending Method Thus the table length is adapted the row count is the number of profile lists passes stands Name and path of the project file is inserted to the remarks editor furthermore customer designation and drawing number Development Table Apply and Create Flower Pattern From the development table the Automatic Flower is created for the currently opened Profile L01 including e The target profile list structure of the new profile must be the same as the source structure this means the angles of the development table must be in the angle columns A1 A4 in the table header If it isn t you can adapt the table by using the function Development Table Columns e Ifan angle entry is below a line header entry L the line is converted to a
91. of the roll radius without changing the axial component Hint e The roll reference point can be set independently from the Profile Reference Point Usually both reference points are set to the same coordinate Inclination Angle A e A ad a gt ea ae es gee eg ee ne The inclination angle belongs to machine data and is displayed in the bottom part of the Machine Window for each shaft Bottom top rolls The normal shaft position is horizontal inclination angle 0 In special cases e g if subsequent processing of the profile behind the exit of the roll forming machine needs a certain angular positioning it is not possible to turn the profile to the optimal angle required for roll forming purposes Thus it is necessary to turn the machine shafts in the optimal angular position A positive inclination angle rotates the shaft counterclockwise a negative clockwise see picture Side rolls The normal axle position is vertical inclination angle 0 A positive inclination angle rotates the shaft to the outside an negative to the inside see picture Calling the function Change Machine Data When you are going to modify the inclination angle select in Options Rolls Changing Machine Data Keep Roll Data if the rolls or if the roll contour only should keep unchanged during this operation Select stand shaft axle Modify the inclination angle optionally by H Machine Window Incl Angle Enter the new inclination angle either posi
92. optionally by e Main menu File Save Profile Project e la Button Save Project in the Button Key Bar e Function key F2 The function key assignment can be modified in Options Keyboard Shortcut Key Assignment Principle of operation The Profile Project is saved to the project file with the extension pro Before saving the old pro file is renamed in a backup file BAK Hints e The function is active only if changes have been done e f you forgot to save the data PROFIL will remind you to save before exit e Before saving the old pro file is renamed in a backup file BAK automatically In case an error occurs during saving or you saved the file erroneously after unwanted modifications you can restore the old content by deleting the new pro file and by renaming the BAK file to pro Save as Use this function to save the Profile Project into another file Calling the function Call this function by e Main menu File Save as The window Profile Project Save as appears Profile projects have the file extension pro In the top area of the window you can change the path or drive if needed After entering or selecting a file name the project will be saved Principle of operation The Profile Project is saved to the project file with the new name and the extension pro Furthermore the name of the current profile project is changed The new name is displayed in the head line of the main window Hint See al
93. profile element behind the current one use the function Element Append e To remove a profile element from the profile list use the function Element Remove e To copy profile elements to the clipboard use the function Element Copy 3 1 3 16 7 Append Pass xi 200 000 Pass x0 200 000 Dist Stand 300 000 pb 150 000 Dist Stand 300 000 y0 150 000 Strp Width 62 887 Direc Strp Width 62 887 Direc i i Radius dis Anale dis StLenath L Di Radius dis Anale dis StLenath 1 11 000 2 000 90 000 2 000 90 000 4 444 16 000 Use this function to append a new empty Profile Element or a set of profile elements from the clipboard behind the current position Numbers of the following elements will be increased by the count of appended profile elements Copyright 2015 by UBECO GmbH Iserlohn 104 UBECO PROFIL Rollform Design Software Calling the function Before you call this function select the profile element Call this function optionally by e Main menu Profile Element Append e Context menu right mouse button click on the profile element in the Drawing Area Profile Element Append Principle of operation If you call this function and the clipboard contains profile elements you are asked Clipboard contains profile element s Paste and in the next line a list of element types are shown e g L
94. profile size in metric system unit mm use 4 integer places and 3 decimal places If you design imperial unit inch use 3 integer places and 4 decimal places For very small profiles we recommend to increase the decimal places by 1 For very large profiles it is better to decrease the decimal places by 1 Metric Imperial Select if PROFIL should work in the Metric System Units mm N or in the Imperial System Units in lb In case of change you should set the decimal places too 3 1 2 8 6 Rolls Use this function to set the parameters for creating forming rolls Number Keys Number Keys Autom Increment fw RollNo fw Part No Bottom Foll PLu01 PR Ps P5 1 01 Top Roll PLo01 PR P24PSo 01 Left Roll PLI01 sPR PSSPSI 01 Right Fall PLrO7 PR PstPSr 01 Use this function to set the keys for the automatic numbering of the roll number and the part number when rolls are created newly If you want to use the number keys for existing rolls call the function Roll Renumber Autom Increment Select if the roll number and the part number should be incremented automatically number 1 when you split a roll with the function Roll Split at Corner and Roll Split between Corners Precondition the last digit must be numeric 0 9 Bottom Roll Top Roll Left Roll Right Roll Select the roll and part number for the roll which you will create with the function Roll Read CAD Contour and Roll Scan Profile Drawing For the automatic
95. profile web 95 LS Dyna Export 51 FEA Simulation 29 Output FEA model 185 View FEA result 143 LS PrePost 29 MO1 File 230 Machine Edit 59 Explorer 218 File 230 Name 207 219 Machine Data 43 Machine File Export 51 Import 50 Machine Window Calibrating Factor 221 Deformation Degree 221 Diameter Shaft 222 Distance between Stands 221 General 216 Inclination Angle 225 Machine Name 219 On Off 59 Reference Point 223 Spacers 220 Transmission Ratio 219 Working Diameter 222 Working Width 220 Main Line Color 64 Manufacturing Data 41 Marked Color 64 Marx Hardlock 259 Mass Scaling LS Dyna 193 Output FEA ABAQUS 194 View FEA ABAQUS 145 Material Copyright 2015 by UBECO GmbH Iserlohn 270 UBECO PROFIL Rollform Design Software Material Additions File 213 Expanded Roll Tool Window 211 File 229 Project Data 207 Spacer Rolls 109 Spacers 220 Max Diameter 245 Max Distance 127 ME10 CAD Systems 257 Interface 261 Mean Energy Ratio 145 Measure 171 Meshing LS Dyna Holes Cut Outs 189 LS Dyna Profile 187 LS Dyna Rolls 189 Options PSA 80 Output FEA ABAQUS 194 Metric 66 MI Export 51 Options Files 75 Mirror Profile 84 Roll 120 Modify Reference Point 90 Sheet Thickness 87 Start Element 85 Strip Width 89 Strip Width Sheet Thickness Options 65 Toolbox 168 Moments 194 of Inertia 127 of Resistance 127 Motion Controller 204 Mouse 82 Move Dimension 177 Move Roll
96. project data Enter your name the first time you create a new project Later your name is automatically set See also Profile Project Revision The revision date belongs to the project data If you save the profile project by using the function Save Project the revision date is automatically set with the current date See also Profile Project Thickness The sheet thickness belongs to the project data Enter the sheet thickness before you use the function Profile Read CAD Contour or before opening a basic profile from the Toolbox Profile Design If you want to modify the thickness afterwards call the function Modify Sheet Thickness or enter the new thickness directly in the input field Thickness In both cases a dialog window opens and you can select which radius should be kept constant during this operation See also Modify Sheet Thickness See also Profile Project Calculation Method The calculation method belongs to the project data Select which Calculation Method should be used for the calculation of the straight length of the arc elements and the strip width of the whole profile The Oehler and the DIN 6935 methods have been implemented Calc M DIN 6935 f by table C by formula In Options Calculate Calc M DIN 6935 you can select if the length should be calculated by by Copyright 2015 by UBECO GmbH Iserlohn Reference 209 3 3 3 Table or by Formula Furthermore you can select Use
97. reference point by the sheet thickness If in the Machine Window both input fields x and y for the top rolls are empty respectively 0 the reference point for the top rolls is moved upwards automatically by the sheet thickness from the reference point of the bottom rolls This way can be used to create top rolls with a desired diameter independently from the sheet thickness Calling the function Change Machine Dat Copyright 2015 by UBECO GmbH Iserlohn Reference 225 3 3 8 13 When you are going to modify the reference point select in Options Rolls Changing Machine Data Keep Roll Data if the rolls or if the roll contour only should keep unchanged during this operation Modify the reference point optionally by e E Machine Window Ref Point x Ref Point y Enter the absolute drawing coordinates e Context menu right mouse button click on a roll or shaft dash dot centerline in the Drawing Area Modify Reference Point Select axial and radial axial only or radial only and choose the new reference point by clicking onto a drawing element The nearest end point is caught Principle of operation e Axial and radial The reference point is set to the nearest end of the selected drawing element e Axial only The reference point is moved axially i e in the direction of the roll centerline without changing the radial component e Radial only The reference point is moved radially i e in the direction
98. roll to another Windows programs is not possible use the function Edit Copy instead Copyright 2015 by UBECO GmbH Iserlohn 122 UBECO PROFIL Rollform Design Software 3 1 4 19 3 1 4 20 Copy Use this function to copy a roll to the clipboard The origin roll remains unchanged Calling the function Before you call this function identify the roll by clicking any Roll Corner Point of the roll Call this function optionally by e Main menu Rolls Copy e Context menu right mouse button click on the certain corner point of the desired roll in the Drawing Area Copy Principle of operation The roll is copied to the clipboard From the clipboard you can insert the roll at any position also to another shaft or to another stand by using the function Roll Paste In this way you also can duplicate a roll Furthermore in this way you can transfer a roll into the Roll Stock Management Hint e Transferring the roll to another Windows programs is not possible use the function Edit Copy instead Paste Use this function to insert a roll from the clipboard into a set of rolls Precondition You have stored a roll to the clipboard by using function Roll Cut or Roll Copy Furthermore in this way you can mount a roll from the Roll Stock Management into your current project This description assumes that all your bottom and top rolls have the first Roll Corner Point at the left side To reach this during
99. selected by button Inspect or by the right mouse button the loading of all arcs of the current profile list is switched on and off The status of the switch is displayed by a yellow coloured background of the table fields in the profile list window to watch this select with spring back in Options Profile List The selected status of the switch is saved into the file of the Profile Project The pass that is displayed in the drawing of the Roll Tools and the calculation of the Stress of Band Edge is also dependent on the status of the switch Hints e The Statics is calculated for the discharged state only e Furthermore you can select if you want to design a profile pass or the roll tools discharged or loaded Set the switch to the desired status before you use the functions Profile Read CAD Contour or Roll Scan Profile Drawing Copyright 2015 by UBECO GmbH Iserlohn Reference 95 3 1 3 13 Center Line Forming Bottom line forming left and center line forming right with lowering to constant centroid s height 100 Center line forming also is called Downhill Forming or Natural Forming In order to decrease the way of the band edge and with itto decrease the stress of band edge it is recommended to lower the profile web from pass to pass This means the flat strip enters into the machine in a higher position than the web of the final profile leaves the machine This can be done by modifying the YO value of
100. split at the selected roll corner point in two partial rolls If the selected corner point has a Fillet Radius the radius will be set to zero Hints e f you want to undo splitting use the function Join e To split a roll between two corners use the function Split between Corners EN Use this function to split a roll between two Roll Corner Points Split between Corners Calling the function Before you call this function identify the previous Roll Corner Point Call this function optionally by e Main menu Rolls Split between Corners e Context menu right mouse button click on the left or right corner of the desired roll in the Drawing Area Split between Corners Give Width for the Split Position of the Roll 2 000 19 000 10 000 I Cancel Help The input window appears with the question Give width for the split position of the roll and an admissible range of values for the input which begins at the end of the last fillet and ends at the beginning of the next fillet The width is related to the Roll Reference Point In the input field appears the rounded mean value as a proposal You can modify this proposal or overwrite it If two fillets touch one another the roll will be split at the point of tangency and the input window will not appear Principle of operation The roll is split at the entered width behind the selected roll corner point in two partial rolls Both partial rolls get the sa
101. stand separately All rolls of the current stand are printed each roll on a separate page All rolls of the project separately All rolls of the whole project are printed each roll on a separate page Hints e Select in File Print Preview previously what should be printed and set up the printer and the font The settings are used for all later print outs with the function Print e The function File Plot can be used to print or plot the Roll Assembly Plan e The function Edit Copy can be used to copy the drawing that is displayed in the Drawing Area to the WINDOWS clipboard From this it can be pasted to any other WINDOWS program in order to print it 3 1 1 11 Plot 10 Wa sae PS AA Lun an 1 5 a a A E A A This function creates the Roll Assembly Plan that shows the mounted rolls and the separated rolls with dimensioning in addition A prepared Drawing Template from a DXF file is opened and the stand drawing is created in the center Then the rolls just can be picked up by mouse click and copied or moved to another position and rotated or mirrored at the x and y axis The dimensioning can be switched on and off as desired The title block of the drawing is filled out automatically Afterwards the drawing template can be saved This means instead of the rolls and the title block entries Variables are saved as placeholders When the template later is reopened from another stand the variables are replaced again by
102. start the INI file has priority however If the INI file is not available e g in case of network the settings from the Registry are used Load Save INI file settings once Buttons for loading and saving the setting from and to respectively the INI file INI file name Select path and name of the INI file If necessary you can select a network path as well Text Editor Text Editor NotePad Several PROFIL function need a text editor If you do not want to use the WINDOWS NotePad you can set up another one After mouse click on this input field the file select window opens and you can select the EXE file of the desired text editor Take care that the text editor saves files in pure ASCII format Open Project and Explorer with preview i Open Project and Explorer with preview While working with larger projects the screen refresh takes more time because refreshing the preview pictures is necessary after each modification This may impede quick working Simply switch off the preview Drawing Use this function to set the parameters for views and drawings View Flower 3D Copyright 2015 by UBECO GmbH Iserlohn Reference 63 View Flower 30 fo 4y go 0 135 0 300 Select the angle for the View Flower 3D View PSA Profile Stress Analysis and View FEA Result The angle means 0 to right side view 45 to upper right 90 to upper 135 to upper left By using the z scaling factor you
103. the functions of the menu Roll Scan Profile Drawin Edge rounding 0 500 Select in Options Rolls Scan Profile Drawing the fillet radius of the automatic edge rounding at the left and right edge of each roll Setup Hints Further function for creating rolls are e Import contour from CAD by Roll Read CAD Contour e Import an existing roll from CAD by Roll Read CAD Roll e Import roll from the Roll Data Base Copyright 2015 by UBECO GmbH Iserlohn Reference 109 3 1 4 4 Spacer Rolls 3 1 4 4 1 Create Spacer Rolls Sp20x60 Sp10x60 SpSxt2ull Sp10x60 2u02 SpSxtSp10x60 Sp20x60 Pstu 01 Ps1u 02 Spacer rolls are needed to fix the horizontal position of the forming rolls on the bottom and top shaft They have a smaller diameter than the forming rolls and do not touch the profile After designing the forming rolls the widths of the spacer rolls result from the residual space between the forming rolls and the machine stand Calling the function Call this function optionally by e Main menu Rolls Spacer Rolls Create e Context menu right mouse button click on a roll in the Drawing Area Spacer Rolls Create If the bottom or top shaft is selected by mouse click on an existing roll the spacer rolls will be created for the selected shaft only Otherwise if nothing is selected button Inspect both bottom and top shaft will be furnished with spacer rolls If spacer rolls already exist a dia
104. the roll which is selected in the Roll Table Window at the bottom Each line of the table displays the data of one roll corner point These are the corner point number and the data from the table of the Roll Tool Window Width Diameter Radius Angle These data are automatically transferred when a roll is inserted into the database or when a roll is taken from the database The belonging projects of the selected roll are displayed in the Project Table Use a Filter to Copyright 2015 by UBECO GmbH Iserlohn 254 UBECO PROFIL Rollform Design Software 3 8 3 3 8 4 reduce the amount of displayed rolls The drawing of the selected roll is displayed in the Drawing Area The top bar of the roll corner table contains these buttons Roll Corners Projects These buttons change the whole area of this part of the window so that the belonging Projects of a roll can be displayed ey 2 41 2 Database Navigator for switching to the first previous next last corner point for inserting deleting and editing a corner point for posting and cancelling the edited data and for refreshing the data e g if in a network several designers use the same database Project Table The left area in the middle of the Roll Stock Management Window displays the belonging projects of the selected roll in the Roll Table at the bottom Each row of the table displays the data of one project These are the project number the project n
105. the rolls and title information from the new stand Since Copyright 2015 by UBECO GmbH Iserlohn 56 UBECO PROFIL Rollform Design Software the drawing template is a DXF file it also can be modified by using any CAD system if desired The created roll assembly drawing can be plotted directly without the help of a CAD system It also can be transferred to any CAD system to plot it from there in case further additions are necessary A third feature is to copy the drawing to the Windows clipboard in order to paste it into any other program When in the course of time a collection of drawing templates for different kinds of roll forming stands exists it is very easy to create new roll assembly plans just by using the appropriate drawing template Calling the function Call this function optionally by e Main menu File Plot vk if Button Plot in the Button Key Bar The window Plot Assembly Plan is opened it contains the last used Drawing Template and the drawing that currently is shown in the Drawing Area of the main window If you attached dimensioning to your drawing objects they at first do not appear in the assembly plan The Navigator helps you to zoom to move and to fit the drawing Furthermore the Wheel Mouse is supported Principle of operation You can call these functions inside this window e Left mouse button Click on an origin object e g a roll in the assembly part The roll is picked up and
106. to the end of the profile Thus trapezoidal profiles with several trapezoids can be created U Profile ql Ay B This function is a part of the Toolbox Profile Design and generates a simple rectangular U profile either symmetrical or asymmetrical Calling the function Call this function by ou Button U Profile from the Toolbox Profile Design The window U Profile is opened Enter Width Height on the right and on the left and if you want the Radii If you enter equal heights and radii a symmetrical profile will be created otherwise an asymmetrical Principle of operation If the profile list already contains profile elements they will be deleted C Profile This function is a part of the Toolbox Profile Design and generates a simple rectangular C profile either symmetrical or asymmetrical Calling the function Call this function by e E Button C Profile from the Toolbox Profile Design The window C Profile is opened Enter Width Height on the right and on the left and the upper Copyright 2015 by UBECO GmbH Iserlohn Reference 157 web Widths If you enter equal values on the right and the left a symmetrical profile will be created otherwise an asymmetrical Principle of operation If the profile list already contains profile elements they will be deleted 3 1 7 1 10 Hat Profile This function is a part of the Toolbox Profile Design and generates a simple rectangular hat prof
107. to the type R Copyright 2015 by UBECO GmbH Iserlohn Reference 47 3 1 3 1 1 3 1 1 1 3 1 1 2 Reference Menu Items File New Project Use this function to create a new and empty Profile Project Calling the function Call this function optionally by e Main menu File New Profile Project e E Button New Project in the Button Key Bar The window New Profile Project appears Profile projects have the file extension pro In the top area of the window you can change the path or drive if needed All existing projects of the selected path are displayed Be sure that you enter a file name that does not exist Principle of operation After entering a valid file name the Project Data Window for the new profile project and the empty Profile List Window for the first bending step finishing step appear Some input fields already contain default values These values come from your last profile project Of course you can change them Hint If the profile project already exists use the function File Open Project Open Project Use this function to open an existing Profile Project Calling the function Call this function optionally by e Main menu File Open Profile Project o a Button Open Project in the Button Key Bar The window Open Profile Project appears and you can select the desired project file by a double click Profile projects have the file extension pro In the top area of the window
108. top rolls do not reach the bottom web of the profile anymore e Complicated shapes of the profile flanks can be better roll formed if the flanks are in a more Suitable horizontal position Calling the function Before you call this function select the line element L that should be converted to an arc element Call this function optionally by e Main menu Profile Element Convert L to A1 e Context menu right mouse button click on the arc element in the Drawing Area Profile Element Convert L to A1 The input window appears with the question Convert L to A1 new angle Enter the desired angle in degree Principle of operation After confirming with the Ok button an arc is created with these properties e Developed Length the same as the line s length e Radius is calculated from the given arc angle and the developed length e Type always A1 If needed the arc type can be modified in the Profile List Window e Direction always downwards or to the outer side If needed the direction can be modified by toggling the direction L against R in the Profile List Window Hint In order to convert an arc to a line you only need to enter the angle 0 in the profile list window Copyright 2015 by UBECO GmbH Iserlohn 102 UBECO PROFIL Rollform Design Software 3 1 3 16 4 Split Enter arc angle as splitting position 0 000 46 000 45 000 A X Cancel Hilfe This function splits the marke
109. topic e Line Segments Select the desired length of the shell elements for line segments Since the divisor must be a whole number the effective length will be approximate to the setting e Small Arc Seg Select the desired length of the shell elements for arc segments The arc angle is divided Regards the whole number divisor see above e Large Arc Seg Select the desired length of the shell elements for arc segments The arc developed length id divided Regards the whole number divisor see above e Def Large Arc Enter the limit between large and small arcs A large arc is detected when the Copyright 2015 by UBECO GmbH Iserlohn 190 UBECO PROFIL Rollform Design Software radius of the arc segment is larger than the preset limit Colors DXF File After pressing the Ok button for the first time PROFIL creates a DXF file with the meshed flat sheet After pressing the Ok button again the holes cut outs inserted from the user are extracted from the file and prepared for the simulation Get more details from the the chapter Defining prepunched holes cut outs later in this topic e Meshing Lines Modify the color for the meshing lines This is only necessary in case the CAD system is not able to display the default color grey e Holes Cut Outs In order to enable PROFIL to extract the holes cut outs entities from the file they must be drawn in the preset color default color red 3 1 8 8 1 4 Start This dia
110. tube edges only if the edges of the tube are bent inside e Lower Roll Radius R1 The inner radius of the first arc segment is proposed in the input field If necessary you can lower the radius if the roll should touch the profile at the bottom part only e g if you want to design a roll set for various sheet thickness Working diameter and reference point are taken from the Machine Data Principle of operation After pressing the Ok button the roll is generated If a roll is yet existing it will be replaced Copyright 2015 by UBECO GmbH Iserlohn 166 UBECO PROFIL Rollform Design Software 3 1 7 2 8 Break Down Pass Bottom Roll This function is a part of the Toolbox Tube Design and is used for generating the bottom roll for a break down pass Calling the function Before calling this function you should have created a break down pass by using the function Break Down Pass If you created the break down pass in another way pay attention that the profile list contains exactly 3 entries A1 A1 PS Only for such a tube profile a roll can be generated automatically Call this function by e E Button Break Down Pass Bottom Roll from the Toolbox Tube Design The window Break Down Pass Bottom Roll is opened Enter these parameters e Roll Diameter D If your entered diameter is too small that the roll cannot touch the tube an error message appears e Total Width W If your entered value is too small th
111. with a mirror If the top roll has a larger working diameter profiles with higher legs can be processed without risk that the band edges touch the top shaft spacers Below the profile there is no need to consider this This is why material can be saved and a smaller roll diameter is sufficient Unequal working diameter require unequal rotation speed of the shafts and with it a transmission ratio of e g 1 1 4 However some roll forming machines are using the transmission ratio 1 1 mostly if small profiles with small legs should be processed Enter dividend and divisor of the transmission ratio between the bottom and the top roll You need this information for defining the Working Diameter of the driven shafts if you want to get equal velocities of the bottom and the top roll When the working diameter of a shaft is set the working diameter of the counterpart shaft can be calculated dependent on the transmission ratio see Working Diameter Copyright 2015 by UBECO GmbH Iserlohn 220 UBECO PROFIL Rollform Design Software 3 3 8 4 3 3 8 5 3 3 8 6 Working Width The working width W belongs to the machine data and is displayed in the top part of the Machine Window The working width of the machine is the maximal available roll space If you do not utilize the maximal space left and right of the bottom and top forming rolls you must use Spacers for fixing the position of the forming rolls Between two alt
112. yield point and are distributed uniformly If necessary you can modify and optimize the bending angles The following rules are important e avoid increasing the stress of the edge to or over the limit of the yield point e all stresses at the edge should have nearly the same amount with exception or the first and the last bending step e in the first and the last passes the stress should be smaller than in the other passes You define by using the switch Profile Loaded whether the stress of the band edge is calculated for the discharged or the loaded state of the profile The status of the switch is displayed by a coloured background of the table fields in the profile list window Center Line Forming also called downhill forming or natural forming is often used to reduce the strain at the edge In this case decrease the position of the web of the profile from pass to pass in order to reduce the ways of the band edges lf the centroids of all profile cross sections have the same height the stress is partitioned to the whole profile more regular After checking the box Center Line Forming the stresses are calculated for constant height of centroids and you can see the effect of lowering to the stress If this solves the stress problem you can decide if you want to use this method Proceed the lowering by using the function Profile Center Line Forming Hints e Use the functions File Print Preview or File Print to print the table
113. 0 Use this function to append a Profile List behind the current one Calling the function Before you call this function select the pass behind whose position a new profile list should be appended Call this function optionally by e Main menu Profile Append e Context menu right mouse button click on any profile element of the desired pass in the Drawing Area Profile Append e Button Append Profile List in the Button Key Bar Principle of operation A new profile list is appended The list numbers of all following lists will be increased by 1 The content of an existing profile list is copied to the new one Setup Inserti ppen C Fas f Previous Pass Select in Options Profile List Insert Append if the contents of pass 1 or of the previous pass will be copied into the appended list Copyright 2015 by UBECO GmbH Iserlohn Reference 93 xi 2 Source profile list contains rolls Copy with rolls If the pass to be copied contains rolls yet you are asked Source profile list contains rolls Copy with rolls Please consider that rolls are renumbered when copied into another stand dependent on the number keys in Options Rolls and that rolls are modified dependent on the data of the shafts of the new stand in the Machine Window Change Machine Dat Furthermore the setting Keep Roll Data in Options Rolls determines how the rolls are treated by changed machine data Hints
114. 180 degree Because the developed length of the arc increases by this operation the adjoining line segments have to be decreased by half of the arc lengthening each in order to keep constant the whole sheet width Afterwards the new arc is developed as usual to the flat sheet in design direction i e against the sheet running direction In sheet running direction s view an open fold is roll formed first Then it is compressed by a roll pair Why doesn t this fold spring up D Explanation Imagine the new arc with the larger inner radius consists of three parts The center part has exactly the developed length of the final 180 degree bend with inner radius zero The two small parts have the developed length that is subtracted from the adjoining line segments When the fold is compressed this happens the large arc is bent down to inner radius zero and springs up after leaving the roll forming stand The two small arcs however are bent up to flat sheet and spring back to the closed state So the spring back of the small arcs have an affect in the opposite direction to the spring back of the large arc By choosing the correct inner radius it is possible that the sum of all spring forces is zero and the 180 degree fold keeps closed In practice an inner radius in the range 0 4 0 8 x sheet thickness is used A larger inner radius gives more effect on the small arcs and creates a permanent force that holds the fold closed Calling the function
115. 199 Cylindrical 111 Explorer with pass number stand name 60 Machine 59 f m NC 184 poe 183 Factor File 230 Redo 58 Factor for Spring Back 229 aie 2a Factor Method 242 Window visible 59 FAQ 23 Element FEA Append 103 Contact Rolls 214 Copy 104 Export Model 51 Insert 103 Import Result 50 vol 102 Output Simulation Model ABAQUS 194 REMOVE 106 Output Simulation Model LS Dyna 185 Split 102 Simulation Rollforming Process 29 Element Separator Lines 62 View FEA ABAQUS 145 Ellipse 153 View FEA LS Dyna 143 Elliptic Tube 131 FIL File 50 E Mail 201 File Empty Exit 57 Profile Element 84 Export 51 Enable ActiveX 77 Import 50 End Flare New Project 47 Arc Types 238 Open Project 47 Options Calculate 66 Partial Project Add On 48 End Point 226 Partial Project Save as 50 Excel Plot 55 Options Parts List 70 Print 54 Output Create Parts List 181 Print Preview 53 Exit 57 Save as 48 Expanded Roll Tool Window Save Project 48 Bore Hole 212 Files Bushing 213 Additions File 232 Diameter Shaft 212 Contour File DXF Format 231 Driven 212 Contour File KTR Format 231 General 211 Drawing Template 232 Identification Groove 213 Factor File 230 Material 213 Machine File 230 Touching the Profile at 214 Material File 229 Treating Surface Addition Remark 214 Profile List 233 Explorer Profile Project 228 Options General 61 Fillet Profile Explorer 205 1 Radius 67 With pass number stand name 60 2 Radii 113 Export 51 Filter Machine Flle 230 Profile Catalogue 250
116. 2015 by UBECO GmbH Iserlohn 234 UBECO PROFIL Rollform Design Software 3 5 2 3 5 3 3 5 4 Dist Stand Sheet Running Direction gt lt _ _ Design Direction D2 The distance between stands is the horizontal distance between the current and the previous stand in sheet running direction center roll to center roll Example The distance between stands D2 in profile list L02 is the distance between L02 and LO3 For the first stand enter the length of the spheroidizing zone Please estimate the value The distance between stands belongs to the Profile List data and is displayed in header of the the Profile List Window Principle of operation If you create a new profile list the distance between stands is taken from the Machine Window and copied into the profile list data The distance between stands is used by the calculation of the Stress of Edge See also Profile List Strip Width L The Strip Width L is the width of the flat sheet that is needed to form the profile with the desired cross section PROFIL contains different Calculation Methods to calculate the strip width The strip width belongs to the Profile List data and is displayed in header of the the Profile List Window Hint e By using the function Profile Modify Strip Width the profile elements at the band edges can be modified in order to have a profile list with a given strip width Referen
117. 236 U UBECO GmbH 13 UBECO Web Site 201 Undo Count of Steps 61 Recent Operation 57 Units 66 Update 13 Update Info Releases 3 x 21 Releases 4 x 16 Releases 5 x 14 U Profile 156 USB Hardlock 259 User 1 3 Profile Catalogue 248 Roll Stock Management 252 User Defined Calculation Methods 242 User Defined Columns 69 Using PROFIL 27 NV Value Filter Profile Catalogue 250 Roll Stock Management 255 Variables Definition 256 Copyright 2015 by UBECO GmbH Iserlohn Index 277 Variables Drawing Template 232 Options Rolls 67 Vault Resistance 128 Vertical Dimension 172 Video Start Stop 145 View Dimensioning 150 Flower 3D 139 Flower Nested 138 Flower Separated 139 Grid 150 Next Pass 148 Pass 136 Previous Pass 148 PSA 141 Roll Tools 140 Spacer Rolls 149 Statics 137 View FEA Result ABAQUS 145 LS Dyna 143 Viewport 204 Visible 59 V Profile 85 W Wear 114 Weight 128 Welding Pass 160 Welding Station 218 W Forming 162 What s new Releases 3 x 21 Releases 4 x 16 Releases 5 x 14 Wheel Mouse Navigator 204 Options Mouse 82 Width Allowances 89 Corner Point 246 Hole Cut Out 237 Modify Strip Width 89 Roll 244 Spacer Rolls 109 Working 220 Window Drawing Area 214 Expanded Roll Tool 211 Machine 216 Profile List 209 Profile Explorer 205 Project Data 206 Read CAD Contour Scan Profile Drawing 226 Roll Tool 211 Spring Back 210 visible 59 WKD File 229
118. 3 Product data representation and exchange EXPRESS language can be created So the pass the rolls of a stand or all stands can be transferred to any 3D CAD system with STEP interface In order to set up this interface open Options Files and select Output to CAD STEP AP214 If you want to use this function occasionally only and you do not want to change the setting every time it would be better to use the Export function This function is useful e g for designing the side roll support If the machine drawing already exists in CAD the rolls simply can be inserted Another application is to create photo realistic images for e Advertising clear view of your products e g for info brochures exhibitions websites etc e Presenting introduction of your company and your products e g by using PowerPoint e Offers if the decision maker of your customer is a non technician clear views are more expressive than technical drawings Calling the function select View Pass or View Rolls if you want to transfer a straight piece of profile or the roll tools of a stand Call this function by e Main menu Output 3D Model gt CAD 3D Model gt cao ETE f Curent Stand Le with Straight Sheet Length 200 000 All Stands i X Cancel Help In case of View Rolls a dialog window is opened for selecting After calling this function select in the dialog window e Current stand If needed a straight sheet with desired length can b
119. 4 Each corner point may have a fillet radius R2 R3 so that the connections to the neighbouring line elements are tangential If the radius is larger than 0 the roll corner point is not a real point but a virtual point of the roll it is the intersection point of the tangents The width is related to the width of the Roll Reference Point This means the width can be positive or negative Furthermore each corner point has an angle W1 W3 to the next corner point If the next point has a bigger diameter the angle is positive in the other case negative With the help of the rubber band model you can easily illustrate by yourself what happens in the case of modifying and moving the corner points The rubber band keeps stretched across the corner points the radii cause a fillet in the corner points For each roll corner point a revolution line with the auxiliary line color can be drawn Select it in Copyright 2015 by UBECO GmbH Iserlohn 246 UBECO PROFIL Rollform Design Software 3 6 7 1 3 6 7 2 3 6 7 3 3 6 7 4 Options Drawing Width The width of the Corner Point belongs to the roll data and is displayed in the table of the corner points of the Roll Tool Window You can modify the width by e data input into the input field e pressing PgUp Dn on the keyboard e using the Toolbox Modify The width is related to the y coordinate of the Roll Corner Point positive and negative values are possibl
120. 50 for scale 1 4 Select Fit if the scale should be adjusted in order to have the whole print out on one page only This function is limited to small table lengths I will not work in case the table lengths need a form feed anyway Hint All settings in this window are also effective in the function File Print Print Use this function to print out the drawing that is displayed in the Drawing Area and the data of the selected Profile Project In order to select the desired printer print modus and content of the print out call File Print Preview previously Calling the function Call this function optionally by e Main menu File Print e Button Print in the Button Key Bar Principle of operation If View Pass View Statics View Flower Nested View Flower Separated or View Flower 3D is the current view the content of the Drawing Area or what is selected is printed If needed successive pages are printed Copyright 2015 by UBECO GmbH Iserlohn Reference 55 x c Print we Stand or roll as selected 7 All rolls of the stand separately All rolls of the project separately i Abort Help If View Roll Tools is the current view the dialog window appears and you can choose Stand or roll as selected If a roll is selected in the Drawing Area only this roll is printed If nothing is selected function Inspect all rolls of the current stand are printed together on one page All rolls of the
121. 70 000 156 000 50 00 0422 Maschine 4223 156 000 50 000 0422 137 971 50 000 0422 61 2 wp3591 1000 13 000 103 000 50 000 0422 Maschine 4229 sus wp3591 3080 63800 137971 50 000 0422 Maschine 4229 137100 50 000 0422 soo 156 500 50 000 0422 Only with option Database Afterwards the manufacturing of a profile has been finished the roll tools are removed from the roll former and are taken to the roll stock so the roll former can be set up for the next project This is the right time to transfer the rolls from the project to the roll database The roll database gives information about the rolls in the roll stock This helps while designing a new profile project if you want to re use existing rolls for reducing the costs The roll database performs quick filter and search functions To transfer the rolls from and to the database the clipboard can be used All rolls of a shaft a stand or of the complete project can be stored directly Also a roll drawn in CAD can be stored Rolls from the database can be transferred directly to CAD If only a paper drawing of old rolls is available the data can be entered directly into the database Calling the function Before you call this function select the View Roll Tools This prepares opening the roll stock management for the button in the top button bar Call this function optionally by e Ma
122. A ga oan so sae tase es van gegs ageuncngoeaseenen eee oes 95 Development Table ria di ds dd deals hayes daa aa 96 Prole Gata qUe 97 A O o e E E 98 PADS AMO A ta 98 open Fold di taa 99 CONVE LIA cba 101 SPP E Sa re a aaa hoes 102 JON sa E E TN 102 Copyright 2015 by UBECO GmbH Iserlohn PP e o A ested stametieauideat meahoahaiaa E E E 103 PO DOING APO E E EO E E E INNS 103 ROMOV tard 104 CODY sie E O esse 104 ROIS oeae a a ar a 105 Redd Oy 21 Bog 6 U pees near odas 105 POS AD ROM vto cba 106 dB AAA O O OO CA cise asatieess eres kee estes 107 Spacer ollas dedico least idad 109 Great Spacer ROIS a 109 Remove Spacer ROS aaa a odie 110 Gonical Extension 110 GylitidriCall Extension EEE EERE pelle 111 Arched A O OR 112 Double slut anat ba 113 Acc A O O eee a Re 114 A A o Gaveayl os sevessendeenedadedeatigummadiasterbetha ea lnene ine eatieoe ee 116 FRONTS GIG ada aa 117 SPILA COM da 117 Ad AA ante east cen RES EE O ae N ett 118 J Aralvarveapeetates ats dseauiatcatta qaucienacuiatalaaciebtasvatiessavecvs staves vatadenetianeaataneariary acu betaiaontea nathan eaves 119 A Y 119 MOVE a ta ia it 120 A ON 120 A 121 CODY zara EO ON 122 PASOS ad a 122 DAS li 123 SOC Manage Mende cesiones pelle 123 ELE APPEAR nn de ieee sats E E EE E aaede see A EE 124 APP dass 124 REMOVE tasa 125 Calculate rua ai 125 A RR 125 Reference POE its dadas 126 811 01150 10 POE OA NO SR POR ra om a OE cP Ee ER ener a 126 Fi
123. AMI AAA AA E 1 C Jooo 100 000 100 000 100 000 100 000 100 000 2 100 000 100 000 66 667 100 000 100 000 66 667 3 100 000 100 000 33 333 100 000 100 000 33 333 4 100 000 100 000 100 000 100 000 5 83 333 88 889 63333 esse 6 66 667 77 778 66 667 77 778 7 50 000 61 111 50 000 61 111 8 33 333 44 444 33 333 44 444 9 16 667 27 778 16 667 27 778 10 5 556 11 111 5 556 Fam 11 This can be done easier Call from the old project the function Development Table and select Development Table Create from current project Save the development table to a file after converting the angles to percent function Development Table View Angle in This is recommended in order to apply the development table to new project with various bending angles Now open the new project with the final profile cross section L01 Open the development table of the old project and select Development Table Apply and Create Flower Pattern The profile flower for the new project is created automatically Similar means the profile list has the same profile element sequence regarding line and arc types If it is not you can move certain columns function Development Table Column or you can create and edit a new development table manually Toggle the development table to Bending Methods function Development Table Bending Method and define bending methods that should deviate from the method in
124. AutoCAD 2005 AutoCAD Application 16 1 AutoCAD 2006 AutoCAD Application 16 2 AutoCAD 2007 AutoCAD Application 17 AutoCAD 2008 AutoCAD Application 1 7 1 AutoCAD 2009 AutoCAD Application 17 2 AutoCAD 2010 AutoCAD Application 18 AutoCAD 2011 AutoCAD Application 18 1 AutoCAD 2012 AutoCAD Application 18 2 AutoCAD 2013 AutoCAD Application 19 AutoCAD 2014 AutoCAD Application 19 1 etc e AutoCAD Application Connects to the topical AutoCAD Release this is the last installed one e SldWorks Application nn Connects to SolidWorks release nn Use this Program ID if you have installed more than one SolidWorks release and you want to select a special one SolidWorks 2003 SldWorks Application 1 1 SolidWorks 2004 SldWorks Application 12 SolidWorks 2005 SldWorks Application 13 SolidWorks 2006 SldWorks Application 14 SolidWorks 2007 SldWorks Application 15 SolidWorks 2008 SldWorks Application 16 SolidWorks 2009 SldWorks Application 17 SolidWorks 2010 SldWorks Application 18 SolidWorks 2011 SldWorks Application 19 SolidWorks 2012 SldWorks Application 20 SolidWorks 2013 SldWorks Application 21 SolidWorks 2014 SldWorks Application 22 SolidWorks 2015 SldWorks Application 23 etc e SldWorks Application Connects to the current SolidWorks release this is the last installed one e SolidEdge Application Connects to the current SolidEdge release this is the last installed one e BricscadApp AcadApplication nn Connects to B
125. CO GmbH Iserlohn Reference 221 3 3 8 7 3 3 8 8 3 3 8 9 from machine data is selected Distance to Next Stand Sheet Running Direction gt lt Design Direction The distance between stands is the horizontal distance between the current and the previous stand in sheet running direction center roll to center roll Example The distance between stands D2 in profile list L02 is the distance between L02 and LO3 For the first stand enter the length of the spheroidizing zone Please estimate the value The distance to next stand belongs to the machine data and Is displayed in the bottom part of the Machine Window Principle of operation If you create a new profile list the distance between stands is taken from the Machine Window and copied into the Profile List data The distance between stands is used by the calculation of the stress of Edge Calibrating Factor The calibrating factor belongs to machine data and is displayed in the bottom part of the Machine Window The input field is active only in case of calibrating stands The calibrating factor has affect on the developed length stands during the function Shaped Tube Calibration The calibration factor says how much the developed length of a tube decreases when the rolls of the calibrating stand mesh in Read the documentation of your machine for the determination of the calibrating factor Deformation Degree The calibrat
126. Contour Input file Take care that in UNIX file names with uppercase and lowercase letters determine different files While reading PROFIL converts the UNIX file format LF automatically to DOS format CR LF Interface to other CAD Systems You need 2 CAD macros They should be created by someone who is experienced in CAD or by your CAD supplier Macro 1 is for transferring the drawings generated by PROFIL to the CAD system It has the task to load the temporary DXF or IGES file which is set in Options Files to CAD Optionally the macro should examine which layers are in the file If these layers yet exist in CAD they should be deleted because modified passes or rolls should be updated in CAD Macro 2 is for transferring pass and roll contours drawn in CAD to PROFIL If the CAD system is able to save DXF files normally available in all CAD systems the macro only needs to save the current drawing into the temporary Contour File DXF Format that is set in Options Files from CAD If the CAD system is not able to save DXF files the KTR file format can be used for the transfer A description of the Contour File KTR Format is available from UBECO Copyright 2015 by UBECO GmbH Iserlohn Index 263 Index ae Variables 256 180 Degree Fold 99 3D Flower 139 3DConnexion Space Mouse 204 3D Stand gt CAD 179 A A1 A2 A3 A4 Bending Methods 238 A11 Export 51 Options Files 75 ABAQUS Explicit Export 51 FEA S
127. Copyright 2015 by UBECO GmbH Iserlohn Reference 219 3 3 8 2 3 3 8 3 Machine The machine name belongs to machine data and is displayed in the top part of the Machine Window Enter a specification that characterises your machine or the location or your machine The name will also be shown in the Machine Explorer in the header bar of the Machine Window and in the field Machine of the Project Data Window Transmission Ratio Example of a gear with transmission ratio 15 teeth 24 teeth 1 1 6 The transmission ratio also called gear transmission ratio belongs to machine data and is displayed in the top part of the Machine Window Most roll forming machines have the gear transmission ratio 1 1 4 In order to have the same circumferential speed peripheral velocity of the top and bottom roll at the profile web the working diameter pitch diameter of the top roll must be the bottom roll diameter multiplied by 1 4 This enables a non slip traction of the sheet and better drawing the profile through the machine Why have roll forming machines this transmission ratio The reason is Normally profiles are guided through the machine with the open side on the top this means the band edges are bent upwards by the rolls This makes it easier to set up the machine because the operator can better look into the profile during jog mode Below the profile the machine base impedes the view it would be necessary to work
128. D PC DRAFT 411 WINDOWS Latin 1 AutoCAD ete DXF with Blacks C DOS PC 8 ME10 M1 C C IGES 1651 UNI Roman 8 STEPAP214 Profile built from sep bodies CAD Outputfile C Trmp Profil DXF Sheet Length 30 200 000 Use layer numbers instead of names Edit Otherwise if ActiveX is disabled and a Output File to CAD file format and file name is selected in Options Files the temporal file will be created Afterwards you have to open the file in your CAD System Hints e In order to create a set of different files sequentially it is recommended to use the function File Export e Select by View Show Spacer Rolls whether the CAD output should contain spacer rolls Drawing gt NC Use this function to transfer a single roll or all rolls of the stand which is currently displayed in the Drawing Area or all rolls of the Profile Project to your NC system The file format is DXF Calling the function Select View Rolls If a drawing object is selected in the drawing area only this one is transferred If you want to transfer the whole drawing call the function Inspect previously If you want to transfer all rolls of the project select this in Options NC previously Before you create NC data you should use the function Calculate Plausibility Check to check the whole profile project on errors Call this function optionally by e Main menu Output Drawing gt NC e PE Button Drawing gt NC
129. D_ISO10W100 Dash Dot is been loaded from the file ACAD LIN Fixed font text style for the statics table If not existing the font MONOTXT SHX is loaded and assigned to the text style MONO Dim style for the profile and roll tool dimensioning If not existing the dim style PROFIL is created with these properties e dimension line color extension line color text color text height number of decimal places as preset in PROFIL e dimension unit decimal e suppression of zeroes on Dim style for the roll diameter dimensioning If not existing the dim style RollDiam is created with the same properties as PROFIL but e extension line 1 suppressed e arrowhead block none If special modifications of the settings are necessary simply create the style by your own before you transfer the drawing If the styles with the above names yet exist they are not replaced but used Output 3D gt CAD Copyright 2015 by UBECO GmbH Iserlohn 78 UBECO PROFIL Rollform Design Software Rolling Direction s ie p The function Output 3D Model gt CAD transfers the 3D model of all stands of the whole roll tool set should be transferred to CAD Select if the rolling direction should be shown in positive or negative y direction Sw Properties of the SolidWorks interface Since PROFIL Rel 4 0 and SolidWorks 2003 this interface has been provided to transfer profile and roll tools drawings from PROFIL to
130. Database Roll Database and Profile Catalogu Path for Database CAPROFIL D ata Path for Database Enter the path to the database files After clicking into the input field the Explorer appears The path must be valid either on the local disk or on a network server If the database files do not exist they will be created when you call the Profile Catalogue or the Roll Stock Management for the first time The files are Profiles db and Profeles db for the profile catalogue and Rolls db Corners db and Projects db for the roll stock management at least further index files are created automatically if they do not exist User defined columns of profile table and the roll table User def col of the roll table Tithe of column 1 User 1 Title of column 2 User 2 Title of column 3 User 3 Title of column 1 3 Enter the titles for the last 3 columns of Profile Table and the Roll Table You can define these columns for your own needs User def col of the profile catalogue Tithe of column 1 User 1 Tithe of column 2 User 2 Title of column 3 User 3 Copyright 2015 by UBECO GmbH Iserlohn 70 UBECO PROFIL Rollform Design Software 3 1 2 8 9 Parts List Use this function to set the parameters for the creating of the parts list of the rolls by the function Output Create Parts List Excel Program ID Excel Excel Application Parts List to Excel Check here if the parts list directly
131. Down Pass from the Toolbox Tube Design The window Break Down Pass is opened Enter the desired Angle and Radius for the first arc segment and the Radius for the second arc segment into the input fields If the message appears Incorrect Input the entered parameters are not suited for creating a break down pass the developed length of which is the same as the one of the previously appended profile list Principle of operation After pressing th Ok button the tube profile for the break down pass is entered into the profile list The first arc segment at the bottom has the desired angle and radius The second one at the outside has the desired radius and its angle is calculated on this way that the developed length of the whole profile is the same as the one of the previously appended profile list Call this function for each break down pass one after another For generating the rolls for the break down passes use the functions Break Down Pass Bottom Roll and Break Down Pass Top Roll Hint e For creating the rolls for the break down pass use the function Break Down Pass Top Roll and Copyright 2015 by UBECO GmbH Iserlohn 162 UBECO PROFIL Rollform Design Software Break Down Pass Bottom Roll 3 1 7 2 4 Break Down Pass W Forming A1 This function is a part of the Toolbox Tube Design and creates the tube profile for a break down pass W Forming is a special forming method which raises the middle of the pr
132. Empty e Context menu right mouse button click on any profile element of the desired pass in the Drawing Area Profile Empty Principle of operation All profile elements or the profile list are deleted An empty profile list will remain Hints e To recall data in case of an error call function Open Project and answer Cancel to the question Save data Reopen the same profile project e To remove a whole profile list use the function Profile Remove Mirror Use this function to mirror a unsymmetrical profile list at the Reference Point X0 YO Calling the function Before you call this function select the pass whose profile list should be mirrored Call this function optionally by e Main menu Profile Mirror e Context menu right mouse button click on any profile element of the desired pass in the Copyright 2015 by UBECO GmbH Iserlohn Reference 85 3 1 3 4 Drawing Area Profile Mirror Principle of operation The profile is mirrored at the Reference Point X0 YO The left leg is mirrored to the right and the right is mirrored to the left If the profile list is symmetrical mirroring does not make sense and a message is shown x 2 Stand contains rolls Should them be mirrored as well If the stand contains rolls they can be mirrored as well In this case the user is asked to agree The width of top and bottom rolls are mirrored at the Roll Reference Point Side rolls are exchanged a
133. Features of this interface are e PROFIL controls CAD i e all operations are made in PROFIL CAD does not need to be operated e No special adaptation of the CAD system is necessary the standard installation is sufficient Any user defined adaptation is permissible e The drawings transferred to CAD are using layers for every part All layers can be updated separately i e before transferring the matching layers will be deleted e While reading contours from CAD first the entities of all layers and colors are transferred Disrupting layers and colors can be removed subsequently Properties of the AutoCAD interface Since PROFIL Rel 2 5 and AutoCAD R14 this interface has been provided to transfer profile and roll tools drawings from PROFIL to AutoCAD and to transfer profile and roll contours from AutoCAD to PROFIL e AutoCAD Full Version is needed in AutoCAD LT the ActiveX interface is not enabled e When dimensioned drawings are transferred to AutoCAD genuine associative AutoCAD dimensioning is created e PROFIL needs special line types textfonts and dim styles If they exist in AutoCAD they are used If not they will be created automatically Hints The ActiveX interface will only work if AutoCAD accepts external control It will not work if a window is open or if AutoCAD is waiting inside a multi stage command Finish it or break it by using ESC Line type Dash Dot for center lines If not existing the line type ACA
134. IL with your own calculation methods to get the straight length Call Options Calculate and Register User Defined Calculation Methods Edit the Factor File to define your own calculation procedure of type Factor Method or Addition Method Factor Method The length of the neutral line of the sheet is calculated by using the factor method The position of the neutral line is defined by a factor f which is between 0 and 1 f 0 means the neutral line is at the inner side of the sheet f 1 means the neutral line is in the center of the sheet In addition you can enter a correction factor k1 in and a correction addend k2 The straight length of a bent part of the sheet is calculated by a s k L 2n r f 1 k mtj 2 i 360 i 100 with L Straight length or length of the neutral line blue line see picture ri Inner radius f Factor for the position of the neutral line 0 inner sheet side 1 center line S Sheet thickness a Bending angle k1 Correction factor in pos or neg k2 Correction addend in mm pos or neg Copyright 2015 by UBECO GmbH Iserlohn Reference 243 3 5 12 3 6 3 6 1 The Factor File contains factor f correction factor k1 and correction addend k2 dependent on the relation inner radius sheet thickness See also Addition Method Addition Method The addition method works with the theory that the outer lines of the straight parts be
135. List Append 92 Center Line Forming 95 Development Table 96 Direction 235 Distance between Stands 234 Empty 84 Export 51 General 233 Import 50 Insert 91 Loaded 94 Mirror 84 Modify Reference Point 90 Modify Sheet Thickness 87 Modify Start Element 85 Modify Strip Width 89 Pass 233 Profile Catalogue 97 247 Read CAD Contour 82 Reference Point XO YO 234 Remove 93 Start Element 234 Strip Width 234 Profile List Window 209 234 Profile Opening 85 Profile Project Add On 48 General 228 New 47 Open 47 Part Save as 50 Print 54 Save 48 Save as 48 Profile Reference Point Modify 90 Profile Stress Analysis Options 80 Quality Management 28 View 141 Profile Table 248 Program ID Options ActiveX 77 Options Parts List 70 Project Data Calculation Method 208 Customer 207 Date 208 Description 207 Drawing No 207 Machine 207 Material 207 Name 208 Revision 208 Thickness 208 Project Data Window 206 Project Name LS Dyna 190 PROFIL 228 Project Table 254 PSA Options 80 View 141 psi 66 PTC Creo Elements Direct Drafting Interface ME10 261 Punched Profiles Holes Cut Outs 240 LS Dyna 189 Options Profile List 65 tis Quality Management Profile Stress Analysis 141 Simulation Rollforming Process 29 Three Step Concept 28 Quotation 135 R Radius Corner Point 246 Dimension 174 discharged 237 loaded 237 Radius Angle Method 238 Reaction forces 194 Copyright 2015 by UBECO GmbH Iserlo
136. NDOWS Latin 1 writes all letters unchanged to the output file DOS PC 8 converts to the PC 8 symbol set for DOS based systems UNIX Roman 8 converts to the Roman 8 symbol set for UNIX based systems Sheet Length 3D If you transfer 3D models you can preset the sheet length in sheet running direction Use layer numbers instead of names Select this option if your CAD system does not support layer names then PROFIL writes layer numbers into the output file Press the button Edit to enter the numbers Edit 1 Pass 1 Bottom Roll 101 1 Top Roll 01 1 Left Roll mi 1 Right Roll E Spacers Bottom 100 Spacers Top j200 Statics TE View Flower 3D 149 M Cancel Enter the layer numbers for the 1st pass and the 1st bottom top and side roll The next passes and rolls are numbered consecutively Furthermore you can enter the layer numbers for the spacers the statics and the 3D drawing Settings in to CAD are only possible if in Options ActiveX the ActiveX Output to CAD is disabled Hint Select by View Show Spacer Rolls whether the file output should contain spacer rolls Copyright 2015 by UBECO GmbH Iserlohn Reference 77 3 1 2 8 13 ActiveX ActiveX in former times called OLE Automation is a very useful interface to control programs under WINDOWS with one another and to transfer data to and from other programs The CAD system is working as ActiveX Server and PROFIL as ActiveX Client
137. O Sie a a a r nN O KO Om Y Shaped tube calibration from a round tube left from an elliptical tube center and by keeping the cross section unchanged right Sheet Running Direction This function is a part of the Toolbox Tube Design and creates the calibrating stands for a shaped tube It also can be used to calibrate a round tube A shaped tube is a tube with any symmetrical or unsymmetrical but closed cross section It is manufactured by a welded tube or a welded elliptic tube that is gradually formed by a certain count of calibrating stands A Calibrating Factor defines how much the developed length of the tube decreases in each stand Furthermore a Deformation Degree enables to partition the 100 of the forming between the welded tube and the shaped tube to each stand Calling the function Before you call this function use the Toolbox Profile Design the Graphical Method or the Numerical Method to define the cross section of the shaped tube lt can be symmetrical or unsymmetrical with any count of profile elements Take care that both ends touch together both at the outer and inner side of the sheet If the final product should be a calibrated round tube use the function Welding Pass to define the final tube and enter O for the addition for welding Select a Machine that contains calibrating stands For each calibrating stand define the Calibrating Factor and the Deformation Degree Call this function optionally by e
138. Output of a fold with inner radius 0 is now correct e FEA No penetrations anymore in the display of sharp inner corners e FEA The stand drawing is now displayed in case of missing bottom rolls as well PROFIL Rel 4 4 01 Dec 2007 New features e 3D Model gt CAD transfers the rolls of the current stand or all rolls of all stands to AutoCAD or SolidWorks Automatic Trapezoidal Profile Forming either with cosine band edge course or linear course with user defined fillet radii e Trapezoidal Profile as a new component of the Profile Design Toolbox e Copying of marked profile elements as a block via the clipboard also into other profile lists e Angle Dimensioning also related to the horizontal or vertical axis with selection from the context menu e Angle Dimensioning also for rolls e Mirroring side rolls to the opposite side e FEA improved message handling when critical ratio length width is exceeded e FEA reduction factor pressure overclosure can now be preset in order to simulate extreme small sheet thickness New HTML based help system by this fit for Windows Vista Bugfixes e Roll assembly plan templates now always are saved with file extension DXF e DXF files again contain dimensioning e Assembly Plan Drawing gt CAD transferred a template in error e Invisible buttons in Window Read CAD Contour Scan Profile Drawing now are visible again when the screen resolution is set to 120 dpi e Drawi
139. PROF IL Rollform Design Software SOLIDWORKS Es mesi mp ME Ma SHOWS sp mera RIGHT PESE mo DIFI ED cauonarinc USING se TI sure sips END passes POINT process INNER DEVELOPED BACE w DRAWINGS POSSIBLE N CREATES WI NOOW ARO STANDS e DEFINED PATTERN CALCULATION M AUTOMATICALLY FLOWER PROFILE FEA FORMING STRESS me con HOVER PRORIEFEN a peer Te Su ae PELL ANGLE EET DR AW iii LA ni 22 SIMULATION SHEET DRA EDsecment caine WING STAND BENDING r ca BAND FORM T nos DESIRED smu DATA 3 MATERIALTURE SPRING constant SIDE DIFFERENT USER al DISPLAYED CREATED ne ECESSAR oo DIRECTLY ENABLES me WHOLE ROLLFORMING FINAL q an PREVIOUS BSE liegt oar ii RADII IMPORTANT STRAIN User Manual Copyright 2015 by UBECO GmbH Iserlohn Notice This document is the manual of the software package PROFIL release 5 3 Last revision September 2015 This document is protected by copyright All rights are reserved No part of this document may be photocopied reproduced or translated without the prior written consent of UBECO Unternehmensberatungsdienst fur Computeranwendungen GmbH Iserlohn Germany UBECO GmbH makes no warranty of any kind with regard to this material including but not limited to the implied warranties of merchantability and fitness for a particular purpose UBECO GmbH shall not be liable for errors contained herein or for incidental consequ
140. Pass 5 a Breakdown 5 aN LOG HN Pass 4 5 44 Breakdown 4 Select how the profile lists in the Explorer should be called e Show profile list number default e g L01 L02 counting against the sheet running direction e Show pass from profile list e g Pass 1 Pass 2 counting in sheet running direction It comes from the Pass input field of the Profile List Windows e Show stand from machine data e g Welding Pass Fin pass It comes from the Stand Name input field in the Machine Window Copyright 2015 by UBECO GmbH Iserlohn Reference 61 Calling the function Call this function optionally by e Main menu Edit Explorer Hint The function Output Drawing gt CAD uses the profile list name as layer name for the pass or the stand 3 1 2 8 Options Use this function to adapt PROFIL to your individual needs Calling the function Call this function optionally by e Main menu Edit Options og Button Options in the Button Key Bar Select the following options Options General Options Drawing Options Profile list Options Calculate Options Rolls Options Spacer Rolls Options Database Options Parts List Options NC Options Files Options Activex Options PSA Options Keyboard Options Mouse Principle of operation The options are saved by pressing the Ok button After restarting PROFIL the options will be restored 3 1 2 8 1 General Use this function for these general set
141. Principle of operation The marked profile elements are copied to the clipboard can be inserted or appended inside PROFIL at any other position The content of the clipboard keeps available until PROFIL is terminated or you copy a roll to the clipboard function Roll Copy Hint This function does not allow to transfer profile elements to other Windows programs For this use the function Edit Copy Roll Read CAD Contour Use this function to read a contour which you have prepared in your CAD system into PROFIL to generate a roll Whether a Contour File KTR format or a Contour File DXF Format is being read you select in Options Files from CAD If you have enabled the ActiveX Input from CAD in Options ActiveX the drawing is directly read from the CAD system If you want to read files with frequent varying file names instead of a temporary file with a constant file name better use the Import Function Use this function in the roll designing stage if the function Scan Profile Drawing cannot produce the desired result and you prepared the roll contour in CAD because the roll should get a contour that differs from the profile contour considerably Only the working contour without side flanks should be imported working diameter reference point and shaft diameter are taken from the Machine Data Calling the function Before reading the contour select one of the center lines for defining whether a bottom a top or a side roll shou
142. Profile Explorer the selector From Layer To Layer is set automatically to the layer that is between the rolls of the selected stand Precondition the layer exists in the FEA result To reset the selection click on the center button of the Navigator 3D or on the button One layer only Hints e The Navigator helps you to zoom to move and to fit the drawing e By using the Navigator 3D you can rotate the drawing and toggle to a 2D view e With the function Output Drawing gt CAD you can transfer the drawing to your CAD System Copyright 2015 by UBECO GmbH Iserlohn Reference 145 3 1 6 8 2 ABAQUS Result of an FEA simulation with ABAQUS Explicit shown in the PROFIL drawing area Use this function to display the result of the roll forming simulation with ABAQUS Explicit by FEA Finite Element Method in the Drawing Area Calling the function Before you call this function proceed the FEA Simulation The ABAQUS Solver creates a FIL file that is opened with View FEA Result Open the project file pro that contains the belonging project Call this function optionally by e Main menu View FEA Result ABAQUS e EH Button View FEA Result in the Button Key Bar Select in Output FEA page Files whether the FEA result of the currently opened project should be displayed or if you want to select the desired FEA result within the file selection window The file selection window appears as well if the FEA result fil
143. Read the documentation of your machine for the determination of the diameter of the shafts Hint When a roll is created the Diameter Shaft is taken from the machine data and copied to the roll data It is shown in the input field Diameter Shaft in the Expanded Roll Tool Window and can be modified in case of e g the roll is a not driven idle roll on a Bushing Working Diameter The working diameter pitch diameter belongs to machine data and is displayed in the bottom part of the Machine Window for each shaft The working diameter is the double of the distance between the Reference Point and the center line of the shaft Pay attention that it can be a real diameter i e a diameter that can be measured at the roll It is also possible that it is a a fictitious diameter which cannot be measured For a more detailed description see chapter Reference Point If you define the working diameters pay attention to the Transmission Ratio of the machine equal velocity at the important points of the profile and if the shafts are adjustable Read the documentation of the machine for the optimum value Experienced designers increase the working diameter of top and bottom roll by a small value of e g 1mm in each stand in sheet running direction As a result the profile is drawn through the machine and the spring back and longitudinal strain behind each stand is decreased Though the profile web climbs up in the machine opposite of Center Line Forming
144. Rollform Design Software B Background Color Options Colors 64 Options General Clipboard 61 Backup File 48 BAK File 48 Bending Angle Sequence 96 Bending Methods 238 Blank Manufacturing 193 Bore Hole Bore Hole File 212 Expanded Roll Tool Window 211 LS Dyna 189 Bore Lines 62 Bottom Line Forming 95 Bottom Roll Break Down Pass 166 Fin Pass 164 Boundary 193 Break Down Pass Bottom Roll 166 Normal Forming 161 Pass W Forming 162 Side Rolls 167 Top Roll 165 Break Down Pass Machine Explorer 218 BricsCAD CAD Systems 257 Interface by ActiveX 260 Options ActiveX 77 Output 3D Model gt CAD 179 Bushing Bushing File 213 Expanded Roll Tool Window 211 Bushings Set Up Parts List Columns 71 Button Calculator 205 Dimension on off 203 Inspect 203 Key Bar 202 Navigator 204 Navigator 3D 204 C CAD Interface AutoCAD SolidWorks 260 ME10 261 Other CAD Systems 262 CAD Systems 257 Calculate Options 66 Plausibility Check 135 Shaped Tube 131 Statics 125 Stress of Edge 129 Trapezoidal Profile Forming 133 Calculation Method Oehler DIN User 240 Selection 208 Calculator 205 Calibrating Factor Machine Window 221 Shaped Tube Calibration 131 Calibrating Stand 218 Center Line Forming Function 95 Preview 130 Centroid 126 Check for Update 201 Circumference Speed Clearance Angle 114 Circumferential Speed Transmission Ratio 219 Classification 244 Clearance Angle Adapting the Roll Tool
145. Rollform Design Software Hint e See Toolbox Dimensioning for further information 3 1 7 4 6 Radius Dimension 3 1 7 4 7 This function is a part of the Toolbox Dimensioning and can be used for a radius dimensioning Calling the function Call this function by e 3 Button Radius Dimension from the Toolbox Dimensioning After calling this function you are asked to enter e Dimension Point identify an arc and a drag dimensioning appears afterwards e Dimension Text Position Afterward the dimensioning appears You can position it inside and outside the arc Hint e See Toolbox Dimensioning for further information Angle Dimension 60 This function is a part of the Toolbox Dimensioning and can be used for angle dimensioning between two drawing elements Calling the function Call this function by E Button Angle Dimension from the Toolbox Dimensioning After calling this function you are asked to enter e 1 Dimension Element afterwards a drag line appears between the selected element end and the cursor position e 2 Dimension Element afterwards a drag dimensioning appears between both selected element points and the cursor position as dimension text position e Dimension Text Position Afterwards the dimensioning appears Copyright 2015 by UBECO GmbH Iserlohn Reference Als is r sis axis 175 Angle Dimensions also can be set related to
146. Rolls for the part number before you generate a roll by using the function Roll Read CAD Contour or Roll Scan Profile Drawing The part number can be incremented automatically when you split a roll by using the function Roll Split at Corner or Roll Split between Corners Select the Automatic Increment in Options Rolls for the part number Use the Roll number for marking the install location in the machine and use the Classification for marking the type of the roll Classification The classification code belongs to the roll data and is displayed in the header of the Roll Tool Window For the classification all numbers and characters included special character are allowed Define the classification key so that it marks the type of a roll e g CY100 50 cylindrical roll 100 diam 50 width CO120 30 50 conical roll 120 diam 30 degree 50 width With the help of the classification code it is easier to find a roll in the roll database for re use Width The width of the roll belongs to the roll data and is displayed in the header of the Roll Tool Window The width is only an output field this means you cannot enter data into this field The width is calculated out of the difference between the width of the first and last corner point of a roll Copyright 2015 by UBECO GmbH Iserlohn Reference 245 3 6 5 3 6 6 3 6 7 Max Diameter The maximum diameter of the roll belongs to the roll data and is display
147. SA Profile Stress Analysis was added a three step quality management concept was available Remarks for Licence Copyright and connected rights for delivered programs and documentation are reserved by UBECO GmbH Unternehmensberatungsdienst fur Computeranwendungen Iserlohn Germany By signing the bill of sale the customer obtains the right to install and use the program system PROFIL on a single workstation He is not allowed to install PROFIL on further workstations neither handing PROFIL to third parties nor copying original UBECO disk with the exception of copy ensuring one backup Support If you are owner of the PROFIL Service Agreement you not only will regularly get PROFIL updates but you also can contact UBECO if you have questions or problems while using PROFIL or the CAD interfaces Best way is contact by E Mail you can send us your project file and we will examine it Please do not forget to give us the PROFIL release number and the CAD system you are using UBECO Unternehmensberatungsdienst fur Computeranwendungen GmbH Address Baarstr 121 D 58636 Iserlohn Tel 49 2371 9771 0 FAX 49 2371 45550 E Mail info ubeco com Internet http www ubeco com Copyright 2015 by UBECO GmbH Iserlohn 14 UBECO PROFIL Rollform Design Software 1 9 What s new Releases 5 x PROFIL Rel 5 3 01 Dec 2015 New features Output FEA LS Dyna Profile Element type SOLID alternatively to element tyoe
148. Set the count of Integer Decimal Places as well Copyright 2015 by UBECO GmbH Iserlohn 138 UBECO PROFIL Rollform Design Software 3 1 6 3 Colors of Drawin Austen Line Main Line Profile Main Line Rolls Text e Reset Select the Auxiliary Line Color Main Line Color Profile and Text Color in Options Drawing Tex Height 3 000 Preset the text height for the table of statics in Options Drawing Text Height Hints e The Navigator helps you to zoom to move and to fit the drawing e With the function Output Drawing gt CAD you can transfer the drawing to your CAD System Flower Nested NY P TEAN SHAT ae EEE A Zz e a Use this function to display the flower pattern nested of the profile project in the Drawing Area Nested means the webs of all passes have the same y coordinate Calling the function Call this function optionally by e Main menu View Flower Nested e E Button View Flower Nested in the Button Key Bar Principle of operation The flower pattern nested of the project is displayed in the Drawing Area Settings are the same as described in View Pass Hints e The Navigator helps you to zoom to move and to fit the drawing e Use the Toolbox Modify to bend the profile up and down and to modify the size of the profile e With the function Output Drawing gt CAD you can transfer the drawing to your CAD System e f the drawing is not clear
149. Step 1 Calculate Stress of Band Edge Strain and stress at the band edge are calculated and displayed as a bar diagram Properties e quick and approximate check of keeping the dangerous yield point limit e canbe displayed simultaneously while designing and optimizing 1 I a O PSA Profile Stress Analysis sh Step 2 PSA Profile Stress Analysis Stresses in the whole profile are calculated while passing through the roll forming machine and are displayed as colored faces in a 3D graphic Properties e quick and approximate check of keeping the dangerous yield point limit especially when extreme stresses are not at the band edge e g if edges are folded and the folds are bent e canbe checked by key stroke Copyright 2015 by UBECO GmbH Iserlohn Tutorial 29 2 3 Result of an FEA simulation with ABAQUS Explicit shown in the PROFIL drawing area Step 3 FEA Finite Element Analysis The FEA simulation calculates how a flat sheet is formed by the designed roll tools Properties e simulation of the roll forming process very precise calculation of strain and stress e very precise calculation of the cross section of the final profile that will be produced by the designed roll tools Check if the deformation is within the given allowances e because of the computation time the simulation makes sense at the end of the design process All three steps can be combined excellently step 1 can be used simultaneousl
150. Whole Project in Separate Files If not selected a temporary file is created which path and name are taken from the input field Filename for Entire File Temporary means the file is overwritten at every output and should be transferred to the NC programming system afterwards The file contains either the selected roll or the complete stand if no roll is selected by button Inspect The roll contour consists of Lines and Arcs If Whole Project in Separate Files is selected for all rolls of all stands DXF files will be created that contains one roll only The roll contour consists of Polylines the center line and the bore hole line are normal lines The start point of each roll is 0 0 and all rolls are turned and displayed like bottom rolls PROFIL avoids double file names and with it overwriting existing files by attaching 1 2 etc to the file name if necessary In a first step after calling this function all existing NC program files that belong to the project are deleted before they are created newly So the function can be called repeatedly Build Filename from Select if the filename should be built by using the roll number or the part number or a combination of them Pay attention that filenames are unambiguous otherwise the files are overwritten Turn over Roll 1 In order to make visible the labeling groove roll 1 can be turned over in the output file Filename for Entire File Enter path and filename for the temporary en
151. Window Stand number is shown in the table in the Machine Window e Profile Insert or Profile Append copy rolls too if existing The user is asked for confirmation Roll Renumber creates new roll and part numbers dependent on the number keys Improved DXF interface from CAD Profile Read CAD Contour and Roll Read CAD Contour now open any DXF format created by CAD Contour definition and tracking is done in PROFIL now e New help assistant for easier learning the software e Profile Explorer gives clear overview of the project the passes stands and rolls Useful for quick selection of any component Options Explorer for clear selection of option settings The status bar shows the maximum stress of the PSA Profile Stress Analysis e Check for Update online e System and user settings can be stored in an INI file as well Setting in Options General e Profile Mirror mirrors unsymmetrical profile lists at the reference point Bugfixes e No stand number change anymore after saving the machine data e Scrolling of the content of the Stress of Band Edge Window now possible PROFIL Rel 4 0 01 Dec 2003 New features e PSA Profile Stress Analysis calculation of the approximate stress within the whole profile cross section with colored 3D display e Profile Catalogue profile database gives an overview of all earlier produced profiles with quick search functions graphic display of the final profile and quick
152. Working Diameter Machine 222 Reference Point 223 Working Width 220 X XO 234 Y YO 234 Yield Point Curve Generator 199 Material File 229 Young s Modulus LS Dyna 191 Material File 229 Output FEA ABAQUS 194 Youngs Modulus Curve Generator 199 Z Zero Radius Fold 99 Zoom 204 Zoom Direction 82 Z Profile 157 Copyright 2015 by UBECO GmbH Iserlohn
153. a SolidWorks drawing and to transfer profile and roll contours from a SolidWorks drawing to PROFIL e Before you transfer a 2D drawing by Output Drawing gt CAD select in SolidWorks a document Drawing Otherwise an error messages appears e Before you transfer a 3D model by Output 3D Model gt CAD select in SolidWorks a document Part Otherwise an error messages appears e Colors an line types are transferred as preset in PROFIL e f dimensioned drawings are transferred in SolidWorks non associative dimensioning is created by using the current settings Output 3D gt CAD Rolling Direction 2 ie z The function Output 3D Model gt CAD transfers the 3D model of all stands of the whole roll tool set should be transferred to CAD Select if the rolling direction should be shown in positive or negative z direction AF y Properties of the SolidEdge interface Since PROFIL Rel 4 3 and SolidEdge Rel ST7 this interface has been provided to transfer profile and roll tools drawings from PROFIL to SolidEdge and to transfer profile and roll contours from SolidEdge to PROFIL preliminary only for 2D drawings The extension to 3D models is planned for a later release e Before you transfer a 2D drawing by Output Drawing gt CAD select in SolidEdge a document Drawing Otherwise an error messages appears e Colors an line types are transferred as preset in PROFIL e Dimensions currently are not transferred A Pro
154. access to the project file e ActiveX Interface to SolidWorks 2003 2D Drawing see Options ActiveX e rack Holding Method A4 with constant intersection point on the inside or outside as selected preset in Options Profile List e Calculation Method DIN 6935 of the developed length by table or formula as selected preset in Options Calculate Bugfixes e No empty entries anymore in the Parts List Columns e Statics parameter table can be Copied to the clipboard now Copyright 2015 by UBECO GmbH Iserlohn General 21 e New representation of arcs by polylines in the Drawing Area Thus the arcs do not disappear anymore while zooming by the Navigator and more enlargement is possible 1 11 What s new Releases 3 x PROFIL Rel 3 4 01 Dec 2002 New features e Shaped Tubes automatic creation of the calibrating stands for any shaped tube cross section dependent on given calibrating factor and forming degree e Bending Method A4 as a combination of A2 and A3 with user defined distribution of the residual lengths to the previous and next segment and with automatic distribution for guiding the strip straightaway track holding method Perspective angle 0 side view for View Flower 3D Setting in Options Drawing Automatic adaptation of the rolls when changing the working diameter or the reference point Setting in Options Rolls Change Machine Data Search path for the bore hole bushing identificat
155. ach bending zone Copyright 2015 by UBECO GmbH Iserlohn 196 UBECO PROFIL Rollform Design Software Individual Enter the count of shell elements for each Profile Element of the Profile List individually L and A elements only P and PS elements are ignored The row numbering is the same as in the Profile List Window In case the project file still does not contain saved FEA parameter a proposed meshing is shown in the table You can modify it for your own needs Meshing Long 21x Meshing Transv Meshing Long Files Machine Material Contact Others In Longitudinal Directiorr Lenath 4 000 mm Analysis Count ao Predecessor Count 10 Successor Count 10 30 Temporally Intervals Count x Cancel Hilfe Set the meshing in longitudinal direction Length select the desired length of the shell segments in longitudinal direction Analysis Count Select how many shell elements should appear in the FEA result The Analysis Length Analysis Count multiplied by Length should be the distance between stands at minimum better 2x the distance Predecessor Count Successor Count In front of the Analysis Length predecessor and successor elements are set that should take over the oscillation effects at the front and at the end of the sheet during the simulation Later the predecessor and successor elements will be cut off and they will not be visible in the FEA r
156. activated The left part of the window contains the Machine Explorer The top part of the window contains the following data Machine Transmission Ratio Working Width Spacers The bottom part of the window contains the following data Stand Name Distance to Next Stand for calibrating stands only Calibrating Factor Deformation Degree and the table with the data of the shafts axles Copyright 2015 by UBECO GmbH Iserlohn Reference 217 Diameter Shaft Working Diameter Reference Point Inclination Angle The data of the shafts axles for each stand are available separately By clicking on an item in the Machine Explorer the corresponding stand data are selected First the standard shaft axle types B Bottom T Top L Left and R Right are shown If a stand has additional side axles you see the identifier e g L1 L2 and so on By clicking on this identifier the corresponding column of the table of shaft axle data changes to e g Left 2 and at the same time the corresponding axle in the Drawing Area is activated Thus interactive working is possible After right click on a stand symbol of the Machine Explorer the context menu opens and forming stands and calibrating stands can be attached and removed again By right click on a side axle symbol further side axles an be attached and removed again By calling the function Append Forming Stand or Append Calibrating Stand the shaft data are copied So it is recom
157. ad from CAD and the Window Read CAD Contour appears You define the desired contour inside this window The same window appears if you have disabled ActiveX and in Options Files from CAD DXF Format is selected LS LS LS Scanning the profile bottom side the sheet center line and the profile top side Optionally scanning the profile bottom side the sheet center line or the profile top side bottom and top related to the reference point is possible In case profile legs touch each other and have common lines it can be valuable to scan the opposite side Copyright 2015 by UBECO GmbH Iserlohn Reference 83 lt _ rO l y Ah Symmetrical profile Asymmetrical profile If you design a symmetrical profile left picture set both the marker Reference Point x0 y0 blue and the marker Contour Start Point green to the Reference Point X0 Y0 of the profile If you design an asymmetrical profile right picture set the marker Contour Start Point green to the left corner of the profile and the marker Reference Point x0 y0 blue to the Reference Point X0 Y0 of the profile For both set the marker Contour End Point red to the right corner of the profile More information Window Read CAD Contour By checking the color changes to light blue you can find out if the right contour is tracked between Contour Start Point green and Contour End Point red If not proceed like this e Atan
158. al points Sum cells are created automatically by PROFIL the sum formula is transferred and the summarization is done by Excel Parts List Columns available Count Designation Count Designation Material Actual Diam Actual Width Blank Diameter Blank Width O Shaft Bore Hole Bushing Identification Gre Fertiqungsverfar Blank Diameter Blank Width O Shaft Blank Weight Finithed weight The composition of the parts list is fully user defined in the window Parts List Columns call it by the button Set Up Columns in Options Parts List Equal parts list rows are combined to one single row In this row count gross and final weight are summed up Parts list rows are equal if all visible entries are equal Representation of Values Integer Decimal Places fa a Metric N mm Imperial lb in Select in Options Calculate whether the representation of the values should be metric mm Kg or imperial in lb You can preset the Integer Decimal Places as well Headin 7 Without f Top i Bottom In case of Text File the Heading can be attached Hints e Select by View Show Spacer Rolls whether the parts list output should contain spacer rolls e In order to save the parts list to a file with a different name use the Export function Copyright 2015 by UBECO GmbH Iserlohn Reference 183 3 1 8 5 3 1 8 6 Edit Parts List Use this function to
159. all this function by v Button Parallel Dimension from the Toolbox Dimensioning After calling this function you are asked to enter e 1 Dimension Point afterwards a drag line appears between the selected point and the cursor position e 2 Dimension Point afterwards a drag dimensioning appears between both selected dimensioning points and the cursor position as dimension text position e Parallel to identify any drawing element which the dimensioning should be parallel to or click to an empty area of the drawing as a result of it the dimensioning will be creates parallel to the dimension points e Dimension Text Position Afterward the dimensioning appears Hint e See Toolbox Dimensioning for further information Diameter Dimension This function is a part of the Toolbox Dimensioning and can be used for a diameter dimensioning for roll tools only Because roll tools are drawn in a half intersection manner the 2nd dimension point don t exist Because of that a radius dimensioning is created the dimension text however is the diameter with the sign Calling the function Call this function by al Button Diameter Dimension from the Toolbox Dimensioning After calling this function you are asked to enter e Dimension Point afterwards a drag dimensioning appears e Dimension Text Position Afterward the dimensioning appears Copyright 2015 by UBECO GmbH Iserlohn 174 UBECO PROFIL
160. alogue e a Button Profile Catalogue in the Button Key Bar Profile Catalogue Open After calling this function the window Profile Catalogue appears which contains 4 areas e Profile Table lower area This is the real profile catalogue each row displays the project data of one profile e Profile Element Table in the middle left This area displays the profile list LO1 final pass data of the profile selected in the profile table e Drawing Area top on the right This area displays the drawing of the profile selected in the profile table e Filter top on the left Any filters can be defined for reducing the amount of displayed profiles Profile Catalogue Save Copyright 2015 by UBECO GmbH Iserlohn 248 UBECO PROFIL Rollform Design Software 3 7 1 Use this function to store the final pass of one or more projects into the profile catalogue e Current Project The currently opened project is stored e All Projects of a Path The path selection window appears and all projects of the selected path are stored If the window Profile Catalogue is not yet open it will be opened after calling one of these functions Setup Roll Database and Profile Catalogue Path for Database CAPROFIL D ata Set the path to the database in Options Database Profile Table The lower area of the Profile Catalogue displays the table of the project data of the profiles This table contains all profiles if the
161. ame file name and a subset of the data that are displayed in the Project Window and belong to the Profile Project Customer Description Drawing No These data are automatically transferred when a roll is inserted into the database or when a roll is taken from the database The roll corner points of the selected roll are displayed in the Roll Corner Table Use a Filter to reduce the amount of displayed rolls also for given projects The top bar of the project table contains these buttons Roll Corners Projects These buttons change the whole area of this part of the window so that the Roll Corner Table can be displayed ma 414121 Database Navigator for switching to the first previous next last project for inserting deleting and editing a project for posting and cancelling the edited data and for refreshing the data e g if in a network several designers use the same database Drawing Board The top area on the right of the Roll Stock Management Window contains the drawing area which displays the drawing of the roll which is selected in the Roll Table in the bottom area of the window The drawing is always refreshed from the data of the Roll Corner Table so that you have a clear idea how the roll looks like If you enter the data manually e g from a paper drawing and the data input is not yet finished completely non rational drawings can be displayed The colors of the drawing are the same as the colors of Drawi
162. any horizontal or vertical axis When you are asked 1 2 Dimension Point press the right mouse button and select the desired axis from the context menu e x Axis e 7 x Axis oT y Axis ot y Axis Afterwards click on the end point of any drawing element for defining the origin of the axis Hint e See Toolbox Dimensioning for further information 3 1 7 4 8 Automatic Roll Dimensioning This function is a part of the Toolbox Dimensioning and can be used for automatic roll dimensioning for roll tools only Calling the function Call this function by Button Automatic Roll Dimension from the Toolbox Dimensioning Autom Roll Dimensioning ajx Iv width e Diameter E At the Contour Left f Atthe Shaft f Fight Ref Point Aight E a Radius e Delete Existing Dim 36 Cancel Help After calling this function you are asked to enter Copyright 2015 by UBECO GmbH Iserlohn 176 UBECO PROFIL Rollform Design Software e Width at Contour at Shaft Select if the roll width should be dimensioned and whether the dimensioning should appear at the roll contour or at the shaft e Ref Point Right Select if the width dimensioning should be related on the left or right side of the roll m 140 e Diameter Left Right Select if the roll diameter should be dimensioned and whether it should appear on the left or on the right side of the roll
163. arc types bending methods which are treated differently while bending Al Arc type A1 has a constant straight length By changing the bending angle the bending radius is calculated and modified Also possible by changing the radius the angle is calculated and modified This method often is used in case of sharp bending this means small inner radii AZ Arc type A2 has a constant straight length together with its previous segment and has a constant Copyright 2015 by UBECO GmbH Iserlohn Reference 239 bending radius The result of changing the bending angle is a modified straight length of the arc In order to keep constant the sum of all lengths the length of the previous segment is adapted PROFIL calculates the new lengths if you define a new bending angle The method often is used in case of large radii Because bending mostly takes place in the horizontal part of the profile the use of side rolls can be avoided Put Arc type A3 is similar to arc type A2 but instead of the previous segment the next one is used for the length compensation PROFIL calculates the new lengths Also this method often is used for large radii Are Type 44 e Track Holding inside outside Addition Part Previous Segment so s Remainder Hests f Modify angle constant radius Modify angle and radius UA di Arc type A4 is a combination of A2 and A3 Select in Options Calculate Arc Type A4 Additio
164. ardlock is running under WINDOWS 98 WINDOWS ME Aug 2000 Release WINDOWS NT 4 0 SP6 WINDOWS 2000 WINDOWS XP WINDOWS XP 64bit WINDOWS 7 and WINDOWS 8 Proceed the following steps in the described order e Login at WINDOWS as Administrator Copyright 2015 by UBECO GmbH Iserlohn 260 UBECO PROFIL Rollform Design Software 4 4 e Call before connecting the Marx USB hardlock a Marx CBUSetup exe and follow the instructions of the setup procedure e Now connect the Marx USB hardlock to an USB port of the computer e Login at WINDOWS under the correct USERNAME before you start PROFIL exe for the first time this is why PROFIL creates the working path under this USERNAME ActiveX Interface to AutoCAD SolidWorks SolidEdge BricsCAD ri Object The interface to AutoCAD R14 AutoCAD 2000 and higher to SolidWorks 2003 or higher is integrated into the profil exe file If the CAD system is already installed and you install PROFIL afterwards you do not need to do anything more PROFIL notices that AutoCAD or SolidWorks is present and enables the interface automatically if you answer YES to the question AutoCAD SolidWorks SolidEdge BricsCAD found on your computer Do you want to enable the ActiveX Interface when you start profil exe for the first time If you want to enable the interface manually open Options ActiveX Program ID CAD System Determine the Program ID of the ActiveX target system For expla
165. ards call the function Shaped Tubes Calibration of the Toolbox Tube Design The cross section patterns for the calibrating stands and the welding stand are created automatically By using the function Welding Pass you can attach the addition for welding e Creating the passes For each stand create a pass by using the function Profile Append one after another and call in each pass one of the functions Fin Pass Break Down Pass or Break Down Pass W Forming dependent on whether it is a fin pass or a break down pass All these functions bend open the existing profile dependent on the entered parameters as desired e Generating the roll tools For each pass call the functions Fin Pass Top Roll Fin Pass Bottom Roll Break Down Pass Top Roll Break Down Pass Bottom Roll Fin Pass Side Rolls or Break Down Pass Side Rolls dependent on whether it is a fin pass or a break down pass or whether you want to create top bottom or side rolls The rolls for the calibrating stands can be created by using the function Roll Scan Profile Drawing Properties Except of the function Welding Pass which is called in a new project with an empty profile list all other functions use the pass in which they are called i e the functions Fin Pass and Break Down Pass bend the tube profile dependent on the entered parameters This is why you should have called the function Profile Append previously The functions Top Roll Bottom Roll and Side Rolls gener
166. ate rolls for the current pass All functions of the Toolbox Tube Design except Shaped Tube Calibration are designed for symmetrical tubes with two arc segments on each side e the profile list belonging to it must look like this A1 A1 PS With other kinds of profile lists the Toolbox Tube Design will not work Modifications by hand or be the Toolbox Modify are allowed however e The function Shaped Tube Calibration needs a closed cross section pattern which can be symmetrical or unsymmetrical with any count and type of profile elements Before using the Toolbox Tube Design it is recommended to prepare the machine data in the Machine Window Copyright 2015 by UBECO GmbH Iserlohn Tutorial 37 2 5 3 Automatic Flower Creation lf the flower design of a similar profile already exists and a new profile should be developed by the same scheme creating the flower pattern is quite simple Imagine an old profile project exists and you know that the profile was roll formed on the machine successfully Now you get the task to design a flower pattern for a new similar profile which has slightly differing dimensions or angles You surely would look into the old project and use the same forming concept if it was successful in the past Development Table DevTable E 215 xi File Development Table evelopment T able ource C PROFIL32 DevT able pro 7 L 8 P 9 O
167. ated roll tools for all stands see How to Work L01 contains the final profile and the last pass Lnn contains the flat sheet normally without rolls Furthermore important for the FEA simulation Set in Expanded Roll Tool Window the check box Touching the Profile at Call this function by Copyright 2015 by UBECO GmbH Iserlohn Reference 195 e Main menu Output FEA ABAQUS Principle of operation In the dialog window FEA Parameters is opened These settings are necessary for the FEA simulation Meshing Transv 2 x Meshing Transw Meshing Long Files Machine Material Contact Others C General Individual Meshing means the strip is divided into small rectangular faces shell elements The smaller the faces are the more precise the calculation is but the more calculation time is needed So select the meshing as fine as necessary Possibly select a more coarse meshing in profile parts that are less interesting Select if you want to define the meshing General lengths and angles for lines and arcs or Individual count of shell elements per profile element Line Segments select the desired length of the shell elements for Profile Elements of type Line Since the divisor must be a whole number the effective length will be approximate to the setting Small Arc Seg select the desired length of the shell elements for Profile Elements of type Arc The arc angle is divided Regards th
168. atically The automatic spacers are transferred to CAD and they appear in the parts list However because they are not objects like the forming rolls in the PROFIL object hierarchy they cannot be selected by mouse click and they cannot be dimensioned and split They also do not get a designation like the forming rolls In case a spacer is needed between forming rolls a cylindrical roll with small spacer diameter must be inserted Spacer Rolls These kind of spacers are handled like all other objects in the PROFIL object hierarchy They are created with the function Rolls Spacer Rolls Create and are removed by Rolls Spacer Rolls Remove and they can be selected by mouse click can be dimensioned and split and they get roll numbers and part numbers dependant on special number keys for spacer rolls only in Options Spacer Rolls The width adaptation is not automatic if the width of the forming rolls is changed the spacer rolls have to be re created If Split Spacers to Shims is checked in Options Spacer Rolls the spacer rolls are split automatically dependant on the Shim Width Table Spacer rolls also are created between forming rolls if a gap is left between them during roll design Spacer rolls appear in the parts list and in the NC program For both kinds of spacers is effective Because spacers do not contact the profile they are not considered during the Finite Element Simulation Both kinds of spacers can be switched on and off in order e g
169. be Flower Pattern ns lead 35 Automatic Flower CCA cin aca 37 PROM TOONS ai iii ba 38 Designing NE Roll TOONS A A er PAEAS EEEE EE AE EE 38 Roll Design using the Profile Drawing 2 cccceeceeeseneseeeeeeeeeeeeenaaeeeeeeeeaeeneaaaseeeeeeeaenneaaaseeseseeeaanneaseeseees 38 Roll Design using the CAD System oocoococcccnccccnnonononnonnonancnncnnnnannnannan nan nnnnnnn nen nr corr r rr rr rr rnnnnnrnnnnnannnnnnnaanaananas 39 Searching for existing ROS a eee 40 Adapting the Roll TOONS aaa raaa eren ceeds coasts e E Ea E aa ada N Eee aaae ea ENEAN EEEE canes EE EE EEEE 40 ei nnn nn ans nacesuseuuas aeesescesansanscuecnecatatenienrenteriuereneece tases 40 Output of the Manufacturing Data ooococcnnncnncnccononnncncnnccnononcnnnnn cnn nn nenen rr rr rr nnmnnn nnmnnn 41 Saving the Rolls into the Roll Data Base seceeesseeeeeeeeeeeeeeeeeeeesensseseesensesneseeaeeeeeesesseeseseeeeeeeeeneenenas 42 WAC INNING siii dia a E a a a e 43 New Handling Of Machine Dala eana aena anaa eaaa aapea eead deavansdavaasaineinaiveivaineinzes 43 MUNTA XIOS ci A a E A aa EESAN EE EAEN RENE 44 Reference 47 Menu GINS sranna a aaa e a E ax woaces seevecusaecuaddeudeatal 47 A A 47 NeW Pro Eladio 47 Copyright 2015 by UBECO GmbH Iserlohn UBECO PROFIL Rollform Design Software DIT e o An 47 o A os re red eee sha Spaces ese an nara sd oansoosaee tase es vaa gags aueuaenaoe aheomeh needs 48 SANG A nn A onal ala deus a 48 Pat
170. be created automatically Do not draw a fillet at the first and last corner they can simply be inserted later Reading the roll contour First open the Machine Window and enter the machine data Select the desired profile pass and select the drawing of the rolls by using the function View Rolls Now the center lines of the shafts will be displayed Select one of the center lines for defining the type of roll Afterwards call function Roll Read CAD Contour _ Now a roll can be created which has the prepared CAD contour Copyright 2015 by UBECO GmbH Iserlohn 40 UBECO PROFIL Rollform Design Software 2 6 4 2 6 5 2 6 6 Searching for existing Rolls Only with option Roll Stock Management To search for suited rolls in the roll database select among these methods to create a filter e First define the contour of the desired roll by using the method Roll Design using the Profile Drawing or Roll Design using the CAD System Function Roll Cut moves the roll to the clipboard Now call the Roll Stock Management and create a Filter by pressing the button Create Filter from Clipboard If needed modify the filter conditions manually e The second method is to define the filter conditions manually If a suited filter yet exists it only needs to be loaded Get more information in chapter Filter If the filter is defined press the button Filter On Now only those rolls are visible that match to the
171. by e Main menu Rolls Corner Remove e Context menu right mouse button click on the certain corner point of the desired roll in the Drawing Area Corner Remove Principle of operation The roll corner point is removed After removing the previous and next corner points will be connected Calculate Statics 07 44865 101 statics Related ta Centroid of an Area Ret Point x0A 0 shear Center Point Ret Point 0 0 Moment of Inertia pelin Centroid Moment of Inertia in Principal Axes Moment of Resistan pelin Centroid Moment of Resistan In Principal Axes Max Distance In Principal Axes Inertial Radius In Principal Axes Area of Cross Sec Weight without Holes Princip Axes Angle c xis In Centroid Vault Resistance Shear Center Point Torsion Moment Centroid Use this function to calculate the statics of the profile list which is showed in the current Profile List window The statics parameters are displayed in the Statics Window They are calculated by using the discharged columns of the profile list only they are not dependent on the status of the menu switch Profile Loaded Holes Cut Outs will weaken the area of cross of the profile The calculation of statics considers this Exception for the Weight holes cut outs are not considered since input of count and length is not supported Calling the function Before you call this function select the pass that should be calculated Call this function optionally by
172. c Extension 111 Development Table 96 Export File 51 FEA Model ABAQUS 194 FEA Model LS Dyna 185 Final Profile 30 Manufacturing Data 41 NC 183 Parts List 181 Profile by Graphical Method 33 Profile by Numerical Method 31 Profile Element 103 Profile Flower Pattern 34 Profile List 92 Profile Project 47 Roll by CAD Drawing 105 Roll by Profile Scan 107 Roll Corner 124 Roll from CAD Drawing 39 Roll from Profile Drawing 38 Simple Profile 151 Spacer Rolls 109 Trapezoidal Profile 133 Tube Flower Pattern 35 158 Creo Elements Direct Drafting CAD Systems 257 Interface ME10 261 Critical Minimum Bending Factors 229 Curve Generator 199 Customer 207 Cut Roll 121 Cylindrical Extension 111 D Database Options 69 Profile Catalogue 97 247 Roll Stock Management 123 251 Date 208 Decimal Places 66 Deformation Degree Machine Window 221 Shaped Tube Calibration 131 Delete Dimension 177 Roll 123 Copyright 2015 by UBECO GmbH Iserlohn 266 UBECO PROFIL Rollform Design Software Delete Roll Corner Point 125 Density LS Dyna 191 Material File 229 Output FEA ABAQUS 194 Statics Weight 128 Description 207 Design of Profiles 27 Designation Set Up Parts List Columns 71 Designing Automatic Flower 37 Final Profile 30 Profile by Graphical Method 33 Profile by Numerical Method 31 Profile Flower Pattern 34 Roll Tools 38 Developed Length Addition Method 243 Calculation Methods 240 Factor File 230 Facto
173. c PRINCI EWAK CS dirimir nati aao ia ea EnS E 126 Shear Cemer na eee ee eo ROT Oe TNA ee ee ae 127 Moments O INS da as Gap Oe es 127 Moments o0l Resistance canada 127 Ma A DISTANCE Eiss eia doi dad aid aaa 127 A A Aen A Re ee ee ee 128 NETO CMO catarata cae ces 128 N21 Lo 9 OOO CONO re ee ee PR eR Pe Ee A er ee 128 PrnecpalAxes AMG Criascccsnsdessisncesiacdad se aaa aa 128 WAUIFESISIAIC Cy sisi a IR cta 128 TOISIO INOW OU sees tacos is des 129 A O a ree ener eee 129 Center LING F OVC iniciando 130 Shaped TUDE C aliDral oM eas cies ca ince ese oa asc anaes suescees A ebeaseeoueene seen ees 131 Trapezoidal Prole Form socias iso 133 Red red COMA COLS ee 135 dei nn A A 135 MIMI id ciaiE 136 Pas Maio 136 SEE POCA OO nO E Ranta ee 137 FO Wer Nested sa lin tirando 138 EOI oe 139 Copyright 2015 by UBECO GmbH Iserlohn UBECO PROFIL Rollform Design Software POW OF 3 Dira lesbiana dada oral tees 139 A NS 140 POR Prone Stress ANAIS S aiii isis 141 FEAS 142 LS DY OA Po PEC O 143 ABAQUS o E IA A E 145 ET rol O q caen OOO Un E E E EE NRAN 146 SHOW o e r 148 Previous NEH PASS hre a a dida 148 Spacer ROMS he a O A N 149 DIMCASIOMd a a ds ieee 150 GA CI CO a Re SOME RE ERS Oe ee PS EOE Pa er ea 150 TOGIDOX GS esse E E A E reece tit is 151 Profile OSI odas 151 ENE A ae tare hate eh ete ee at a eee nee ae athe aa eae ae eee 151 O 152 Rs A O A e because etea EEA 153 FAN oca ace gc nO PON ec Et oe 153 PC
174. can be negative too in this case first an arc to the right and afterward to the left will be created Please enter the upper width first The insert point is the tangential point of the arc see drawing this means the length of the previous element will be shortened The width is measured in the direction of the previous element the height is perpendicular to it Principle of operation If you have selected a Profile Element previously the new profile elements will be appended to the selected one Otherwise they will be appended to the end of the profile Trapeziodal Profile This function is a part of the Toolbox Profile Design and generates a trapezoidal profile The opening is on the bottom or on the top as desired Calling the function Call this function by o PA Button Trapeziodal Profile from the Toolbox Profile Design The window Trapeziodal Profile is opened Enter the dimensions in any sequence When enough Copyright 2015 by UBECO GmbH Iserlohn 156 UBECO PROFIL Rollform Design Software 3 1 7 1 8 3 1 7 1 9 parameters are entered the remaining dimensions are calculated automatically and the Ok button is enabled If the trapezoid should open on the bottom enter negative angles A1 and A2 The height H always is positive Principle of operation If you have selected a Profile Element previously the new profile elements will be appended to the selected one Otherwise they will be appended
175. ce 163 3 1 7 2 5 Fin Pass Top Roll This function is a part of the Toolbox Tube Design and is used for generating the top roll for a fin pass Calling the function Before calling this function you should have created a fin pass by using the function Fin Pass If you created the fin pass in another way pay attention that the profile list contains exactly 3 entries A1 A1 PS Only for such a tube profile a roll can be generated automatically Call this function by Button Fin Pass Top Roll from the Toolbox Tube Design The window Fin Pass Top Roll is opened Enter these parameters e Total Width W If your entered value is too small the width is set automatically to a minimum width that has enough space for all fillet radii The result is rounded to 10 mm or 1 in e Fillet Radii R1 R2 Select a fillet radius at the inside at the tube and a fillet radius at the outside at the roll edges e Fin Height FH Enter the fin height Remark The fin width is set in Fin Pass If the opening in the tube is less than 1 mm or 0 1 in no fin is created e Half Air Gap AG Enter the desired vertical air gap between the roll and the center of the tube more exact center of the first arc segment of the tube profile Working diameter and reference point are taken from the Machine Data Principle of operation After pressing the Ok button the roll is generated If a roll is yet existing it will be replaced If the fin
176. ce Point X0 YO V The Reference Point defines the start point of the profile in the xy plane Copyright 2015 by UBECO GmbH Iserlohn Reference 235 3 5 9 The reference point normally should be at or near the center of the profile s web on the sheet metal s bottom side see left pic If the profile has not a horizontal web the reference point can be set on the bottom point of an arc segment instead see right pic Because both legs turn around the reference point during forming it is recommended to put it in such a position in order nearly to have equal leg heights on both sides also in case of a unsymmetrical profile Thus the Stress of Band Edge is distributed equally to both sides This also can be optimized by selecting a suitable Direction Some results of the function Calculate Statics are related to the reference point You can set the start point to any point Practical values are 0 0 or 200 150 dependent on the used CAD system 200 150 is the center of a DIN A3 page In order to move the reference point to another position use the function Modify Reference Point The reference point belongs to the Profile List data and is displayed in header of the the Profile List Window Hints e Modify the first profile element in the Profile List the element that starts at the reference point by using the function Modify Start Element e Some Statics are related on the reference point e The Roll Referenc
177. contour tracking manually Inserting a roll from CAD into the project or into the roll database You have called this window with the function Roll Read CAD Roll or Insert Roll from CAD of the Roll Table Set the marker Contour Start Point green to intersection point of the left edge with the centerline and the marker Contour End Point red to the intersection point of the right corner with the centerline of the roll The color change to the mark color light blue by default must mark the outer contour of the roll Otherwise see topic Controlling the contour tracking manually Controlling the contour tracking manually If the automatic contour tracking does not find the desired contour you can control it manually by selecting certain drawing elements with the mouse cursor If the blue point exists reference point x0 y0 in case of defining the profile list by reading CAD contour the start element from the blue point directing to the red point contour end point can be defined by mouse click The direction to the green point contour start point always is opposite turned by 180 degree If the blue point does not exist in case of defining a roll the start element from the green point directing to the red point can be defined by mouse click If the automatic contour tracking does not find the desired contour at any intersection you can define the correct connection by mouse click If a wrong connection was given
178. creating the rolls in the Window Read Contour set the green start point to the left and the red end point to the right contour point Otherwise if you built the rolls in inverse direction replace left by right For side rolls replace left by smallest width coordinate see Roll Tool Window Calling the function Before you use this function mark the position for inserting by clicking to the left or right Roll Corner Point If no roll exists mark the shaft Call this function optionally by e Main menu Rolls Paste e Context menu right mouse button click on the certain corner point of the desired roll in the Drawing Area Paste Principle of operation If you marked the left corner point of an existing roll the new roll is inserted at the left of the existing roll Further existing rolls on the left are moved to the left if the user agrees The marked roll and further rolls on the right are not moved Otherwise if you marked the right side the new roll is inserted at the right analogously If a gap exists beside the marked roll e g after deleting a roll the width is checked if the new roll fits into the gap exactly or the new roll is smaller than the gap the roll is inserted A remaining gap has to be filled by the user If the roll is wider than the gap further rolls are moved if the user agrees the marked corner point determines the direction of movement If no roll exists on the marked shaft the
179. ct should be saved The selection boxes first show all passes Related to the ref point Left Side Right Side Select if the left side only the right side only related to the reference point or both sides should be saved The terms left and right are effective if the start direction of the profile is to the right 90 90 degree and the rolls are defined from negative coordinates to positive coordinates related to the reference point Otherwise left and right are mixed Content Profile Rolls Select if the partial project should contain the profile only the rolls only or both Principle of operation After pressing the Ok button the file selection box appears for selecting the path and the file name The partial project is saved to the project file with the new name and the extension pro Hints e In order to add the partial project to the current project use the function Partial Project Add On e Because the file format of the partial project file is identical to the project file you can open edit and save it by using the functions Open Project and Save Project Import This menu item contains all import functions that can be used for data transfer from other software systems These functions also can be called from other menu items with fixed file names and input paths pre set in the options window Therefore they can be used as temporary files for data transfer only Unlike this the import function opens a file s
180. ction Profile Append one after another and call in each pass one of the functions Fin Pass Break Down Pass or Break Down Pass W Forming dependent on whether it is a fin pass or a break down pass All these functions bend open the existing profile dependent on the entered parameters as desired e Generating the roll tools For each pass call the functions Fin Pass Top Roll Fin Pass Bottom Roll Break Down Pass Top Roll Break Down Pass Bottom Roll Fin Pass Side Rolls or Break Down Pass Side Rolls dependent on whether it is a fin pass or a break down pass or whether you want to create top bottom or side rolls The rolls for the calibrating stands can be created by using the function Roll Scan Profile Drawing Properties Except of the function Welding Pass which is called in a new project with an empty profile list all other functions use the pass in which they are called i e the functions Fin Pass and Break Down Pass bend the tube profile dependent on the entered parameters This is why you should have called the function Profile Append previously The functions Top Roll Bottom Roll and Side Rolls generate rolls for the current pass All functions of the Toolbox Tube Design except Shaped Tube Calibration are designed for symmetrical tubes with two arc segments on each side i e the profile list belonging to it must look like this A1 A1 PS With other kinds of profile lists the Toolbox Tube Design will not work
181. ctions DXF KTR Profile Lists FEA Result Extended Export functions DXF IGES MI A11 Profile Lists Parts List NC Program FEA Model New drivers for the USB Hardlock by this fit for Windows XP 64bit Integer places digits left of the decimal separator can be preset in Options Calculate Mirror Roll Roll No and Part No are kept is this is preset in Options Rolls Roll Stock Management New import function FEA General Contact FEA FIL files created on Dual Core Processors can be opened now FEA Toggling to sequential reading of a FIL file in case the file is too big for direct opening FEA Mass scaling time interval and recommended value with 2 decimal places Copyright 2015 by UBECO GmbH Iserlohn 18 UBECO PROFIL Rollform Design Software Bugfixes e Roll Assembly Plan templates now are saved again with variables e Open Fold now calculates the developed length correctly if the profile starts with a 90 degree bend e For the roll corner point functions shortcuts can be defined as well e Center Line Forming Warning message in case of empty profile elements is now added e Dimensioning No wrong geometry reference anymore if mirrored profile elements are dimensioned and profile elements are removed e Radius Dimensioning is now removed if the profile is unbent to flat Part List The gross and final weight is not doubled anymore in case of saving to text file SolidWorks Interface 3D
182. curve over the limit of 100 But the value is not safe so you must use it at your own risk It is a good idea to provide for an adjusting mechanism in the machine in order to compensate the springback in case of very large radii Copyright 2015 by UBECO GmbH Iserlohn Reference 211 3 3 5 Roll Tool ES ilA4865 R01 Bottom Roll Ho fioi Width 60 000 Part No A4865 R01 01 Max B 127 000 Classif More 1 100 00 0 0 4 20 000 127 00 270 000 D In this window the data of both a forming roll and a spacer roll are displayed and you can edit them The window contains in the top part the following data Roll Number Width Part Number Max Diameter Classification Spacer Roll More Button More opens the Expanded Roll Tool Window In the lower part there is the list of the Roll Corner Points Width Diameter Radius Angle PE Click into a row of the table and the corresponding roll corner point in the Drawing Area will be highlighted by a little cross hair in the predefined mark color Vice versa if you identify a roll corner point in the drawing the corresponding row of the table in the roll tool window will be activated All values are shown in mm if you have selected in Options Profile List the representation of values Metric If you have selected Imperial they are shown in inch 3 3 6 Expanded Roll Tool Window 21x A Shaft FO 000 f Driven Bore Hole NSD Edit Bu
183. d Profile Element of type Line B or Arc A1 4 at a desired position in two parts Application spectrum e The Reference Point should be set to a certain point of the profile in order to form the profile in a position as symmetrical as possible or the deformation energy should be as equal as possible on the left and right side If there is no splitting point at this position it can be created by this function e A part of an arc should be developed by using another Bending Method because the design of the roll tools requires it e Two or more Holes Cut Outs should be added to a line segment It is necessary to split the line Calling the function Before you call this function select the profile element type L line or A arc that should be split Call this function optionally by e Main menu Profile Element Split e Context menu right mouse button click on the profile element in the Drawing Area Profile Element Split The input window appears with the question Enter arc angle as splitting position or Enter line length as splitting position Enter the desired value Principle of operation After confirming with the Ok button the profile element will be split as follows Type L Line The length of the marked line will be modified to the given length Behind the marked item a new line will be appended with the residual length The Strip Width i e the sum of all straight lengths will keep constant during this operation
184. d also the Direction will be adapted in order that the position of profile in the stand is not changed Unless you have selected a point on the sheet s top side then the profile is turned When you continue developing the Flower Pattern the unbending is related to the new develop point If you modify the start element of a symmetrical profile list with Symmetrical Point PS the list becomes unsymmetrical with Point P Hints e f needed you can Split a profile element previously if the new develop point should be on the split point e f you get an inappropriate start element after importing a CAD drawing use the function Modify Start Element for correction Modify Sheet Thickness This function enables to modify the sheet thickness in the design state of the final profile during flower pattern design or in a finished project This may be necessary if the roll tools should be designed for various sheet thicknesses and if the position of the sheet for the minimal and maximal thickness should be checked Another application is A running roll forming machine should be refitted for another sheet thickness The task is to check if this is possible with the existing rolls plus additional spacers or if in part new rolls have to be prepared Calling the function Call this function optionally by e Main menu Profile Modify Sheet Thickness e Context menu right mouse button click on a profile element in the Drawing Area Prof
185. d lines should be visible on the screen or not Copyright 2015 by UBECO GmbH Iserlohn 64 UBECO PROFIL Rollform Design Software 3 1 2 8 3 Hints e If you have selected a grid lines distance that starts with number 1 2 or 5 most significant digit the grid lines with double 5 fold or 10 fold distance are drawn bold e Select the grid lines color in Options Colors e Disable the grid lines with Options Drawing Grid or Button Grid on off Colors Use this function to preset the colors in the Drawing Area Colors of drawing Colors of Drawin Ausiliarny Line Main Line Profile Main Line Rolls Text e Reset Auxiliary line main line profile main line roll text Select the colors for the drawing The numbers of the colors are the same as in AutoCAD 0 by block 1 red 2 yellow 3 green 4 cyan 5 blue 6 magenta 7 white The selected colors will be transferred into the CAD and NC output file Default All colors of the drawing are reset to the default colors Colors of drawing area Colors of Drawing rea Inactive Marked Background Profile Explorer e Reset By mouse click a color selection window will appear Select the desired colors for the Drawing Area Inactive Color of the parts of the drawing which does not represent the active pass Marked Color of the drawing element that you have selected by mouse click Background C
186. d to enter e Dimension identify a dimension text and the identified dimensioning will be deleted Hint e See Toolbox Dimensioning for further information Output Drawing gt CAD PROFIL ls Ceiba fon fi Ema fees ij je ja eee ji Liria TES LE AutoCAD D Dn e ee Ea as 10 el 9 joya 9 918 ue ayudo 315 dell Tram al ActiveX EA Use this function to transfer the drawing which is currently displayed in the Drawing Area to your CAD System Calling the function Select from the menu View what should be transferred Select by mouse click if a certain pass or a certain roll or if all button Inspect should be transferred Call this function optionally by Copyright 2015 by UBECO GmbH Iserlohn 178 UBECO PROFIL Rollform Design Software 3 1 8 2 e Main menu Output Drawing gt CAD e CED Button Drawing gt CAD in the Button Key Bar Principle of operation The drawing which is currently displayed in the Drawing Area is transferred CAD System either directly or by interface file Setup Actver Outpu e Enable Actives Output to CAD disables File Outout to CAD If you have enabled the ActiveX Output to CAD in Options ActiveX the drawing will directly be transferred to CAD AutoCAD or SolidWorks or SolidEdge or BricsCAD and the correct view port and zoom window is set automatically If layers yet exist they will be deleted before updating Output to CA
187. ddle part springs back to a larger radius the other flat parts however want to reconvert to an arc again This means the springback acts in different directions By a smart selection of the radius in the input window the springback can be compensated completely Recommended values for the radius are Until 1mm sheet thickness Final radius plus 1 0 1 5mm addition until 2mm sheet thickness Final radius plus 1 5 1 7mm addition until 3mm sheet thickness Final radius plus 1 7 2 5mm addition The input window for entering the radius opens when an arc should be unbent by modifying the arc angle see Designing the Flower Pattern Hints e Enter the bending method into the column Type of the Profile List e Normally bending with modification of the neighbor segment arc type A2 A3 and A4 only makes sense if the neighbor is a line type segment type L However if it is an arc type segment the material is moved without bending This behavior can be intended by the user if he wants to modify the profile list in this way In order to bend up the profile this trick may be helpful Before bending select the position in the profile list where the material should be moved Copyright 2015 by UBECO GmbH Iserlohn 240 UBECO PROFIL Rollform Design Software 3 5 8 3 5 9 to Then insert a profile segment of type L and with length zero at this position by using the function Element Insert During bending of the arc th
188. deceuctalseas AEE e A 248 Prole Element Table concro a aos 249 Drawing AAA A a O e e 250 FILE onina 250 S Roll STOCK MaMaGGMme ME veccscesbcvs stcececwaredecsesiee ciadcouscadeccncaincccassvecssaweecsassecnevaccespancecsneveasescenteas 251 Y eas hea saat OO 252 RO COME Tale vere e aio 253 Project TAM aa 254 Copyright 2015 by UBECO GmbH Iserlohn Section IV oo Ff W N index Drawing Board iccosar nta citrico denia Pier a ia OTE a ee Variables laicas CAD SV SMS eaaa eaaa a ae Ea AE shearer Installation Contents of the Disks Installing PROFIL Driver Installation for Marx USB Hardlock ActiveX Interface to AutoCAD SolidWorks SolidEdge BricsCAD Interface to ME10 Interface to other CAD Systems Copyright 2015 by UBECO GmbH Iserlohn General 9 1 1 1 General Roll Forming Roll forming Roll forming is a continuous bending operation with rotating tools in which sheet or strip metal is gradually formed in tandem sets of rollers until the desired cross sectional configuration is obtained During this operation only the cross section is modified not the sheet thickness Roll forming is ideal for producing parts with long lengths or in large quantities ASC LI HORO E f Profiles Any kind of shapes can be roll formed simple and complicated ones Some examples for roll formed profiles are U and C channels door frames shutter profiles trapezoidal profiles cor
189. defined by the Initial Graphics Exchange Specification See also DXF Files e MI Files CoCreate ME10 MI File format defined by Hewlett Packard CoCreate PTC for Copyright 2015 by UBECO GmbH Iserlohn 52 UBECO PROFIL Rollform Design Software the CAD system ME10 OneSpace Designer Drafting or Creo Elements Direct Drafting respectively See also DXF Files A11 Files PC DRAFT A11 File format defined by ISD for the CAD system PC DRAFT in the mean time discontinued See also DXF Files STEP AP214 Creates the profile pass the roll tool stand or all stands as 3D models in STEP format in accordance with DIN ISO 10303 Product data representation and exchange EXPRESS language The single stand can contain a profile pas with user defined length See also Options Files Profile built from separate bodies Profile Lists PROFIL DOS Lnn Converts the current Profile Project to a set of Profile Lists with the same name In previous MS DOS releases of PROFIL the data were not saved in a project file extension pro but every profile list was saved in a profile list file extension LO1 LO2 and the roll tools of every stand were saved in a roll file extension RO1 RO2 You need this function if you want exchange data to and from a subcontractor customer who is using such a release Exporting of roll data files R01 is not implemented Machine Files m01 By using this function you can
190. detailed information from the ABAQUS User Manual Chapter Getting Started Topic Materials Plasticity in ductile metals Import TXT Imports a stress strain curve from a text file e g from a tensile test according DIN standard Each line of the file must contain a pair of values either strain stress or stress strain of one curve point Either decimal numbers are possible with dot or comma as decimal separator or numbers in exponential notation The delimiter between the values can be space or tabulator After Copyright 2015 by UBECO GmbH Iserlohn 198 UBECO PROFIL Rollform Design Software importing check the stress strain curve graphically by opening the Curve Generator Curve Generator In case the stress strain curve of the used sheet material is not available and you nevertheless want to proceed a FEA simulation with approximate values you quickly can create a curve by the Curve Generator by defining three characteristic curve points Hints e In a roll forming process also larger strain sometimes occurs either desirably or undesirably During simulating also for larger strain the belonging stress must be found So it is recommended to extend the stress strain curve to strain 1 at least better strain 2 e Take care that the stress strain curve increases continuously at the end this means the stress must be related the current area not to the original area of the tensile test specimen Contact 2 x
191. ds the dangerous yield point Calling the function Before you call this function select the pass that should be calculated Call this function optionally by e Main menu Calculate Stress of Edge F Button Stress of Edge in the Button Key Bar Principle of operation The window Stress of Band Edge is opened The strains are calculated by using an approach model that depends on an empirical analysis and the results converted to relative stress related to the yield point are displayed in the window The first row shows the Material entered in the Project Data Window and the stress of the yield point for this material Re Each row in the table represents a stand The column St displays the number of the stand 1 finishing stand numbering opposite the sheet running direction The columns display the relative stress of the band edge related to the yield point A value of 100 means the stress will presumably reach the yield point Because the maximum stress occurs shortly in front of a stand it is allocated to the stand Example In the line of stand 1 the stress is displayed that occurs in front of stand 1 seen from stand 2 Copyright 2015 by UBECO GmbH Iserlohn 130 UBECO PROFIL Rollform Design Software 3 1 5 2 1 The two bar diagrams show she relative stress for the left and the right side of the profile in a clearly laid out manner So it is easy to check if the stresses of all stands are below the
192. e Diameter The diameter of the Corner Point belongs to the roll data and is displayed in the table of the corner points of the Roll Tool Window You can modify the diameter by e data input into the input field e pressing PgUp Dn on the keyboard e using the Toolbox Modify Radius The radius of the Corner Point belongs to the roll data and is displayed in the table of the corner points of the Roll Tool Window You can modify the diameter by e data input into the input field e pressing PgUp Dn on the keyboard e using the Toolbox Modify The radius causes a fillet at the corner point with tangential connections to the drawing elements of the neighbouring corner points In case of pure arc transitions width and diameter both of the selected and of the neighbouring corner points are modified if necessary If the fillet is not possible e g if the radius is too large and the arc would exceed the limit to the neighbouring corner point this is shown in the drawing area and a warning is displayed in the bottom status bar Angle The angle of the Corner Point belongs to the roll data and is displayed in the table of the corner points of the Roll Tool Window The angle is positive if the next corner point has a larger radius in the other case it is negative The roll axle is the reference line for the angle Thus a cylindric part of a roll has the angle 0 You can modify the angle by e data input into the input field e pressi
193. e If General Contact is set in Output FEA Touching the Profile at is ignored Drawing Area The drawing area in the background shows permanently the drawing of the profile the flower pattern or the roll tools Use the Navigator in the upper right corner to select the view port In order to have a better general overview of the proportions of the objects you can attach Grid Lines to the drawing background Select what you want to see View Pass View Statics View Flower Nested View Flower Separated View Flower 3D View Roll Tools Copyright 2015 by UBECO GmbH Iserlohn Reference 215 View PSA Profile Stress Analysis View FEA Result If you select Flower only the active pass is shown in its defined colors To activate another pass e Select the pass in the Profile Explorer e Activate the Profile list Window if opened e Click into the drawing and identify a line element not arc element of the desired pass Inside an active pass you can identify line and arc elements the color changes The data of the selected profile element are displayed in the bottom status bar Simultaneously the corresponding Profile Element in the Profile List Window will be activated if the window is open Inside the drawing of the roll tools you can identify rolls and roll corner points The data of the selected roll corner point are displayed in the bottom status bar Simultaneously the corresponding Roll Corner Point in the R
194. e Or use the arrow buttons in the header bar for modifying e Select Interpolation Points in the header bar in order to get a continuous curve without kinks Copy drawing to clipboard Use this button to copy the stress strain curve as pixel drawing to the Windows clipboard see also Edit Copy e EAD Drawing gt CAD Use this button to transfer the stress strain curve as vector drawing to the CAD system The settings of the function Drawing gt CAD in the PROFIL main window are used as well Principle of operation The stress strain curve is rebuilt permanently after each modification A new curve appears with these properties e Tangential connection to the Hookean line e Continuous rising with rising strain true strain for FEA not nominal strain from the tensile test After pressing the Ok button the new stress strain curve is entered into the Stress Stain Curve Table in Output FEA Copyright 2015 by UBECO GmbH Iserlohn Reference 201 3 1 9 Help 3 1 9 1 Assistant ij UBECO PROFIL Help Assistant El The PROFIL Help Assistant will accompany you during your design of roll tools For roll formed profiles and tubes Use the right mouse button to preset if you wank to see all unread only or no hints The help assistant accompanies you during your design work by showing helpful hints in a speech balloon In case the display time was too short click on the PROFIL symbol in the right corner and
195. e cross section is needed for this operation Calling the function Define as pass L01 the profile that the estimated count of stands is needed for Use the Toolbox Profile Design the Graphical Method or the Numerical Method for it Select pass L01 Call this function by e Main menu Calculate Required Count of Stands Principle of operation LT i x For roll forming this profile at least the following count of stands is required Calculation according to Dreistern Schopfheim Germany Left 6 Right 22 A window opens and shows the estimated count of stands for the left and right half of the profile Left side is the side left of the Reference Point X0 Y0 provided that the Start Direction points to the right The calculation is according the method of the company Dreistern Germany Hint e f you have not selected the final stand L01 previously but another stand of a already partly existing flower pattern a message is shown If you confirm the estimated count of stands from the selected stand to the flat sheet is calculated and displayed Plausibility Check This function is useful to check the whole project on e Errors in the logical structure of the profile list e g empty profile elements negative radii existence of P or PS missing distance between stands e Overlap of roll contour arcs Calling the function Call this function by e Main menu Calculate Plausibility Check Principle of o
196. e Expanded Roll Tool Window from the Expanded Roll Tool Window from the Expanded Roll Tool Window weight of the cylindrical tool blank with the blank size Unit kg or lb Multiplied with Count weight of the finished roll the outer contour and the bore hole are considered Unit Kg or Ib Multiplied with Count diameter sign can be inserted in front of blank or finished diameter by sign can be inserted between diameter and width for any user defined characters Parts List Columns From the list available any entry can be copied into the Parts List Columns table by using the button with the left arrow Afterwards the entry can be moved by using the buttons with the up and down arrow To remove an entry from the list use the button with the right arrow The parts list is created by function Output Create Parts List dependent on the order in the Parts List Columns table Copyright 2015 by UBECO GmbH Iserlohn 72 UBECO PROFIL Rollform Design Software Blank Diameter ls a Count CO Left f Centt Righ fi Decimal Places fi Frio of Sorting Calculate Sum Column Properties For each entry in the Parts List Columns table the properties can be set Count of characters Position left center or right Decimal Places Priority of Sorting and if the Sum should be calculated Decimal places sorting and sum are only possible for numerical values Count Position and decimal places are only pos
197. e Main menu Calculate Statics e A Button Statics in the Button Key Bar Principle of operation The Statics Window is opened and shows these statics parameters Reference Point Centroid In Principal Axes Shear Center Point Copyright 2015 by UBECO GmbH Iserlohn 126 UBECO PROFIL Rollform Design Software 3 1 5 1 1 3 1 5 1 2 3 1 5 1 3 Moments of Inertia Moments of Resistance Max Distance Inertial Radii Area of Cross Weight Principal Axes Angle Vault Resistance Torsion Moment Setup Representation of Values Integer Decimal Places fa a e Metric N mm f Imperial Ib ir Select in Options Calculate Representation of Values whether the statics should be displayed in the Metric System mm N or the Imperial System in lb Set the count of Integer Decimal Places as well Hints e Use the functions File Print Preview or File Print to print the statics e Use the function View Statics to display the statics in the Drawing Area and to transfer them to the CAD System Reference Point The reference point is the point inside your drawing that you have defined as your Reference Point X0 YO i e start point of the profile Furthermore it is identical with the symmetrical point of Profile Element PS of symmetrical profiles or with the point P of an asymmetrical profile which is the beginning of the second half Hints e Modify the Reference Point X0 YO by using the function
198. e Point can be set independently from the profile reference point Usually both reference points are set to the same coordinate Direction ry The Direction determines the start angle of the profile in the Reference Point X0 YO It is defined like in CAD systems 0 to the right 90 to top 90 to bottom Most profiles have a horizontal web The reference point is in the middle of it and the direction is 0 Sometimes if it has not a horizontal web the reference point has to be set to a point on an angular part of the profile as shown in the example drawing Then the direction is positive for an ascending and negative for a declining part The direction belongs to the Profile List data and is displayed in header of the the Profile List Window Hints e By using the function Read CAD Contour the direction is automatically set to the direction of the contour e During flower pattern creation do not forget to turn the profile in the machine in order to get the direction 0 for the flat sheet This is important why the decoiled strip always is horizontal This can take place step by step within several passes Copyright 2015 by UBECO GmbH Iserlohn 236 UBECO PROFIL Rollform Design Software 3 5 6 3 5 6 1 3 5 6 2 Profile Elements The profile elements are the components of the Profile List that describe the geometry of the profile as a spread sheet table Each profile element desc
199. e Radius Select if the radii of the roll should be dimensioned e Delete Existing Dimensions Select if the new dimensioning should be attached to an existing dimensioning or if the existing one should be deleted previously Principle of operation After pressing the Ok key the roll will be dimensioned automatically If necessary use the function Move Dimension afterwards for exactly positioning the dimensioning Certain items can be removed by the function Delete Dimension Hint e See Toolbox Dimensioning for further information Copyright 2015 by UBECO GmbH Iserlohn Reference 177 3 1 7 4 9 Move Dimension This function is a part of the Toolbox Dimensioning and can be used for exactly positioning the dimensioning Calling the function Call this function by am Button Move Dimension from the Toolbox Dimensioning After calling this function you are asked to enter e Dimension identify a dimension text and the identified dimensioning appears as a drag dimensioning e Dimension Text Position Afterward the dimensioning is positioned as desired Hint e See Toolbox Dimensioning for further information 3 1 7 4 10 Delete Dimension 3 1 8 3 1 8 1 This function is a part of the Toolbox Dimensioning and can be used for deleting the a dimensioning Calling the function Call this function by e a Button Delete Dimension from the Toolbox Dimensioning After calling this function you are aske
200. e To insert a profile element at the current position use the function Element Insert e To append a profile element behind the current one use the function Element Append 3 1 3 16 9 Copy Use this function to copy the topical profile element or the marked set of profile elements to the clipboard This enables to paste them at another position in the same Profile List in another profile list of the same profile project or in another profile project Use the function Element Insert or Element Append to paste the profile elements Calling the function Before you call this function select one or more profile elements Call this function optionally by e Main menu Profile Element Copy e Context menu right mouse button click on the profile element in the Drawing Area Profile Copyright 2015 by UBECO GmbH Iserlohn Reference 105 3 1 4 3 1 4 1 Element Copy To select a single profile element click on the desired object either in the Drawing Area or in the profile list window 21x Pass xD 200 000 Dist Stand 300 000 y0 150 000 Strp width 62 087 Direc St Lenath 2 000 90 000 In order to mark a set of profile elements click on the first profile element in the profile list window then press and hold the Shift Key and click on the last profile element Or press the Arrow Down Key while the Shift Key is pressed It is sufficient if the row Type is marked
201. e and decides how the rolls should be handled All values are shown in mm if you have selected in Options Profile List the representation of values Metric If you have selected Imperial they are shown in inch Context Menu Stand Final Stand Calibration Factor i 153 000 150 000 Inel Anae In certain input fields further functions are available from the context menu right mouse button a Copyright 2015 by UBECO GmbH Iserlohn 218 UBECO PROFIL Rollform Design Software e Cut Copy Paste Delete Enables transfer of parameters via the clipboard Copy To All Copies the selected parameter to the corresponding input field in all other stands If this function is called in the input field Working Diameter of the first stand a window opens and asks Increase working diameter per stand by The diameters of all previous stands are decreased by the given value thus the diameter increase in sheet running direction This prevents vertical buckling by lead strip tension Also the spring back of the profile legs is reduced between the stands Calculator Opens the Calculator and copies the selected parameter to it s display After closing the calculator the result is transferred back to the input field Press the Enter or Tab key afterwards 3 3 8 1 Machine Explorer F02 FOS E FO4 FOS l FO6 FO FOS FOS F10 Machine explorer of a typical roll forming machi
202. e calculated The length is always positive The insert point is the start point of the line element Width and height are measured in the x y coordinates of the drawing enter the correct sign dependent on the direction of the previous element Principle of operation If you have selected a Profile Element previously the new profile element will be appended to the selected one Otherwise it will be appended to the end of the profile Arc This function is a part of the Toolbox Profile Design and generates a new element of type arc Calling the function Call this function by e Pi Button Arc from the Toolbox Profile Design The window Arc is opened If you enter Angle and Radius width and height will be calculated If the angle is negative an arc to the right will be generated If you enter Width and Height angle and radius and direction will be calculated The length is always positive The insert point is the intersection point of the tangents to the arc this means the length of the previous element will be shortened Width and height are measured in the x y coordinates of the drawing enter the correct sign dependent on the direction of the previous element Principle of operation If you have selected a Profile Element previously the new profile element will be appended to the selected one Otherwise it will be appended to the end of the profile Copyright 2015 by UBECO GmbH Iserlohn Reference 153
203. e from 3DConnexion as navigation input device Either USB Hardlock or hardlock for the parallel interface Bugfixes Saving the Machine File is possible now in case of an empty deformation degree field of calibration stands No data loss anymore when in the Machine Window forming stands are appended behind calibrating stands Roll Table Insert Roll from CAD is now possible again For the Weight in the Statics Table holes cut outs now are not considered since input of count and length is not supported PROFIL Rel 4 2 01 Dec 2005 New features User defined shortcuts for any menu item see Options Keyboard Parts list can be created not only in a fixed output path but also in the path of the belonging project file see Options Parts List Changing the radius of roll corner points fillets now is possible in case of pure arc transitions to the neighbouring corner points see Roll Corner Point Radius Plausibility Check recognizes and flags implausible profile lists and roll contour errors The Calculator can be opened from the context menu of any numerical input field The Explorer is able to show either the profile list number counting against the sheet running direction or the pass number counting in sheet running direction The Development Table represents the angle sequence of the flower pattern Bending angles are shown either in degree or in percent related to the final angle Automatic Flower Creation by using t
204. e inserted between the rolls e All stands of the whole profile project 3D Model gt CAD Rolling Direction cy fe If you select All stands you can preset the rolling direction in Options ActiveX ActiveX output only Principle of operation a AutoCAD You get the 3D wire frame model of the rolls Select the view port by rotating the model function 3D Orbit Call View Render Render in AutoCAD In the dialog box select Photo Raytrace and set e g the background color quality and resolution anti aliasing Furthermore lights can be set You can copy the created image into the Windows clipboard and export it to other programs Get further information from the AutoCAD manual SolidWorks Open a Part Document first After transfer you get the 3D model of the selected stand ATF Y SolidEdge Preliminary the transfer is possible for 2D drawings only The extension to 3D models is planned for a later release hy BricsCAD Preliminary the transfer is possible for 2D drawings only The extension to 3D Copyright 2015 by UBECO GmbH Iserlohn Reference 181 models is planned for a later release STEP AP214 You get the 3D model of your selection The file can be opened in any 3D CAD system with STEP interface Hints e If the outer contour of a roll is not unambiguous e g if lines intersect themselves the 3D model cannot be created In this case please check the roll contour by functio
205. e is smoothly without detours Use the function Calculate Stress of Edge to get the bar diagram of the stresses between all stands on the left and on the right side of your profile Examine if all stresses do not exceed the yield point 100 in the bar diagram Otherwise correct the bending steps The stress of edge can be examined while bending yet If the calculation of the stress of edge is not sufficient use the function PSA Profile Stress Analysis to calculate the stress within the whole profile This is important when the maximum stress is not at the band edge e g when edges are folded and the folds are bent The function File Print prints out the drawing the profile list the table of statics and the bar diagram of the stress of band edge Use the function Drawing gt CAD to transfer the drawing which is displayed in the Drawing Area to your CAD System Hints e During designing the flower pattern you get a set of profile lists L01 L02 LO3 etc The last profile list e g L16 should contain the flat strip as it is decoiled from the coil The names are shown in the Explorer The number sequence is in design direction this means opposite the sheet running direction The next step is Designing the Roll Tools Copyright 2015 by UBECO GmbH Iserlohn Tutorial 35 2 5 2 Designing the Tube Flower Pattern By using the Toolbox Tube Design you quickly can design the flower pattern for seamed tubes and
206. e last step is to export the manufacturing data like parts list Sawing list and the program for the CNC lathe Strain and stress in the longitudinal direction Exactly this is the problem if single points of the sheet cross section are tracked movements on curves with different lengths are observed The result is different strain and stress of the material As long as this occurs within the elastic bounds strain disappears again after the profile leaves the final stand of the roll forming machine and the desired profile form can be obtained If however the yield stress is exceeded remaining strain arises The local too much of material causes unwanted deformations like rippled edges mostly in case of symmetric profiles If the profile is non symmetric twists around the longitudinal axis or curved profiles can result When this occurs time consuming and expensive modifying of the roll tools is necessary 1 2 What is PROFIL ali sl Di pe ff ei e a Jei pai p REA e cd o CL ll bo ai Arles ha i re a jai mE isl Pa a O da Taj Can Pami a nia ox cds bara jii Pe r Pe ahat dr pol opal 7 a s F Dae Line oa al n A 443 IES E 5 F SEs pal gt mi a a Y F E 1 i 1 i in it f i pih E ED ee ee Yi i W ae 7 LE IF pn TA 15 mi E PEL i Ai a F i LA Tem Ia i ia a iy 5 E gt a i Lat E 7 T wok el rr dc F a learg ind E Cde m re mT z Mal gt E mn
207. e new line segment will be lengthened and the profile will be bent up Holes Cut Outs If you have selected in Options Profile List the layout with holes cut outs in the Profile List Window the input fields Size and Position are shown Use these fields to add holes cut outs to any Profile Element of type L Enter the diameter of the hole or the maximum width of cut out into the field Size Enter the distance from the center of the hole cut out to the start of the profile element into the field Position Principle of operation Holes cut outs will weaken the profile this will be considered by function Calculate Statics Statics is only related to the cross sectional area so longitudinal size has no influence But it must be considered in strength calculations based on the statics PROFIL does not deal with strength calculations Hints e View Pass or any other view function will display your defined holes cut outs They will be transferred to the CAD drawing by function Drawing gt CAD e You may also print the profile list including holes cut outs Use the function File Print Precondition is that you have selected the layout with holes cut outs in Options Profile List e f the Profile Element should get more than one holes cut outs you have to split it by using the function Profile Element Split Calculation Methods The Strip Width of a profile is the sum of the Straight Lengths of all Profile Elements In case of a profile
208. e of the current project does not exist If you have moved the result file into a new path you can save the new path by function Save Project into the project file afterwards Principle of operation The FEA result is displayed as a 3D graphic Select the initial view port angle in Options Drawing or modify the angle by using the context menu right mouse button The button bar on the right enables you to modify the view dde hal Mean Energy Ratio If the time increment for the mass scaling selected in Output FEA page Others is too large the FEA result becomes invalid To check the validity the mean energy ratio is displayed For a valid result the mean energy ratio should be lt 0 025 Color Assign i i 2 x Assign Sha E All Mises Stress Sheet Center Mirror Symm ri Autom ALS A pa O EeL A are pee tel ee Les yee Lect e Color Assign By pressing this button the window Color Assign is opened By moving the tabs you can assign the colors blue and red to any strain and stress Furthermore you can select whether all 5 layers within the sheet thickness should get different colors Assign All or if the color of all layers should be assigned to the stress strain of the centerline of the strip Assign Sheet Center The last one is useful if you do not want to see the desirable stress and strain on Copyright 2015 by UBECO GmbH Iserlohn 146 UBECO PROFIL Rollform Design Software 3 1 6 8 3
209. e profile element of the Profile List LO1 final pass Straight Lenth These data are automatically transferred when a profile is inserted into the database via Profile Catalogue Save The belonging project data of the profile elements are displayed in the Profile Table Use a Filter to reduce the amount of displayed profiles The drawing of the selected profile is not stored in the database while browsing through the database it is quickly generated from the profile element table and displayed in the Drawing Area instead The top bar of the profile element table contains these buttons ma A 121 Database Navigator for switching to the first previous next last profile element for inserting deleting and editing a profile element for posting and cancelling the edited data and for refreshing the data e g if in a network several designers use the same database Copyright 2015 by UBECO GmbH Iserlohn 250 UBECO PROFIL Rollform Design Software 3 7 3 3 7 4 Drawing Board The top area on the right of the Profile Catalogue Window contains the drawing area which displays the drawing of the profile which is selected in the Profile Table in the bottom area of the window The drawing is always refreshed from the data of the Profile Element Table so that you have a clear idea how the selected profile looks like The colors of the drawing are the same as the colors of Drawing Area of the main windo
210. e whole number divisor see above Large Arc Seg select the desired length of the shell elements for Profile Elements of type Arc The arc developed length id divided Regards the whole number divisor see above Def Large Arc enter the limit between large and small arcs A large arc is detected when the radius of the centerline of the sheet is larger than the sheet thickness multiplied by the preset factor Transit Elements possibly the FEA system wants to place an arc to a different position than you have planned it in your flower design To enable this transition elements can be set When a line segment touches an arc segment the beginning or the end of the line segment is divided in smaller items with the same shell element length as the neighbouring arc segment Select the count of transition elements This setting is effective for meshing General and Individual The picture shows a snap shot while simulating a hat profile When the sheet enters a roll stand not only the bending zones are bent blue correspondents to the profile elements Arc but also the parts of the profile that properly should keep unbent yellow correspondents to the elements Line The example shows in the top right bending zone the roll attacking point actually is outside the planned bending zone In order to enable the FEA system to calculate properly in this example Transit Elements 2 was selected small yellow items left and right of e
211. e width is set automatically to a minimum width that has enough space for all fillet radii The result is rounded to 10 mm or 1 in e Fillet Radii R1 R2 Select a fillet radius at the inside at the tube and a fillet radius at the outside at the roll edges Working diameter and reference point are taken from the Machine Data Principle of operation After pressing the Ok button the roll is generated If a roll is yet existing it will be replaced 3 1 7 2 9 Fin Pass Side Rolls This function is a part of the Toolbox Tube Design and is used for generating the side rolls for a fin pass without a shoulder Copyright 2015 by UBECO GmbH Iserlohn Reference 167 Calling the function Before calling this function you should have created a fin pass by using the function Fin Pass If you created the fin pass in another way pay attention that the profile list contains exactly 3 entries A1 A1 PS Only for such a tube profile rolls can be generated automatically Call this function by T Button Fin Pass Side Rolls from the Toolbox Tube Design The window Fin Pass Side Rolls is opened Enter these parameters e Roll Diameter D If your entered diameter is too small that the roll cannot touch the tube an error message appears If it is too big the diameter is set automatically that both side rolls touch together e Total Width W If your entered value is too small the width is set automatically to a minimu
212. eSpace Designer Drafting or PTC Creo Elements Direct Drafting Precondition In Options Files Output to CAD ME10 Ml is selected The file Rolle mi is read from the same path that is set for the output file This file must contain the drawing of one roll exactly To get this file select in ME10 the part that contains the roll EDIT PART and store the active part into a MI file STORE MI DEL_OLD Rolle mi The roll has to be drawn with the same colors and line types that are used by PROFIL when a drawing is created in CAD e Others Precondition In Options Files Output to CAD A11 DXF or IGES is selected The KTR or DXF file is read that is set in Options Files from CAD This file must contain the drawing of one roll exactly oa Insert Roll from File This function is equivalent to Insert Roll from CAD but the roll is not taken from a fixed source Instead of it a file selection window opens and any DXF or KTR file can be selected as import file D Copy Roll to Clipboard copies the selected roll from the database to the clipboard From the clipboard the roll can be inserted into the current project by using the function Roll Insert GAD Drawing gt CAD transfers the drawing of the selected roll directly to the CAD system This function uses the same settings as the function Drawing gt CAD in the main window Roll Corner Table The left area in the middle of the Roll Stock Management Window displays the Roll Corner Points of
213. ect In previous MS DOS releases of PROFIL the data were not saved in a project file extension pro but every profile list was saved in a profile list file extension LO1 LO2 and the roll tools of each stand were saved in a roll tool file extension RO1 RO2 You need this function if you want to convert profile lists and roll files from previous releases to project files for example if you obtained an update of PROFIL or if you want to exchange data to and from a subcontractor customer who is using such a release After importing a profile project is created with the name of the imported profile lists If you save the project afterwards by using the function File Save Project it will be saved into the path of the profile lists Machine Files m01 When you start with a new Project that does not contain Machine Data you can import machine data from a machine file m01 which you created with the function Export from another project previously Thus you can transfer machine data created in a previous project to a new project in case the roll tools should be designed for the same machine FEA Result Files ABAQUS Explicit FIL Use this function to display the result of the simulation of the roll forming process by FEA Finite Element Method in the Drawing Area See also View FEA Result Hints e In order to import a partial project file pro use the function File Partial Project Add On e In order to op
214. ection This makes it easier to form the inner radii precisely which are not accessible for horizontal top rolls For this purpose additional side axles with arbitrary inclination angle can be created in the machine window Copyright 2015 by UBECO GmbH Iserlohn Tutorial 45 LIL LO ILeY Ra1r 01 1r1 AA J 1u1 Ra1u 01 Operating Instructions After right clicking on the side axle symbol L or R in the machine window a context menu opens and additional side axles can be defined and removed again in the same way The axle can be vertical 0 normal position or inclined with any inclination angle positive outwards and negative inwards Any number of additional axles can be defined During creation of a new axle the data of the previous axle are copied The inclination angle however is modified in order to have the new axle visible in the drawing area and selectable by mouse click Afterwards the user should set the desired inclination angle Roll Numbering In order to enable the automatic numbering of the roll number and the part number two new variables are provided They can be used in the number keys input fields Options Rolls SA consecutive number over all rolls of a certain stand in the order bottom top left right TA consecutive number over all rolls of a certain shaft axle type B T L R of a certain stand All left side rolls belong to the type L and all right
215. ed if the filter name in the same row determines a numerical field Buttons m Save Filter If a filter name is displayed in the input field i e if you have loaded an existing filter you can use this button to save changed filter conditions If not i e if you have entered new filter conditions you are asked to enter a filter name after pressing this button Afterwards the new filter will be saved Filter On If the table contains filter conditions the filter will be switched on Afterwards the Profile Table displays those profiles only which match to the filter conditions In the top bar of the profile table the number of filtered profiles is displayed If the profile table is empty there is no matching profile in the database 0 Filter Off Use this button to switch off the filter All profiles are displayed in the Profile Table again In the top bar of the profile table the number of all profiles is displayed again Copyright 2015 by UBECO GmbH Iserlohn Reference 251 3 8 Roll Stock Management Roll Stock Management Roll Comers C Projects H a gt m a Oe Comer No Width Diameter Radius Angle 1 156 000 1 000 2 5 250 156 000 0 500 80 000 3 7 013 136 000 1 750 5 000 4 70 000 124 979 2 000 E Max Shaft Stock Position User wp3591 3075 3 e5000 159 666 50 000 0422 Maschine 4229 wp3591 3080
216. ed by the user for selecting the desired profiles The profile catalogue contains the Profile List of the final pass LO1 each and the project data of the Profile Project The belonging drawing of the final pass is quickly generated and displayed while browsing through the database A special button in the profile window enables quick access to the project file 3 different user defined views with desired columns are displayed by key stroke Calling the function Before you call this function select one of the views View Pass View Statics View Flower Nested View Flower Separated View Flower 3D This prepares opening the profile catalogue for the button in the top button bar Call this function optionally by e Main menu Profile Profile Catalogue e P Button Profile Catalogue in the Button Key Bar Profile Catalogue Open After calling this function the window Profile Catalogue appears which contains 4 areas e Profile Table lower area This is the real profile catalogue each row displays the project data of one profile e Profile Element Table in the middle left This area displays the profile list LO1 final pass data of the profile selected in the profile table e Drawing Area top on the right This area displays the drawing of the profile selected in the profile table e Filter top on the left Any filters can be defined for reducing the amount of displayed profiles Profile Catalogue Save Use this function to s
217. ed in the header of the Roll Tool Window The maximum diameter is only an output field this means you cannot enter data into this field The diameter is identical to the intersection point of the corner point with the largest Diameter Spacer Roll Spacer roll is a switch that belongs to the roll data and is displayed in the header of the Roll Tool Window It is set automatically by Rolls Soacer Rolls Create Dependant on the status of this switch the roll is treated differently Treating as Forming Roll box Spacer Roll unchecked e During Renumbering the Number Keys in Options Rolls are used e Inthe Part List the appropriate designation for Bottom Roll Top Roll Left Roll and Right Roll is taken from Set Up Parts List Columns Treating as Spacer Roll box Spacer Roll checked e During Renumbering the Number Keys in Options Spacers are used e Inthe Part List the appropriate designation for Spacer Roll is taken from Set Up Parts List Columns e Rolls Spacer Rolls Remove removes only this kind of roll e View Show Spacer Rolls toggles on off the display and output of this kind of roll Corner Point Ue s z 5 a i l B1 A B3 Bi The contour of a roll is described by a set of roll corner points Each one has the following data Width Diameter Radius Angle Imagine a rubber band stretched across the corner points 1 2 3 4 see picture which are defined by width B1 B2 B3 B4 and diameter D1 D2 D3 D
218. ed on the bottom or top shaft in order to fix the horizontal position of the forming rolls They have a smaller diameter than the forming rolls and do not touch the profile The width of the spacers results from the leftover distance between the forming rolls and the machine stand defined by the Working Width in the Machine Window So Copyright 2015 by UBECO GmbH Iserlohn Tutorial 41 2 6 7 after designing the forming rolls the size of the spacers is defined The diameter of the spacers is constant defined by the Spacers in the Machine Window Spacers also can be inserted between forming rolls In this way roll tools can be used for varying profile widths only by replacing the spacers against others with varying widths In order to avoid to manufacture the spacers for each project newly this method often is used The forming rolls are furnished with extensions Cylindrical Conical or Arched with the option To Width Absolute and a smooth value is entered in the raster 1mm 5mm or 10mm This will lead to smooth spacers widths In addition the spacers are split to shims e g in the raster 100mm 50mm 10mm 5mm 1mm So the spacers can be combined from an existing spacer stock PROFIL provides two alternatives to insert spacers e Automatic Spacers By checking the box Autom Spacers in Options Drawing Rolls the empty space left and right of the forming rolls are filled with soacers autom
219. ed or not e Arollis selected The selected roll can be dimensioned only because the drawing elements of all other rolls cannot be identified The created dimensioning is visible only when the dimensioned roll is selected or when no roll is selected It is not visible when another roll is selected e No roll is selected Function Inspect Now you can dimension all drawing elements therefore dimensioning across roll boarders is possible e g distance between shafts The created dimensioning is visible only when no roll is selected Context menu _ Intersection Point of the Tangents C Arc Center Point gt Arc Quad Point 0 L Arc Quad Point 90 N 0 Arc Quad Point 180 2 Are Quad Point 270 D Are Point Abs Angle Th Arc Point 4 Examples for dimensioning by using the context menu 62 28 Copyright 2015 by UBECO GmbH Iserlohn Reference 171 Call the context menu by using the right mouse button when you are asked 1 2 dimension point Without using the context menu always one of the end points is caught If you call the context menu you can use further extended catch points e Intersection point of the tangents e Arc center point e O Arc quad point 0 90 180 270 e Arc point abs angle Enter the absolute angle related to the horizontal x axes in the following input window e Arc point Enter the relative angle in in the following input wind
220. ehind the point P e Selection discharged or loaded by using the menu switch Profile Loaded just as you have drawn the contour e Call the function Profile Read CAD Contour and you get the profile list for the contour Check the profile list by using the function View Pass If you are using another CAD system you alternatively can use the Contour File DXF Format Contour File DXF Format Use the contour file to transfer the geometry of a profile or a roll tool drawn in the CAD System to PROFIL The DXF format is a file format defined by Autodesk used from nearly all CAD systems The file can contain unsorted LINE ARC POLYLINE LWPOLYLINE and ELLIPSE entities the contour tracking is done within PROFIL To generate a contour file proceed the following steps e Draw the contour in the CAD system Select a Reference Point this is mostly the center point of the lower line of the web of the profile and draw the lower line of the profile beginning in the reference point e Save the contour into a DXF file In AutoCAD use the function DXFOUT Create a small CAD macro to simplify this operation e In PROFIL select the Profile Element in the Profile Lists Window for the start of the contour The start point normally is element 1 except you read the 2nd half of an asymmetrical profile then the start point is the next element behind element P If you have selected the first element the reference point x0 y0 and the direction
221. election window and the file name input path and input format can be set individually So the import function is useful for importing files with frequently alternating file names Calling the function Call this function by e Main menu File Import The file selection window is opened and the file name input path and input format can be set individually The settings are remembered when the function is recalled So it is quite easy to import series of different files Principle of operation Which file formats can be opened is dependent on the used software version These formats are Copyright 2015 by UBECO GmbH Iserlohn Reference 51 3 1 1 8 available e KTR Files PROFIL KTR File format defined by UBECO see Contour File KTR Format Use this format if a macro in your CAD system proceeds the contour tracking and saves the drawing elements in sorted order See also DXF Files DXF Files AutoCAD DXF File format defined by Autodesk Nearly all CAD systems are able to create files in this format Dependent on the current design stage if View Pass or View Roll Tools is selected the function Profile Read CAD Contour or Rolls Read CAD Contour or Roll Read CAD Roll is called During Import the temporal input file pre set in Options Files is not used Profile Lists PROFIL DOS Lnn Use this function to import a set of Profile Lists and a set of roll tool files in order to create a new Profile Proj
222. electors Stresses are calculated by colored faces To assign the colors to the stresses and to set up the width and length of the shell segments and for furthermore settings call Options PSA The bottom status bar shows the maximum relative stress in related to the yield point The analysis range From Pass To Pass is considered By moving the range limits you can explore points of high stress Setup View Flower 30 fo 45 C gp 0 135 0 300 Select the initial view port angle in Options Drawing or modify the angle by using the context menu right mouse button z Scaling Hints e The Navigator helps you to zoom to move and to fit the drawing e By using the Navigator 3Dyou can rotate the drawing and toggle to a 2D view e With the function Output Drawing gt CAD you can transfer the drawing to your CAD System 3 1 6 8 FEA Result Copyright 2015 by UBECO GmbH Iserlohn Reference 143 3 1 6 8 1 LS Dyna Result of an FEA simulation with LS Dyna shown in the PROFIL drawing area Use this function to display the result of the roll forming simulation with LS Dyna by FEA Finite Element Method in the Drawing Area This function currently is possible only if the element type Shell is selected see Output FEA LS Dyna Profile In a later version this function will be available for element type Solid too Calling the function Before you call this function proceed the FEA Sim
223. elements for line segments Since the divisor must be a whole number the effective length will be approximate to the setting e Small Arc Seg Select the desired length of the shell elements for arc segments The arc angle is divided Regards the whole number divisor see above e Large Arc Seg Select the desired length of the shell elements for arc segments The arc developed length id divided Regards the whole number divisor see above e Def Large Arc Enter the limit between large and small arcs A large arc is detected when the radius of the arc segment is larger than the preset limit Meshing Rolls Radial Select in how many angle segments a roll should be split for meshing E g the input Angle Segment Count 90 means the rolls are split radially in 360 90 4 Segments 3 1 8 8 1 3 Holes Cut Outs This dialog window is called by Output FEA LS Dyna Is used for parameterizing the meshing of the roll tools and holes cut outs ax LS Dyna Profile Meshing Holes Cut Outs Colors DF File Rolls Line Segments 5 000 mm Meshing Lines a Stat Small Are Seg 15 000 Holes Cut Outs El Material Large Are Seg 5 000 mm Contact Others Def Large Arc Radius gt 15 0 mm x Cancel Help Meshing Holes Cut outs Line and arc segments are meshed as follows How to define holes cut outs in the flat sheet read in the chapter Defining prepunched holes cut outs later in this
224. elements of Type L Line the straight length is identical to the line length Otherwise in case of a profile elements of Type A Arc the straight length has to be calculated by assuming a neutral line that keeps it s length constant during bending Thus the straight length is identical to the neutral line Laret f 360 with L Straight length or length of the neutral line blue line see picture ri Inner radius f Factor for the position of the neutral line 0 inner sheet side 1 center line S Sheet thickness a Bending angle In case of large radii the neutral line is in the sheet center accurately the factor f for the position of the neutral line is 1 The smaller the radius is the more the neutral line is moved to the inner side of the sheet the factor is lt 1 For sharp bending i e with inner radius near 0 the factor is about 0 4 0 5 Copyright 2015 by UBECO GmbH Iserlohn Reference 241 In order to get the factor f for the position of the neutral line several methods exist Two of them have delivered an optimal performance in practice the Oehler and the DIN method Oehler Method 1 0 a aii 90 30 0 9 0 8 0 7 0 6 0 5 0 4 0 3 0 2 0 1 f f ps2 The Oehler method determines the factor f as a function of the medium radius rm the sheet thickness s and of the bending angle a in the diagram shown as a set of curves This is why the Oehler method is the mos
225. ely e ubeco psf Personality File e Marx Driver for the Marx USB Hardlock CBUSetup exe readme txt version txt The following installation procedure requires these files on a disk in drive a Please start the installation with Installing PROFIL Installing PROFIL DQ ee In order to install PROFIL for WINDOWS proceed as described e Installation Start the setup program a PROFIL32 exe and follow the instructions of the setup procedure e Copy the Personality File ubeco psf into the path of PROFIL It will turn the Version on this means the demo version becomes a LT or Full Version e g copy a ubeco psf c program files UBECO PROFIL e Set the Screen Resolution to 1024 x 768 or higher and select Small Fonts PROFIL LT The software now is fully installed for WINDOWS PROFIL Full Version With it PROFIL Full Version is installed and in case you use AutoCAD or SolidWorks or SolidEdge or BricsCAD the ActiveX interface is ready Now install the hardlock driver PROFIL Full Version only e Driver Installation Marx USB Hardlock Further Information about adapting PROFIL to CAD systems e ActiveX interface to AutoCAD and SolidWorks and SolidEdge and BricsCAD e Interface to ME10 CoCreate OneSpace Drafting PTC Creo Elements Direct Drafting e Interface to other CAD systems Driver Installation for Marx USB Hardlock These steps are necessary if you got a Marx USB hardlock shipped with your PROFIL Full Version The USB h
226. en a PROFIL project pro use the function File Open Project Export This menu item contains all export functions that can be used for data transfer to other software systems These functions also can be called from other menu items with fixed file names and output paths pre set in the options window Therefore they are overwritten each the function is called temporary files for data transfer only Unlike this the export function opens a file selection window and the file name output path and output format can be set individually So the export function is useful for exporting files with frequently alternating file names Calling the function Call this function by e Main menu File Export The file selection window and the file name output path and output format can be set individually The settings are remembered when the function Is recalled So it is quite easy to create series of different files Principle of operation Which file formats can be saved is dependent on the used software version These formats are available e DXF Files AutoCAD DXF File format defined by Autodesk Nearly all CAD systems are able to read files in this format The whole drawing which is shown in the drawing area or the selected drawing object is saved in the file The function Drawing gt CAD does the same the name and the path of the temporal output file however are taken from Options Files e IGES Files IGS IGES File format
227. enerate a parts list Sawing list of the rolls of your Profile Project The parts list contains all rolls of all stands of the roll forming machine Calling the function Select View Rolls Call this function by e Main menu Output Create Parts List Principle of operation The parts list is created either by Text File or within MS Excel After creating the parts list as Text File you can view it change it if you want and print it if you confirm Yes to the question Parts list has been created View now The text editor set in Options General will be opened with the parts list You can do the same with the function Edit Parts List The parts list file contains blanks as separators between the values So it is easy to export this file into a spreadsheet or an ERP system The file name of the parts list file is the same as the name of the project file the file extension is Copyright 2015 by UBECO GmbH Iserlohn 182 UBECO PROFIL Rollform Design Software txt however Setup f In Output Path CAPROFIL D ataEngh In Project Path Program IO Excel Excel Application Preset it in Options Parts List previously whether a Text File is created or the part list is transferred to MS Excel In case of Excel we recommend to use a pre defined work sheet and to set the cursor to the row column where the parts list should start Numerical cells should be formatted as numerical with the desired decim
228. ent it is necessary that the last digit or last two digits are numeric Enter a fixed term e g Sp01 for the first roll of the bottom shaft or a combination of a Variable and a fixed term e g SpS RWx RD would cause the roll number Sp50x70 Copyright 2015 by UBECO GmbH Iserlohn Reference 69 3 1 2 8 8 Shims in W Split Spacers to Shims 100 00 7 Small Shims Outside OU Split Spacers to Shims If a spacer is one item only it has to be manufactured for each project newly Often spacers should be combined from an existing stock of shims it is useful to split them into a set of shims with available sizes If the box is checked PROFIL splits into shims as large as possible until a small shim with a special size remains Table of Shim Sizes Enter the available shim width in descending order Each width must appear only once also if shims of this size are available multiple times The TAB key creates new table entries 0 removes an entry Small Shims Outside Select if the spacer splitting should start outside at the stand or inside at the forming roll More More The Expanded Roll Tool Window opens You can enter default values which are copied into a spacer roll dataset during Creating Spacer Rolls Hint The difference between automatic spacers and spacer rolls is discussed in Tutorial Roll Tools Creating Spacer Rolls Database Only with option Database Profile Catalogue and Roll
229. ential damages in connection with the furnishing performance or use of this material Trademarks MS DOS WINDOWS and EXCEL are trademarks of Microsoft Corporation AutoCAD is a trademark of Autodesk Inc SolidWorks is a trademark of SolidWorks Corp ME10 is a trademark of CoCreate Software Inc LS DYNA in a trademark of Livermore Software Corp ABAQUS is a trademark of Dassault Systemes Inc This document can also be called as a context dependent help directly from the software Index 1 Index Section O O JO oO FB W DY mb 11 12 Section Il bb GW N Section Ill 1 General 9 HOMEM ia 9 Whats PROHE2 0 00 ios 11 What are the alms Of PROFIL daa 12 What does PRORILOO imei cda 12 Proft DY PROFIL ri A E deuce seen 12 The PROFIL Story meiicrsrincuiian ee aa a a 13 R marks TOFLICONACO a aA a aa aaa aa aE a a aaa 13 SUPPO diruari a aeia a a aaa daia a aa 13 What SHEW Releases iii A A EAE 14 Whats new Releases AX orinni aap aE Na Eaa a 16 Whats new Releases Iii 21 Frequently Asked Questions nani ella aa a aa a a aE 23 Tutorial 27 HOWTO WV ORK e Ea a aa aa ubaeeuuye 27 Quality Management urna ia aia 28 PEA FING Element AMAL SIS iuris a 29 REQUIO soroa aE a a aaae FN EES 30 Designing the Profil ica A A ace 30 N merical Method asses eo 31 Graphical Method it 33 Searching for Similar proes aa 33 Flower Pattern id 34 Designing the Profile Flower Pattern iii e acia 34 Designing the Tu
230. er Rolls 68 Roll Tool Window 243 Spacer Rolls 109 Roll Stock Management Drawing Area 254 Filter 255 General 123 251 Project Table 254 Roll Corner Table 253 Roll Table 252 Roll Table 252 Roll Tool Contact 192 Roll Tool Window 211 Roll Tools Classification 244 Designing 38 For different sheet thickness 87 Max Diameter 245 Part Number 244 Roll Number 243 Set Up Parts List Columns 71 View 140 Width 244 Rollformers 11 Copyright 2015 by UBECO GmbH Iserlohn 274 UBECO PROFIL Rollform Design Software Rolling Direction 77 Rolling Speed 194 Rolls on off ABAQUS 145 LS Dyna 143 Rotate Viewport 204 Round Tube 131 Rounded Roll Corner 1 Radius 67 2 Radii 113 Save Partial Project 50 Save as Profile Project 48 Save Drawing 177 Save Filter Profile Catalogue 250 Roll Stock Management 255 Save Project 48 Saving the Rolls into the Database 42 Scale 53 Scaled To Fit 55 Scaling Factor z 62 Scan Profile Drawing Roll 107 Window Read CAD Contour Scan Profile Drawing 226 Seamed Tubes 11 Searching for existing Rolls 40 for Similar Profiles 33 Self Contact ABAQUS 194 LS Dyna 192 Separated 139 Service Agreement 13 Set Up Parts List Columns 71 Shaft Diameter 222 Shaped Tube Calibration 131 Deformation Degree 221 Shear Center Point 127 Shearing Stress 128 Sheet Length 3D 75 Sheet Thickness Graph 146 Sheet s Top Bottom Side 85 Shell Elements 187 Shims Options
231. erest Example The number key So RWx RD creates the designation Sp50x70 Copyright 2015 by UBECO GmbH Iserlohn 110 UBECO PROFIL Rollform Design Software 3 1 4 4 2 3 1 4 5 Spacer rolls are handled like all other objects in the PROFIL object hierarchy They can be selected by mouse click and can be dimensioned All roll modify functions can be applied to spacer rolls as well Also the Expanded Roll Tool Window is available Hints e Remove spacer rolls with Rolls Spacer Rolls Remove e Spacer rolls width is not adapted automatically after changing forming rolls width The spacer rolls must created newly Spacer rolls can be converted to forming rolls by unchecking the box Spacer Roll in the header of the Roll Tool Window As a result the Number Keys in Options Rolls are used during Renumbering and the roll is handled like a forming roll during all output functions e Spacer rolls can be switched on and off by using the function View Show Spacer Rolls This takes effect for the Drawing Area and for the output to CAD Printer Plotter Parts List and NC Program If the spacer rolls are switched off they are switched on automatically by calling the create function e The difference between automatic spacers and spacer rolls is discussed in Tutorial Roll Tools Creating Spacer Rolls Remove Spacer Rolls This function removes spacer rolls The box Spacer Roll in the header of the Roll Tool Window det
232. ermines which rolls are spacer rolls Calling the function Call this function optionally by e Main menu Rolls Spacer Rolls Remove e Context menu right mouse button click on a roll in the Drawing Area Spacer Rolls Remove If the bottom or top shaft is selected by mouse click on an existing roll th spacer rolls will be removed from the selected shaft only Otherwise if nothing is selected button Inspect the spacer rolls from both bottom and top shafts are removed Hints e In order to remove one certain roll only use the function Roll Delete e f spacer rolls should be created newly e g after changing the width of forming rolls they do not need to be removed Use Rolls Spacer Rolls Create and reply Yes to the question Warning Spacer rolls already exist on the shaft Remove Conical Extension Use this function to add a conical extension to the beginning or the end of a roll This will be regularly necessary if you created the roll with function Scan Profile Drawing and the roll set should have more width than the profile itself The extension can be negative in order to geta smaller roll Conical means that start and end of the contour will be lengthened with the same angle You define the amount either or Copyright 2015 by UBECO GmbH Iserlohn Reference 111 3 1 4 6 e by width relative e to width absolute e to diameter absolute Calling the function Before you call this f
233. ernatives can be selected Automatic Spacers and Spacer Rolls see Tutorial Roll Tools Creating Spacer Rolls Spacers Spacer Diameter and Spacer Material belong to the machine data and are displayed in the top part of the Machine Window Spacers red see picture fix the horizontal position of the rolls on the shaft Between two alternatives can be selected Automatic Spacers and Spacer Rolls see Tutorial Roll Tools Creating Spacer Rolls The Parts List is able to show spacers by final diameter blank diameter and material see Parts List Columns Material is the name of an Additions File which is used to calculate the blank size from the finished size of a roll To assign a material to a roll click with the mouse cursor into the input field Select the desired additions file within the file select window If you want to create new additions files press Edit in the Expanded Roll Tool Window and select File Save as The material file name can be used as a column of the Roll Parts List Stand Name The stand name belongs to machine data and is displayed in the bottom part of the Machine Window The stand name first is F01 Fnn for forming stands and C01 Cnn for calibrating stands You can modify the name for your own needs The modified name is displayed in the Machine Explorer afterwards The stand name can also be displayed in the Profile Explorer if in Edit Explorer Show stand Copyright 2015 by UBE
234. esult Set the count of predecessor and successor elements recommended is 10 20 Temporally Intervals Count Select how many time intervals should appear in the FEA result Recommended is 1 2x count of roll forming stands Files Meshing Transv Meshing Long Files Machine Material Contact Others FEA Input Output Path Ic FEA Data Y Analyse Current Project l Create ODE file Reaction forces and moments output x Cancel 7 Hilfe FEA Input Output Path Enter the network path for saving the output files of the FEA simulation model and for loading the file of the FEA result Since the FEA solver needs 100 of computing power the FEA system ABAQUS Explicit should run on a separate computer not on the PROFIL CAD workstation Analyze Current Project If the box is checked PROFIL opens the FEA result with the same project name as the current project when you call the function View FEA Result Otherwise a file selection window appears and you can select any of the available FEA results file If the FEA result Copyright 2015 by UBECO GmbH Iserlohn Reference 197 file cannot be found the file selection window appears as well Create ODB file If not only the ABAQUS Explicit Solver but also the ABAQUS CAE the user interface of ABAQUS is installed you can cause the solver to create an ODB file for ABAQUS CAE additional to the FIL file for PROFIL Reaction forces and moments outp
235. etrate the rolls Recommended is 0 05 for element type Shell and 0 5 for element type Solid see Profile Self Contact Check contact sheet with sheet Check this box if LS Dyna should avoid penetration in case the sheet touches itself Self contact is possible e g if the profile has a Hem or a tube enters the Welding Station Considering self contact needs more simulation time So it is recommended to check this box only if self contact is possible due to the profile geometry Starting from stand in sheet running direction Select the stand from the drop down list to define the start of the self contact check This saves simulation time because normally the first stands are without self contact Copyright 2015 by UBECO GmbH Iserlohn Reference 193 3 1 8 8 1 7 Others This dialog window is called by Output FEA LS Dyna is used for set up the time step size mass scaling and the guiding I ax LS Dyna Profile Time Step Size Mass Scaling Rolls CONTROL_TIMESTEP DT2MS 0 520 us Holes Cut Out Start Guiding the nodes of the profile reference point Material horizontal in profile transverse direction mandatory for sym profiles wees vertical not allowed for Center Line Forming Guiding the node row V at the profile lead end V at the profile tail end X Cancel Help Time Step Size Mass Scaling CONTROL_TIMESTEP DT2MS Mass Scaling is useful for speeding u
236. etrical shaped tube and the developed lengths differ on the left and right side Because the welding seam always is at the top of the round tube in the welding station it is not possible both to keep the reference point and to set the welding seam to the point where the left and the right side touch themselves If you answer Yes the reference point is moved and the shaped tube is rotated if necessary in order to get the welding seam at the desired position If you answer No the reference point is kept and the position of the welding seam is set to the point that has the same developed length on the left and right from the reference point If you later want to use PSA Profile Stress Analysis or FEA Finite Element Analysis you have to answer Yes to this question Shaped Tube Calibration No valid solution found If this message is shown PROFIL was not able to convert the shaped tube cross section into an elliptic cross section The reason Each side or the ellipse is represented by a sequence of 5 arc elements the first in case of a flat ellipse is an arc with a large radius then comes a transition with a medium radius and then at the right or left an arc with a small radius Afterwards again a medium radius and a large radius at the top If the shaped tube has element lengths that not at all fit to the 5 ellipse elements PROFIL cannot convert them correctly Workaround Split the much too large elements of the shaped tube into two parts wi
237. fore and behind a bent part of the profile are lengthened until the intersect another This point often is used as dimensioning point in technical drawings The lengths of these new lines are added and lead to a straight length that is too large first To this result a negative correction addend k2 from a table is added Furthermore a correction factor factor k1 in can be used The straight length of a bent part of the sheet is calculated by f RE e nE ME AS T 4 1 2 1 Boi T 2 with L Straight length or length of the neutral line blue line see picture L1 L2 extended length of the straight parts of the sheet to the intersection points of the tangents L1 L2 length of the straight parts of the sheet k1 Correction factor in neg k2 Correction addend in mm neg The Factor File contains correction factor k1 and correction addend k2 dependent on sheet thickness bending angle and inner radius See also Factor Method Roll Tools Roll Number The roll number belongs to the roll data and is displayed in the header of the Roll Tool Window For the roll number all numbers and characters included special character are allowed Define the roll number so that it marks the install location in the machine e g 03102 Stand 03 Shaft 1 bottom shaft Roll No 02 The roll number can be created automatically if you enter a number key into the dialog Options Rolls for the roll number before you generate
238. g angles and radii of arc segments without bending or unbending the segments e Splitting and Joining profile elements lines and arcs e Modify Start Element for optimizing the orientation of the profile in the machine also for changing the opening direction e DXF Output Objects not only organized on layers but optionally also in blocks e Partial Project Add On and Partial Project Save as for combining new profile projects from parts of existing projects e For the spacers Output to CAD now creates unique layer names that contain the pass number Bugfixes e NC DXF Output and NC Program Output Separate files are now created with unique file names e Profile Read CAD Contour now also is possible in case the first drawing element is an arc with a very small radius Copyright 2015 by UBECO GmbH Iserlohn General 17 PROFIL Rel 4 7 01 Dec 2010 New features Machine Data are handled in the Project and saved in the project file new machine explorer interactive handling of the Machine Window Multi Axles Additional side axles for the precise forming of inner contours that are difficult to access Print Preview Scale Fit adjusts the drawing scale in order to have the whole print out on one page only in case the table lengths are not too large Shaped Tube Calibration also starting from an elliptic cross section in the welding station Useful if the shaped tube is either quite large a
239. g shown on the PROFIL drawing area a hidden lines algorithm is applied to the profile drawing and all non visible contours are displayed in inactive color by default gray Afterwards the contour tracking reads the visible contour only from the selected shaft If there are too many entities in the drawing and the contour tracking does not give the desired result select one special layer and or one special color in the input fields Select Layer and Select Color If the contour tracking is not correct yet delete the entities within CAD that you do not need and call again the window Read CAD Contour The Navigator helps you to zoom to move and to fit the drawing Furthermore the Wheel Mouse is supported The read drawing contains the markers Contour Start Point green and Contour End Point red and if you have called Profile List Read CAD Contour the additional maker Reference Point x0 y0 blue Set the markers to the correct points of the contour by using the buttons in the button bar The entities color changes to the mark color by default light blue and shows which contour is taken by pressing the Ok Button If the automatic contour tracking does nor find the desired contour see topic Controlling the contour tracking manually Contour Start Point Reference Point x0 y0 i Contour End Point Designing a profile by using the CAD system Copyright 2015 by UBECO GmbH Iserlohn Reference 227 LA LS LS
240. ging the order of the Roll Corner Points in the Roll Tool Window The position of the roll on the shaft keeps unchanged Hint If you want to undo the turning turn the roll again with the same function Copyright 2015 by UBECO GmbH Iserlohn 120 UBECO PROFIL Rollform Design Software 3 1 4 16 Move Use this function to move a certain roll or all rolls on the shaft Calling the function Marked Mark the desired roll by marking any Roll Corner Point All of shaft Mark the desired shaft by marking any Roll Corner Point of any roll Call this function optionally by e Main menu Rolls Move e Context menu right mouse button click on the certain corner point of the desired roll in the Drawing Area Move TS lx Give Width hor Moving 12 000 X Cancel Help The input window appears with the question Give width for moving Enter the value for moving Entering a positive value moves the rolls into the direction to the last roll a negative value moves the rolls into the direction to the first roll To obtain the desired amount of moving width the function Measure is helpful Principle of operation The roll is moved by adding the given width to the Width of each Roll Corner Point in the Roll Tool Window If a gap appears after moving a single roll the user has to fill out the gap manually If a neighboring roll exists it will be moved in case there is not enough space between the rolls
241. he automatic roll numbering see Options Rolls Project Data 57 A4865 L01 Ax Customer Precision Profiles Inc Date Descript CProfle Mame smith y Drawing Mo a3 128648 0 Rev 30 06 2012 Material stz24 sf Thickness 3 000 Machine Rolltormer T300 Calc M Oehler In this window the project data of a Profile project are shown and you can edit them The project data are Customer Date Description Name Drawing No Revision Material Thickness Machine Calculation Methods If you want to enter a new customer or a new name you can select it from the list box which shows you the older names To delete an older name from the list box use the backspace key See also Profile List Window Copyright 2015 by UBECO GmbH Iserlohn Reference 207 3 3 2 1 3 3 2 2 3 3 2 3 3 3 2 4 3 3 2 5 Customer The customer s name belongs to the project data Enter the name of your customer who has ordered the profile PROFIL saves the name in the project file for your information and for easier selection See also Profile Project Description The description belongs to the project data Enter any further information that allows easy identification PROFIL saves this information in the project file If needed the description can be used as variable PD for the automatic roll numbering see Options Rolls See also Profile Project Drawing Number The drawing number bel
242. he development table to speed up the design of similar profiles Converting Line to Arc L to A1 Center Line Forming lowers all profile lists to constant height of the centroid or by any other amount Improved roll design By using the functions Roll Paste Roll Read CAD Contour Roll Scan Profile Drawing and Roll Move also certain rolls can be modified and replaced subsequently FEA interface extensions Self contact sheet with sheet can be considered see Output FEA Others Copyright 2015 by UBECO GmbH Iserlohn 20 UBECO PROFIL Rollform Design Software Bugfixes e After Profile Remove it is possible again to save the project e Profile Read CAD Contour now also is possible for extreme small profiles e No sporadic moving of the roll anymore after negative Cylindrical Extension and Conical Extension e Roll Scan Profile Drawing now ignores the cross hair circle of a roll corner point PROFIL Rel 4 1 01 Dec 2004 New features e Roll Mirror for easier designing of rolls for symmetrical profiles e Improved Window Read CAD Contour and Window Scan Profile Drawing respectively zoom and move functions wheel mouse support manual controlling of the automatic contour tracking simply by clicking on the next drawing element Search paths to the system files Material File and Factor file can be preset in Options Calculate e Spacer s material for the Parts List can be preset in the Machine
243. he graph window e Select another time interval e g via pa E Time Interval or or via E View FEA Result The graph window shows the values of the new selected time interval pic bottom right Press again Copy Snapshot to Assembly Window The assembly top picture is extended by the new values In case values already exist at the same sheet position the medium value is calculated e Repeat this procedure for other time intervals until the desired region is covered 2d 2 Bl e In case the sheet front or back end has unwanted deformation that should not be displayed in the assembly reduce the length of the evaluated sheet section by using the selection boxes From Layer To Layer Then copy the snapshot to the assembly window Show 3 1 6 9 1 Previous Next Pass For the design of a roll tool set for a stand not only the form of the profile within the stand is important current pass but also the form of the incoming profile from the previous stand previous pass and the outgoing profile to the next stand next pass If the previous pass is shown it easy to find out which point of the running in profile touches first which roll of the current stand is a good idea to provide a large radius instead of a sharp corner Copyright 2015 by UBECO GmbH Iserlohn Reference 149 3 1 6 9 2 to avoid scratches and to enable the profile to flow smoothly into the rolls Also risk of collision can
244. he outside is predefined in PROFIL If in special cases the legs should point to the inside e g for trapezoid profiles check the box Leg points to the reference point before you press Ok Input Angle Enter the angle Relative to the actual angle or Relative to the roll axle as desired In the first case you get the desired opening angle In the second case you can define a desired rounded roll angle If you select Relative to the actual angle the clearance angle will be increased after entering a positive value and decreased after entering a negative value Actual angle rel to the roll axle If you selected Input Angle Relative to the roll axle pay attention on the box Actual angle rel to the roll axle that shows the angles Leg to the outside and Leg to the ref point This help defining the right value for the input field Pay attention on the sign it must be entered too Principle of operation In order that the fillet of the roll clings to the profile PROFIL keeps the center of the arc constant the angle of the arc is extended or reduced by the clearance angle w The Roll Corner Point intersection point of the tangents moves accordingly A positive clearance angle creates or extends the gap a negative reduces the gap Please check after creating the clearance angle if the line arc transition is correct at the next roll corner point Hints e lfa clearance angle should be continued over multiple roll corner points e g fo
245. he selected stand are displayed in the Drawing Area Furthermore the profile pass is shown between the rolls You define by setting the menu switch Profile Loaded whether the pass inside the roll tool drawing is displayed discharged or loaded Copyright 2015 by UBECO GmbH Iserlohn Reference 141 3 1 6 7 Setup Colors of Drawin Ausiliary Line Main Line Profile Main Line Rolls Tert e Reset Select the Auxiliary Line Color the Main Line Color Rolls and the Text Color in Options Drawing Ralls e Revolution Lines I Bore Lines Text Aligam Center In the same dialog you can define if the roll drawing should contain Revolution Lines Bore Lines and Automatic Spacers Text Alignment Center positions roll number and part number in the center of a roll instead on the left corner Tex Height 3 000 Preset the text height for the roll number and part number in Options Drawing Text Height Hints e The Navigator helps you to zoom to move and to fit the drawing e Use the Toolbox Modify to modify the width diameter or radius of a corner point of the roll e With the function Output Drawing gt CAD you can transfer the drawing to your CAD System PSA Profile Stress Analysis The Profile Stress Analysis is the second step of the three step quality concept for Quality Management The surface of the strip is divided into small rectangular shell elements While running through the roll form
246. hine data are not added from the source to the target project Please pay attention that the machine data fit together Hints e In order to save a partial project to a project file use the function Partial Project Save as e The partial project file has the same file format as the project file so you can open edit and save it by using the functions Open Project and Save Project e f the added project contains rolls they will be locked against automatic renumbering By using the function Partial Project Add On the rolls can be unlocked Copyright 2015 by UBECO GmbH Iserlohn 50 UBECO PROFIL Rollform Design Software 3 1 1 6 3 1 1 7 Partial Project Save as This function is needed if a certain part of a project e g the left or right side only the passes only without rolls or a subset of the passes should be saved to a file This can be used for combining a new project from already existing modules by the function Partial Project Add On Calling the function Call this function by e Main menu File Partial Project Save as y Partial Project Save as aj From current project Al 2 From pass LO1 To pass Los Related to the ref poin Conten Left Side e Profile e Right Side e Rolls i 3 Cancel Help After calling the function the dialog window is shown with these settings From current project From pass To pass Select which passes of the current proje
247. his format if a macro in your CAD system proceeds the contour tracking and saves the drawing elements in sorted order Such macros currently are available for the CAD systems PC DRAFT AutoCAD until rel 12 ME10 and CADDA Please contact your dealer DXF format file format defined by Autodesk used from nearly all CAD systems The Contour File DXF Format can contain unsorted LINE ARC POLYLINE LWPOLYLINE and ELLIPSE entities the contour tracking is done within PROFIL Use this file format for all CAD systems that do not support ActiveX CAD Drawing Scale Enter the drawing scale that has been used in the CAD System when the file was saved This allows PROFIL to recalculate the imported contour in order to have the proper dimensions in the Profile List Settings in from CAD are only possible if in Options ActiveX the ActiveX Input from CAD is disabled Output to CAD Output to CAD C PC DRAFT 411 f WINDOWS Latin 1 AutoCAD etc DXF with Blacks C DOS PC 8 ME10 Ml C C IGES IGS UNI Roman 8 C STEPAP214 Profile built from sep bodies CAD Outputtile C Trmp Profil DXF Sheet Length 30 200 000 Use layer numbers instead of names Edit Select the path the name and the format of the output file of the drawing This temporary file is be used to transfer the drawing to your CAD System This file is generated by PROFIL if you call the function Drawing gt CAD Select among the following possibilities
248. his item if you want to check if an existing or already designed set of rolls will work with a modified sheet thickness The selection which line should keep constant is applied on all passes The inevitably resulting different strip width is corrected by lengthening or shortening the profile elements at the band edges Thus a flower pattern is obtained with different allocation of the straight lengths to the profile elements However because profile and roll contours fit together or are parallel together the displacement of the band edges is an indicator if the roll set is good for the new sheet thickness or if it has to be adapted The occurrence of a negative inner radii is not checked Please check by yourself after proceeding the modification if a negative radius is shown in the Drawing Area or in the column Radius of the Profile List Window Principle of operation selection No rolls existing The settings in the dialog window have influence on the final pass LO1 only In order to have equal strip widths in all passes the following method is applied on the passes L02 Lnn In the background i e not shown on the screen the Development Table is called with the function Development Table Create from current project Then the sheet thickness is changed in the final pass LO1 dependent on the selected keeping constant method Afterwards the function Development Table Apply and Create Flower Pattern is called This means The profile lists
249. hn Index 273 Read CAD Contour Profile 82 Roll 105 Window 226 Read CAD Roll to Project 106 Redo Count of Steps 61 Recent Undo 58 Reference Point Machine 223 Modify 90 Modify Start Element 85 Profile List 234 Statics 126 Window Read CAD Contour Scan Profile Drawing 226 Remark Expanded Roll Tool Window 211 Option Rolls 214 Remarks for License 13 Remesh 187 Remove Profile Element 104 Profile List 93 Roll Corner Point 125 Spacer Rolls 110 Render 179 Renumber Roll 117 Representation of Values 66 Required Count of Stands 135 Resolution Installing 259 Options General Clipboard 61 Restart LS Dyna 190 Revision 208 Revolution Lines 62 Risk of Collision 148 Roll 123 251 Arched Extension 112 Clearance Angle 114 Conical Extension 110 Copy 122 Cut 121 Cylindrical Extension 111 Delete 123 Insert from Clipboard 252 Join 119 Mirror 120 Move 120 Paste 122 Read CAD Contour to Roll 105 Read CAD Roll to Project 106 Renumber 117 Saving the Rolls into the Database 42 Scan Profile Drawing 107 Split at Corner 117 Split between Corners 118 Stock Management 123 251 Turn 119 Roll Corner Append 124 Point 245 Remove 125 Table 253 Roll Corner Point Diameter 246 Radius 246 Roll Corner Point 246 Width 246 Roll Design by CAD System 39 by Profile Drawing 38 by Stock Management 40 Roll Dimensioning automatic 175 Roll Forming Machine 218 Roll Number Options Rolls 67 Options Spac
250. hrough the database it is quickly generated from the Profile Element Table and displayed in the Drawing Area instead Copyright 2015 by UBECO GmbH Iserlohn Reference 249 3 7 2 The top bar of the profile table contains these indicators and buttons La Open Profile Project This button enables quick access to the belonging profile project of the selected profile The belonging project will be opened For the access the contents of the fields Project Path maximum field length 40 and Profile Project maximum field length 20 are used Number of profiles displays the number of all profiles in the database if the filter is switched off or the number of filtered profiles if the filter is switched on ey A 2 Database Navigator for switching to the first previous next last profile for inserting deleting and editing a profile for posting and cancelling the edited data and for refreshing the data e g if in a network several designers use the same database OWEN View 1 2 3 The count of displayed columns can be reduced for more clarity Simply hide unwanted columns by moving the columns separator in the header row The buttons View 1 2 3 enable changing the view quickly Profile Element Table The left area in the middle of the Profile Catalogue Window displays the Profile Elements of the profile which is selected in the Profile Table Window at the bottom Each line of the table shows the data of on
251. hus the they can be transferred to the CAD System by using the function Drawing gt CAD Calling the function Before you call this function select the pass that should be calculated Call this function optionally by e Main menu View Statics U e Button View Statics in the Button Key Bar Principle of operation In the Drawing Area the profile pass the statics table and additionally all static parameters that can be drawn graphically are displayed in the drawing e Centroid Origin of the Principal Axes e In Principal Axes Large axes system e Max Distance Lengths of the Principal Axes Principal Axes Angle Angle of the larger axis of the Principal Axes against the horizontal line Shear Center Point small cross Reference Point small circle The statics are calculated by using the discharged columns of the profile list only they are not dependent on the status of the menu switch Profile Loaded Holes Cut Outs will weaken the area of cross of the profile The calculation of statics considers this and they will be shown in the drawing Exception for the Weight holes cut outs are not considered since input of count and length is not supported Setup Representation of Values Integer Decimal Places ja Ma Metric N mm 7 Imperial lb in Select in Options Calculate Representation of Values whether the statics should be displayed in the Metric System mm N or the Imperial System in lb
252. idth by 0 350 f between topical and next roll comer point 7 for the whole roll x Cancel Help The input window appears and asks Modify gap width by Enter the desired value related to the topic gap width A positive value enlarges the gap and a negative reduces it e Between topical and next roll corner point Select this option if the gap should be created between two corner points e For the whole roll In this case the whole roll gets a gap to the profile Principle of operation Copyright 2015 by UBECO GmbH Iserlohn Reference 117 3 1 4 11 If you selected Between topical and next roll corner point the connection line between the points is moved in parallel by the gap width s If the connection line does not exist i e if one arc is connected to the next tangentially the connection point is moved Thus no new corner points are created but the existing corner points are moved on the outer tangents similar to the Clearance Angle function By selecting For the whole roll the parallel gap is created for the whole roll Renumber Use this function to renumber Roll Number and Part Number of all Forming Rolls and Spacer Rolls of a stand e g if you modified the number keys Calling the function Call this function optionally by e Main menu Rolls Renumber e Context menu right mouse button click on the left or right corner of the desired roll in the Drawing Area Renumber Principle
253. ied and saved see also Hints Copy drawing to clipboard Use this button to copy the graph as pixel drawing to the Windows clipboard see also Edit Copy e EAD Drawing gt CAD Use this button to transfer the graph as vector drawing to the CAD system The settings of the function Drawing gt CAD in the PROFIL main window are used as well Principle of operation The graph shows the course of the stress strain and thickness of the current visible FEA result dependant on the position of the sheet in the machine in sheet running direction The sheet position is Example 3 stands with distance 300mm eac e lt 0 Region after leaving the final stand L01 e 0 Position of the final stand L01 e gt 0 Range within the machine and region before entering the fist stand Stand position at n distance between stands n no of the stand Hints The graph always shows the FEA result values of one time interval If you need the graph displayed for a larger range or for the whole machine plus the region after the machine exit proceed like this Copyright 2015 by UBECO GmbH Iserlohn 148 UBECO PROFIL Rollform Design Software 3 1 6 9 HHH E T AN HHH 600 How to use the Copy Snapshot to Assembly function e Select a time interval and open the H Graph pic bottom left e Press Copy Snapshot to Assembly Window The FEA Result Assembly window opens top pic that first is identical with t
254. ield e g width the value has to be numerical too e g 156 3 In the other case an alpha numerical value can be entered e g Part No BP3517 Allowance Enter the allowance for the filter value Example If the filter value is 100 and the allowance is 0 1 all rolls between 99 0 and 100 1 stay visible The column Allowance is only evaluated if the filter name in the same row determines a numerical field Buttons m Save Filter If a filter name is displayed in the input field i e if you have loaded an existing filter you can use this button to save changed filter conditions If not i e if you have entered new filter conditions you are asked to enter a filter name after pressing this button Afterwards the new filter will be saved di Create Filter from Clipboard If the clipboard contains a roll a new filter is created whose filter conditions match to the roll exactly Previously you are asked to enter an allowance which will be inserted into the allowance column of all numerical fields In this way you can search for a suited roll which you have created e g by using the function Roll Scan Profile Drawing and afterwards copied to the clipboard by using the function Roll Copy From the right too Since rolls can be installed turned the search results can be expanded by rolls that match the filter conditions in inverse direction If you check this box these rolls will be found too Filter On If the table contains f
255. ight of each bending zone Meshing in Sheet Running Direction Select how precise the meshing should be in longitudinal direction e Length Select the desired length a shell segments in longitudinal direction e Analysis Count Select how many shell elements should appear in the FEA result The Copyright 2015 by UBECO GmbH Iserlohn 188 UBECO PROFIL Rollform Design Software Analysis Length Analysis Count multiplied by Length should be the distance between stands at minimum better 2x the distance e Element type Select the element type that should be used for the simulation y Shell element type with 5 integration points in thickness direction e Shell The shell model is adequate in case pure bending is used This means no deep drawing effects occur the sheet thickness is not modified by the rolls and 180 folds hems are not used The shell is positioned in the center of the sheet 5 integration points are calculated in sheet thickness direction besides the shell itself 2 points above and 2 points below the sheet center The calculation is faster than by using solid models Automatic remesh The FEA solver is able to remesh automatically This means if the preset meshing is too large the simulation does not break but the FEA solver refines the meshing during the simulation automatically This causes a higher stability and robustness against incorrect parameterization Prepunched holes and cut
256. ile Modify Sheet Thickness e Project Window Enter the thickness in the input field Thickness Enter new sheet thickness for all passes 0 100 10 000 1 200 Keeping constant sheet metal s line inner radii neutral line f geometric center line outer radii radii on the reference point side radii opposite the reference point side Keeping constant strip width by i no rolls existing f use existing rolls E x Cancel Help Copyright 2015 by UBECO GmbH Iserlohn 88 UBECO PROFIL Rollform Design Software After calling this function a dialog window is opened Enter the desired new sheet thickness and select which sheet metal s line should be kept constant during this operation e Inner radii The outer radii are changed dependent on the new sheet thickness as well as the strip width because the straight lengths of the arc elements are changed e Neutral line The neutral line is the virtual line whose length is not changed during bending It is moved a little bit from the geometric center line toward the inside How much is calculated by the preset Calculation Method Inner and outer radii are changed dependent on the new sheet thickness The strip width sum of all straight lengths keeps constant e Geometric center line This is the virtual line in the center of the sheet Inner and outer radii are changed dependent on the new sheet thickness as well as the straight lengths
257. ile either symmetrical or asymmetrical Calling the function Call this function by y Button Hat Profile from the Toolbox Profile Design The window Hat Profile is opened Enter Width Height on the right and on the left and the upper web Widths If you enter equal values on the right and the left a symmetrical profile will be created otherwise an asymmetrical Principle of operation If the profile list already contains profile elements they will be deleted 3 1 7 1 11 Z Profile D B This function is a part of the Toolbox Profile Design and generates a simple rectangular Z profile either symmetrical or asymmetrical Calling the function Call this function by iz Button Z Profile from the Toolbox Profile Design The window Z Profile is opened Enter Width Height on the right and on the left and if you want the Radii Copyright 2015 by UBECO GmbH Iserlohn 158 UBECO PROFIL Rollform Design Software Principle of operation If the profile list already contains profile elements they will be deleted 3 1 7 2 Tube Design By using the Toolbox Tube Design you quickly can design the flower pattern for seamed tubes and the roll tools without a CAD system Calling the function Call this function optionally by e Main menu Toolbox Tube Design 9 Button Toolbox Tube Design in the Button Key Bar Content Section 1 contains functions for creating the different passes for tube formi
258. ile list should be inserted Call this function optionally by e Main menu Profile Insert e Context menu right mouse button click on any profile element of the desired pass in the Drawing Area Profile Insert Principle of operation A new profile list is inserted The list numbers of the current and all following lists will be increased by 1 The content of an existing profile list is copied to the new one Setup Insert Appern C Fas f Previous Pass Select in Options Profile List Insert Append if the contents of Pass 1 or of the Previous Pass will be copied into the inserted list Copyright 2015 by UBECO GmbH Iserlohn 92 UBECO PROFIL Rollform Design Software xi 2 Source profile list contains rolls Copy with rolls If the pass that is copied already contains rolls you are asked Source profile list contains rolls Copy with rolls Please consider that rolls are renumbered when copied into another stand dependent on the number keys in Options Rolls and that rolls are modified dependent on the data of the shafts of the new stand in the Machine Window Change Machine Data Furthermore the setting Keep Roll Data in Options Rolls determines how the rolls are treated by changed machine data Hints e It is not possible to insert a list before the first list Use Profile Append instead e To remove a list use the function Profile Remove 3 1 3 10 Append SU U30x20 a L
259. ilter conditions the filter will be switched on Afterwards the Roll Table displays those rolls only which match to the filter conditions In the top bar of the roll table the number of filtered rolls is displayed If the roll table is empty no roll is matching 0 Filter Off Use this button to switch off the filter All rolls are displayed in the Roll Table again In the top bar of the roll table the number of all rolls is displayed again Copyright 2015 by UBECO GmbH Iserlohn 256 UBECO PROFIL Rollform Design Software 3 9 Others 3 9 1 Variables PROFIL contains internal variables which can be used in some functions for substituting e g a value or a name Structure A variable consist of a sign and two following capital letters e g PL or one capital letter and a numeral Use Variables can be used for defining the roll number key see Options Rolls or for creating the Drawing Template When the rolls or the assembly drawings are created the variables are replaced by the assigning value or name or by the assigning drawing object Variables from the Project Data Window PR Profile Project CU Customer PD Description DR Drawing No MA Material MC Machine DA Date NV Revision NA Name ST Thickness CM Calc Method Variables from the Profile List Window PL Profile List No only the number against the sheet running direction e g 7 in profile list LO7 PS Pass No only the number
260. imension points must belong to the same dimension object i e roll or axle Use the function Measure instead which has not this object restriction want to copy the whole left half of a profile from an old to a new project Only the right half should be created newly How should proceed appropriately without using a CAD system Copy the whole left half into the clipboard For it select the first profile element in the profile list window press and hold the Shift Key and press the Arrow Down Key until all profile elements of the left half are marked Then copy the whole marked set by using Profile Element Copy into the clipboard In the new project select the desired row and call Profile Element Insert cannot enter machine data into the empty machine window What is going wrong You forgot to create a stand Press the button Append Forming Stand and the final stand F01 appears in the machine explorer Now enter the stand data Afterward append further stands the stand data are also copied and you can modify them if needed Copyright 2015 by UBECO GmbH Iserlohn General 25 Q The automatic trapezoidal profile forming creates an improper result Why A Check if the final profile has arcs with inner radius 0 If yes modify them to a realistic value of 0 2 mm at least Moreover check if the profile has arcs at the top and the bottom These arcs have to be split at the top and bottom poin
261. imulation 29 Output FEA model 194 View FEA result 145 Abs Angle 98 ActiveX Options ActiveX 77 Options Parts List 70 Output Drawing gt CAD 177 Window Read CAD Contour Scan Profile Drawing 226 Adapting the Roll Tools 40 Adaptive Refinement 187 Add On Partial Project 48 Addition Method 243 Addition Part Previous Segment 66 Additional Side Axles 44 Additions 232 Additions File 213 Aims of PROFIL 12 Allowance Filter Profile Catalogue 250 Filter Roll Stock Management 255 Width 89 Analysis Count LS Dyna 187 Output FEA ABAQUS 194 Angle discharged 237 loaded 237 Angle Corner Point 246 Angle Dimension 174 Append Profile Element 103 Profile List 92 Roll Corner 124 Apply Development Table 96 Arc Join 102 Profile Element 236 Split 102 Toolbox Profile Design 152 Arc lt 90 Line 153 Arc gt 90 Line 154 Arc to Line conversion 101 Arc Type A4 66 Arc Types 238 Arched Extension 112 Area of Cross 128 Aspect Ratio Shells 185 Assembly 146 Assembly Plan 55 Assigning Shortcut Keys 81 Assistant 201 AutoCAD CAD Systems 257 Interface by ActiveX 260 Options ActiveX 77 Output 3D Model gt CAD 179 Autom Spacers Creating 40 Set Up Parts List Columns 71 Automatic Flower Creation Development Table 96 Tutorial 37 Automatic Roll Dimensioning 175 Automatic Spacers Options Drawing 62 Auxiliary Line Color 64 AVI File 145 Copyright 2015 by UBECO GmbH Iserlohn 264 UBECO PROFIL
262. in accordance with the Arc Type You define by setting the menu switch Profile List Loaded if the discharged or loaded values should be modified Notice e For the loaded state only the angle not the radius can be modified e For the arc type A2 A3 A4 only the angle loaded or discharged can be modified To modify a length you must have selected a line 4 le R Width Diameter Radius These switches are visible in the left column of the Toolbox Modify if you have called View Roll Tools and you have selected a Roll Corner Point either by clicking into the Drawing Area or into the Roll Tool Window You can modify the Width the Diameter or the Radius AA Y 10x larger larger smaller 10x smaller Use these functions in the right column of the Toolbox Modify to proceed the modification which you have selected in the left column Both single arrow buttons in the middle will modify by using the predefined step interval The double arrow buttons will use the tenfold step interval Copyright 2015 by UBECO GmbH Iserlohn Reference 3 1 7 4 Setup Step Interval for Toolbox Modif Angle 1 000 Radius 0 200 Length 1 000 169 In Options Mouse Step Interval you can preset the step interval for the single arrow buttons Principle of operation While modifying both the drawing and the data displayed in the different windows will be updated Dimensioning Use this toolbox for measuring of distances and a
263. in error you can use the Reset button to start newly After pressing the Ok Button the tracked contour is taken as a profile contour or a roll contour Files Profile Project The profile project contains the project data all Profile Lists and the Roll Tool Data for all stands The profile project is saved in the project file which has a user defined name with the extension pro In this way the project file contains all data belonging to a profile design and can be archived and passed on to other users of PROFIL The project data are Customer Date Description Name Drawing No Revision Material Thickness Machine Calculation Methods Copyright 2015 by UBECO GmbH Iserlohn Reference 229 3 4 2 If needed the profile project name can be used as variable PR for the automatic roll numbering see Options Rolls Material File The material file contains the data of different sheet materials which are necessary for the calculation of Spring Back and Stress of Edge The material file has the name PROFIL WKD if you have selected in Options Profile List the representation of values Metric If you have selected Imperial the material file name is PROFIL WKI Paths to System Files Material Data CAPROFIL O ata Profil wwkd E dit User Def Calc Methods CAPROFIL DatasProfilfkd Edit Select the desired material file by using the function Options Calculate Material Data and open it with the Edit
264. in menu Rolls Stock Management P Button Roll Stock Management in the Button Key Bar Stock Management Open After calling this function the window Roll Stock Management appears which contains 4 areas e Roll Table lower area This is the real roll database each row displays the data of one roll e Roll Corner Table in the middle left can be switched to the Project Table This area displays the data of the roll selected in the roll table e Drawing Area top on the right This area displays the drawing of the roll selected in the roll table e Filter top on the left Any filters can be defined for reducing the amount of displayed rolls Stock Management Save Use this function to store selected rolls into the roll database Which rolls are stored you define by selecting one of the following sub functions and by marking a roll in the Drawing Area respectively e Roll The marked roll is stored Shaft All rolls of a shaft are stored Define the shaft by marking any roll of the shaft Stand All rolls of all shafts of one stand are stored Project All rolls of all stands of the whole project are stored If the window Roll Stock Management is not yet open it will be opened after calling one of these Copyright 2015 by UBECO GmbH Iserlohn 252 UBECO PROFIL Rollform Design Software functions Setup Roll Database and Profile Catalogue Path for Databaze CAPROFIL Data Set the path to the roll databa
265. in sheet running direction PN Pass Name full name incl number DS Distance between Stands SW Strip Width Variables for the rolls SA consecutive roll number of the rolls of a stand TA consecutive roll number of the rolls of a shaft type B T L or R of a stand Variable from the drawing SC Drawing Scale see Plot Variables that represent drawing objects AS Roll stand assembly Bn Bottom roll n if separated Tn Top roll n if separated Ln Left side roll n if separated Rn Right side roll n if separated MX Roll mirrored at the x axis Supplement to Bn Tn Ln Rn MY Roll mirrored at the y axis Supplement to Bn Tn Ln Rn These variables are used in the assembly plan only Further variables CO Company Your own company name from the initial window IM Imprint Designed by CO by using UBECO PROFIL Copyright 2015 by UBECO GmbH Iserlohn Reference 257 3 9 2 CAD Systems PROFIL is able to exchange data to and from different CAD systems You only need to select the data exchange format in Options Files ij dar i Sw y h CAD system AutoCAD R14 and higher or SolidWorks 2003 and higher or SolidEdge ST7 or higher or BricsCAD release 15 and higher Use the built in ActiveX interface Setting in Options ActiveX E CAD system ME10 or OneSpace Designer Drafting or Creo Elements Direct Drafting respectively Macros are available for generating a Contour File
266. in the Drawing Area to the WINDOWS clipboard From this it can be pasted to any other WINDOWS program in order to print it Exit Use this function to terminate PROFIL Calling the function Call this function optionally by e Main menu File Exit x Button Exit Principle of operation PROFIL is terminated If you forgot to save your profile project PROFIL will remind you Edit Undo Use this function to reverse the most recent operations Calling the function Call this function optionally by e Main menu Edit Undo e Button Undo in the Button Key Bar e Shortcut Ctrl Z Setup in Options Keyboard Undo Spacer Ralls Create Copyright 2015 by UBECO GmbH Iserlohn 58 UBECO PROFIL Rollform Design Software 3 1 2 2 3 1 2 3 The menu item and the button hint shows the name of the operation that can be reversed next Setup Menus 20 Count of recent projecte on file menu E Count of Undo Redo steps Select in Options General Menus how many steps should be available for Undo Hint If you did this in error you can Redo the commands Redo If you called 4 Undo too often in error you can reverse the effect of the last undo command by using this function Calling the function Call this function optionally by e Main menu Edit Redo e Button Redo in the Button Key Bar The menu item and the button hint shows the name of the operation
267. ination is possible Guiding the nodes of the profile reference point The node row in sheet running direction at the Reference Point X0 YO of the profile is guided Copyright 2015 by UBECO GmbH Iserlohn 194 UBECO PROFIL Rollform Design Software 3 1 8 8 2 Guiding the profile reference point edge horizontally for symmetrical left and asymmetrical profiles right Horizontal Checking this box causes no horizontal movement of the profile reference point This is mandatory for symmetrical profiles of which only one half is simulated the right half because of saving computing time In order to avoid horizontal movement caused by the absent left half it is necessary to guide the reference point edge the center line edge horizontally see left picture In case of asymmetrical profiles right picture the guidance can be enabled if needed e g a very short strip length causes unwanted horizontal movement Guiding the profile reference point vertically Vertical After leaving a stand often the section drifts downwards if at the top edges plastic strain occurs In reality the tractive of the sheet in front of the section avoids the movement Checking this box avoids unrealistic vertical movement also for simulation However the guidance only is allowed if the Reference Points X0 Y0 of all profile lists have the same height bottom line forming Otherwise in case of Center Line Forming the vertical guidance shou
268. ines and texts these are not associative anymore Transparency Concerning the zoom and move functions of the Navigator not Zoom window however the dimensioning functions are transparent i e you can select the view port while dimensioning Input After calling the function of this toolbox you are asked in the dialog line at the bottom of the screen to enter some inputs one after the other e 1 2 dimension point or 1 2 dimension element Select a drawing element by mouse click one of the end points is caught on principle By selecting a roll corner revolution line see Options Drawing Rolls Revolution Lines the intersection points of the tangents at a roll corner can be dimensioned In some cases you can open a context menu by using the right mouse button that contains further catch points Because dimensioning is associative it is not possible to create dimensioning where no drawing elements are e Text Position If you are asked for the text position you can position the text sticking to the mouse cursor as desired e Dimension Click on the text of an existing dimension is used for identifying a dimensioning Repetition After you created a dimensioning the dimensioning function starts again This is useful for creating series of dimensioning of the same kind For breaking off the function use the Esc key or select another dimensioning function Visibility While dimensioning pay attention if a roll is select
269. ines have to be sorted in ascending order and the last F line should have a large value in column 2 for example 999 to ensure proper calculations even for unusual proportions For the Addition method follow some lines with a leading Z Column 1 Z for the Addition Method Column 2 Limit of the sheet thickness for correction factor and addend Column 3 Limit of the bending angle for correction factor and addend Column 4 Limit of inner radius for correction factor and addend Column 4 Correction factor in pos or negative Column 5 Correction addend in mm pos or negative The lines have to be sorted in ascending order first by column 2 then by column 3 and then by column 4 The last F line should have a large value in column 2 for example 999 to ensure proper calculations even for unusual proportions The E line marks the end of the file To define own methods modify the file which contains only examples You can modify the examples or append new methods Machine File The machine file is useful for exchanging machine data which are shown in the Machine Window between projects After finishing a project a set of machine data have accumulated which are saved with the Project in the project file Now you can export the machine data into a machine file in order to re use them and import them in another new project For this use the functions File Export and File Import or the export and import functions in the Machine Wind
270. ing factor belongs to machine data and is displayed in the bottom part of the Machine Window The input field is active only in case of calibrating stands Use the deformation degree to have an influence on the shapes of the calibrating stands during the function Shaped Tube Calibration Partition the 100 forming between the round tube in the welding station and the final product Shaped Tube to all calibrating stands in a suitable manner If the sum of the deformation degrees of all calibrating stands is not 100 PROFIL adapts them linearly To get a final product with small allowances select a smaller deformation degree for the last calibrating stand C01 than for the others If the final product is a round tube the deformation degree is unconsidered Use the Calibrating Factor for decreasing the diameter of the tube If there are round tube calibrating stands behind the welding station i e calibrating to a round tube with a smaller diameter and behind them shaped tube calibrating stands enter a Calibrating Factor but no Deformation Degree in the round tube calibrating stands As a result of it the tube keeps round during the function Shaped Tube Calibration Copyright 2015 by UBECO GmbH Iserlohn 222 UBECO PROFIL Rollform Design Software 3 3 8 10 Diameter Shaft 3 3 8 11 The diameter of the shafts D belongs to machine data and is displayed in the bottom part of the Machine Window for each shaft
271. ing machine the shell elements are deformed this means the lengths of the edges are changed From these changes the strains and stresses in longitudinal direction are calculated and displayed by colored faces in the Drawing Area The calculation works quickly and approximately and does not need FEA Finite Element Analysis Compared with step 1 Stress of Edge the Profile Stress Analysis has the advantage that the longitudinal stresses are not only calculated at the edge but within the whole profile This is Copyright 2015 by UBECO GmbH Iserlohn 142 UBECO PROFIL Rollform Design Software important when the maximum stress is not at the edge e g when edges are folded and the folds are bent Compared with step 3 FEA Finite Element Analysis the Profile Stress Analysis has the advantage that the method is very quick and can be used while designing On the other hand FEA calculates much more precisely and not only stress and strain but also the final profile pattern is calculated Calling the function Select the start pass for the calculation Call this function optionally by e Main menu View PSA Profile Stress Analysis e F Button PSA Profile Stress Analysis in the Button Key Bar Principle of operation A 3D drawing is created in the Drawing Area that shows the strip while running through the roll forming machine ANAL EN You can modify the analysis range by using the From Pass and To Pass s
272. intersection the contour tracking turned in the wrong direction it prefers the straight on direction Click onto the path of the right direction behind the intersection Clicking onto the path of the right direction is ineffectively Double lines exist in the CAD drawing or there is no start point of a connection element at an end point of the previous element Modify the CAD drawing The blue line ends before the contour end point red is reached At this position a faulty connection between two elements exist gap overlap etc Correct the CAD drawing Left and right profile half have common contour elements and cannot be tracked unambiguously Move apart the left and right profile half in the CAD system and import only the right half first Then append a point P in the profile list manually select the next empty line and import the left haft separately Or import the top profile side instead of the bottom side and vice versa contr Create profile list now A The scanned contour should represent the top profile side fat the reference point 0 sheet center line bottom profile side at the reference point After confirmation by pressing the Ok button the dialog window appears with the question Create profile list now The scanned contour should represent the Select if you scanned the top profile side the sheet center line or the profile bottom side previously It is mandatory that this selection is the same as in the p
273. ion Principle of operation After confirmation by pressing the Ok button the position on the shaft is checked first e The position is free the new roll is inserted at the defined position The user has to check if there are remaining gaps between the rolls e Aroll already exists with same width and position the existing roll is replaced by the new one if the user agrees e An overlap occurs between an existing roll and the new one the existing rolls are moved by the overlap width if the user agrees The imported roll appears at the selected position of the roll set Check if the roll touches the profile correctly otherwise modify the Working Diameter in the Machine Window Hints Further function for creating rolls are e Automatic creation by Scan Profile Drawing e Import contour from CAD by Roll Read CAD Contour e Import roll from the Roll Data Base Scan Profile Drawing Use this function to scan the profile drawing in the Drawing Area and to generate a roll for the desired shaft automatically Only the contour of the profile and other already existing rolls are considered that are visible from the shaft HH Undercuts are considered Copyright 2015 by UBECO GmbH Iserlohn 108 UBECO PROFIL Rollform Design Software A roll is created that touches the complete visible contour By using the switch Profile Loaded you can define whether the discharged or loaded state of the profile should be used
274. ion groove and material files are remembered see Expanded Roll Tool Window e Reference point of automatic roll dimensioning can be set to the left or right side see Automatic Roll Dimensioning e Main line color of the profile and the rolls can be set separately Setting in Options Drawing e Decimal places of the co ordinates of the NC program can be preset Setting in Options NC Bugfixes e Inthe parts list column Actual Diam the options setting Diameter from Intersection Point Actual Maximum now is considered see Parts List Columns e Open Fold now calculates the correct strip width in case of symmetrical profile PROFIL Rel 3 3 01 Dec 2001 New features e FEA Interface to the leading FEA system ABAQUS Explicit from SIMULIA Dassault Systemes The simulation of the roll forming process enables the designer to validate and optimize his roll form design at an early stage before the rolls are manufactured to ensure that the final product meets the particular needs e Undo Redo command for reversing the 5 most recent operations and for reversing the effect of the previous undo command e Copying of the drawing as a pixel image to the Windows clipboard for transfer it to any other Windows application e Open Fold command useful if in the last pass a 180 degree fold with inner radius 0 should be created by pressing together the legs of a bend e Clearance Angle by entering a desired angle value and by extending
275. is recommended to apply this function to the final profile L01 in case the succeeding passes flower pattern do not exist Afterwards create the flower pattern for the profile with the modified Copyright 2015 by UBECO GmbH Iserlohn 86 UBECO PROFIL Rollform Design Software 3 1 3 5 start element Principle of operation If you selected a point on the sheet s bottom side more precisely a point on the same side as the reference point the profile list will be re sorted accordingly and turned if necessary In doing so the co ordinates of the Reference Point X0 YO and also the Direction keep unchanged Afterwards the profile with the selected start point will be the first in the profile list Thus the drawing of the profile is moved The picture shows an example wherein the function has been applied to the top profile The center profile shows the result If you selected a point on the sheet s top side more precisely a point on the opposite side of the reference point the whole profile will be turned by 180 degree first and afterwards the profile list will be re sorted just like above If the profile opening was on top previously it will be now on bottom and vice versa In the picture the function has been applied to the center profile The bottom profile shows the result If you modify the start element of a symmetrical profile list with Symmetrical Point PS the list becomes unsymmetrical with Point P Hi
276. ject Principle of operation Clicking the sign opens the tree node and the objects of the node become visible The sign closes the node By clicking on an object the belonging drawing is shown in the drawing area If necessary the view changes automatically between flower pass stand and roll If another object is selected in the drawing area the belonging explorer entry is marked Copyright 2015 by UBECO GmbH Iserlohn 206 UBECO PROFIL Rollform Design Software 3 3 2 Setup Function Edit Explorer toggles the Explorer between Profile List Number counting against the sheet running direction left Pict and Pass Number counting in sheet running direction center Pict and Stand Name right Pict i Open Project and Explorer with preview While working with larger projects the screen refresh takes more time because refreshing the preview pictures is necessary after each modification This may impede quick working Simply switch off the preview in Options General Colors of Drawing rea Inactive Marked Background Profile Explorer e Reset The background color can be preset in Options Drawing By moving the vertical split line between explorer and drawing area the width of the explorer can be modified If more explorer entries exist than the window is able to display a vertical scroll bar appears Hint e l needed the profile list number can be used as variable PL for t
277. l deviation of centroid of the area is kept So you will get another result every time you call the function for the same shaped tube repeatedly e the shaped tube should be formed to a elliptic tube This method should used if the shaped tube is either quite large and flat or quite high and narrow this means tt differs extensively from the square form with same width and height High deformation would be required to calibrate this kind of shaped tube from a round tube Better is to calibrate it from an elliptic tube The inout window Aspect ratio major minor axis of the ellipse requests to enter the desired ratio The value must be between 1 1 and 16 0 PROFIL decides by itself dependent on the position of the final shaped tube whether a flat or upright ellipse is created Get further details from the selection to a round tube e the cross section of the shaped tube should keep unchanged The deformation degree is ignored and dependent on the calibrating factor the straight length of each profile element is increased Principle of operation Starting with the current profile list normally LO1 the passes for all calibrating stands are created automatically calibrating factor and deformation degree are considered If profile lists with a number higher than the current yet exist you are asked if they can be deleted Modify the reference point that the welding seam is at the desired position This question appears if you have defined a unsymm
278. l part number is not renumbered if a roll is mirrored function Rolls Mirror at a roll edge bottom top rolls or from one side to the opposite side side rolls It also is not renumbered if a roll is copied to another position via the clipboard function Roll Copy and Roll Paste Otherwise it get a new number dependent on the preset number keys Mirror Copy Rolls More More The Expanded Roll Tool Window opens You can enter default values which are copied into a roll dataset when you create a new roll by Roll Read CAD Contouror Roll Scan Profile Drawing Spacer Rolls Use this function to set the parameters for Creating Spacer Rolls Number Key Number Keys Autom Increment RollNo T PartNo Bottom Shaft SpsawssAl Top Shaft SpeRwxsAl This setting enables the automatic numbering of the roll number and the part number for spacer rolls only when spacer rolls are created newly If you want to use the number keys for existing rolls call the function Roll Renumber Autom Increment Select if the roll number and the part number should be incremented automatically number 1 when you split a spacer roll with the function Roll Split at Corner and Roll Split between Corners Precondition the last digit must be numeric 0 9 Bottom Roll Top Roll Select the roll and part number for the roll which you will create with the function Roll Read CAD Contour and Roll Scan Profile Drawing For the automatic increm
279. lated for the cost assessment e Double clicking on the mouse wheel fits the drawing into the Drawing Area Bugfixes e Changing roll corner radius with Toolbox Modify does not causes overlaps with neighboring radii anymore e Split rolls on multi side axles now can be dimensioned too PROFIL Rel 5 1 01 Dec 2013 New features e FEA Interface to the leading FEA systems LS Dyna from Livermore Software Technology Corp The simulation of the roll forming process enables the designer to validate and optimize his roll form design at an early stage before the rolls are manufactured to ensure that the final product meets the particular needs e Curve Generator for quick creating a stress strain curve for FEA simulation by defining three characteristic curve points in case the exact curve is not available e Bottom top rolls with arbitrary Inclination Angle optionally e Profile Read CAD Contour Besides scanning the bottom profile side also scanning the top side and the sheet center line is supported e Grid Lines in the drawing area preset in Options Drawing and Options Colors e Showing the Previous Next Pass also in the Pass View e Printing all rolls of a certain stand or of the whole project Printing rolls also with NC program Printing profile list radius and angle bold for determination Loaded Discharged state Bugfixes e ActiveX Output to AutoCAD now creates correct width dimensioning in case of an Inclination A
280. ld be created The center lines are visible in the Drawing Area if you have selected View Rolls and the Machine Window contains machine data In case of rolls already exist on the shaft select any roll in order to mark the shaft Call this function optionally by e Main menu Rolls Read CAD Contour Copyright 2015 by UBECO GmbH Iserlohn 106 UBECO PROFIL Rollform Design Software 3 1 4 2 e E Button Read CAD Contour in the Button Key Bar gt The Window Read CAD Contour appears and you define the Contour Start Point green and Contour End Point red of the contour Do not include the side flanks vertical lines to the shaft in the contour By checking the color changes to light blue you can find out if the right contour is tracked between Contour Start Point green and Contour End Point red If not proceed like this e At an intersection the contour tracking turned in the wrong direction it prefers the straight on direction Click onto the path of the right direction behind the intersection Clicking onto the path of the right direction is ineffectively Double lines exist in the CAD drawing or there is no start point of a connection element at an end point of the previous element Modify the CAD drawing The blue line ends before the contour end point red is reached At this position a faulty connection between two elements exist gap overlap etc Correct the CAD drawing Principle of ope
281. ld not be enabled LL Guiding the first row of nodes at the profile lead end Guiding the node at the profile lead end This method forces safe threading of the profile into the next roller stands and prevents pushing against the rollers This also is assured if the Reference Points X0 YO have different height see Center Line Forming The designed flower pattern defines the target profile cross section within the stands between stands a model of cubic B spines is used for approximately calculating the molding geometry This clones the tractive of the sheet in front of the section and approximates the reality at the best In other respects Guiding the node at the profile tail end This method prevents up and down oscillation of the profile tail end while the lead end enters the next stand In other respects the mode of operation is like in Guiding the node at the profile lead end However the guidance can be wrong This occurs if the designed flower pattern differs from the cross section calculated by the FEA system This is shown by deformations of the lead or tail end during evaluating the FEA result In order to mask this affect out during evaluation a selectable count of rows can be cut off at the lead and tail end see View FEA Result ABAQUS Use this function to create the simulation model for the FEA Simulation which can be processed by the FEA system ABAQUS Explicit Calling the function Precondition You have cre
282. le is displayed in the Drawing Area for examination You can correct your input by using the functions Element Insert Element Append Element Remove and Profile Empty Hints e f you have made a mistake in entering an arc you must not modify the angle or the radius of the arc By doing so you would bend up the arc with constant straight length For correction toggle to the Draft Modus which enables to modify angle and radius without bending the arc e By using the numerical method it is not so easy to enter profiles that have not 90 angles see example 3 Better use the Toolbox Profile Design or the Graphical Method Copyright 2015 by UBECO GmbH Iserlohn Tutorial 33 2 4 3 2 4 4 Graphical Method Use the graphical method for data input of more complicated profiles if you do not know all data and you cannot simply calculate them Preparing the profile contour inside the CAD system First step is to draw the contour of the desired profile inside your CAD system LS LS LS Optionally drawing the profile bottom side the sheet center line or the profile top side bottom and top related to the reference point is possible If you want to design a symmetrical a you only need to draw one half If you design a symmetrical profile take care that the web line is split in two halves so that the split point defines the profile reference point Reading the contour Use the function Profile Read CAD Conto
283. le most universally also if the angles of the target profile list differ from the source it is recommended to convert the angles from degree to percent related to the final angle The top left table field shows the setting furthermore the setting is saved to the development table file Before applying the development table to a new profile the angles are converted to degree again this time related to the final angle in the target profile list Development Table Row Column By using these functions you can adapt and modify the development table for best applying to a new profile By using Insert Append a new empty row column is created Paste from clipboard replaces the entries All functions Column only modify the content of a development table not the header which is created from the profile element types of the current project Thus you can adapt the development table from another project to the element type sequence of the current project in case the angles are not in an appropriate arc column 3 1 3 15 Profile Catalogue Profile Catalogue if 15 x St Lenath 15 500 2141 JL 1 500 30 000 1 284 reat 4 0001 Radius Angle 1 500 60 000 2 652 x Profiles 15 j a gt mM t aj Go O OF 3 Profile Pi Customer Descript Drawin Class Ma Material Machin Date Name Rev width Height Thickt Strp wic Direc Project Path
284. lls Mirror e Context menu right mouse button click on the certain corner point of the desired roll in the Drawing Area Mirror Principle of operation The new roll with same size is created dependant on the specification In case of top bottom rolls the order of the Roll Corner Points in the Roll Tool Window is changed in case of side rolls preserved Mirror Copy Rolls e Keep Aoll Part No In Options Rolls Mirror Rolls can be preset if the Roll Number and Part Number should be kept during mirroring Otherwise they are renumbered dependent on the defined Number Keys Cut Use this function to cut a roll This means the roll will be removed from the set of rolls and will be transferred to the clipboard Calling the function Before you call this function identify the roll by clicking any Roll Corner Point of the roll Call this function optionally by e Main menu Rolls Cut e Context menu right mouse button click on the certain corner point of the desired roll in the Drawing Area Cut Principle of operation The roll is moved to the clipboard From the clipboard you can insert the roll at any position also to another shaft or to another stand by using the function Roll Paste In this way you also can duplicate a roll Furthermore in this way you can transfer a roll into the Roll Stock Management Hints e f you want to undo the cutting call function Roll Paste at the same position e Transferring the
285. log box asks if they should be removed and replaced As a distinctive mark to forming rolls the box Spacer Roll in the header of the Roll Tool Window is checked Principle of operation Available space between forming roll flanks and stands and between rolls among themselves are filled with spacer rolls Shims A Y Split Spacers to Shims 100 00 7 Small Shims Outside 50 000 10 000 e Width The width of the spacer rolls results from the available space between the forming rolls and the machine stand defined by the Working Width in the Machine Window If Split Spacers to Shims is checked in Options Spacer Rolls the spacer is split into shims dependant on the Table of Shims The checkbox Small Shims Outside causes if the spacer splitting should start outside at the stand or inside at the forming roll e Diameter The diameter of the spacer rolls is obtained from the input field Spacers in the Machine Window It is possible to change it later by changing the two corner point diameter just like at forming rolls e Material The material of the spacer rolls is obtained from the selection box Spacers Material in the Machine Window Number Keys Autom Increment 7 RollNo T PartNo Bottom Shaft SpsawssAl Top Shaft SpeRwxsAl e Designation Roll number and part number are created dependant on Number Keys in Options Spacer Rolls For spacer rolls the variables RW roll width and RD roll diameter are of int
286. log window is called by Output FEA LS Dyna is used for set up the FEA input output path start and restart and the start position Fen parameters ts ovna 2x E LS D yna Profile FEA Input Output Rolls Simulation Path CAFEA D ata gee FEA Project Name max 20 char 4965 Material Contact Start Simulation e With flat sheet Others C Restart behind stand Start position in front of a stand in of the largest roll radius In front of the 1st stand in sheet running direction 230 In front of all other stands 80 X Cancel Help FEA Input Output Simulation Path Enter the network path for saving the output files of the FEA simulation model and for loading the file of the FEA result Hint Since the FEA solver needs 100 of computing power the FEA system LS Dyna should run on a separate computer not on the PROFIL CAD workstation FEA Input Output FEA Project Name The files of the simulation model are saved under this name By default the input field shows the Profile Project name However it can be modifies in case e g several simulations should be made for the same project with different settings Hint the length of the input name should not exceed 20 If it does the background color becomes red and the name is shortened to 20 characters The name must not contain umlaute blanks and other special characters the will be replaced by substitute characters Start
287. lower After every modification of a bending angle the stress of the band edge is recalculated and displayed e PROFIL supports drawing with automatic creation of flower pattern in a nested or separated view or as a perspective 3D drawing Drawings can be dimensioned associatively e PROFIL speeds up the roll design by directly using the profile contour or any contour drawn in CAD Use the powerful commands to modify the rolls to your individual needs Create the drawing of the rolls just by key stroke Roll tool drawings are dimensioned automatically e PROFIL supports manufacturing of the roll tools by creation of parts lists and NC programs DIN 66025 e PROFIL helps searching for suited rolls if existing old rolls from the roll stock should be re used in a new project Profit by PROFIL In the past cold rolled profiles or tubes were designed by manual drawings or by CAD only All calculations were made by hand The designer needed a lot of experience and much intuition To get drawings for very similar profiles or rolls he had to repeat the whole process PROFIL supports the design as far as possible Saving you considerable time in creating drawings and using the technological power to check the design during design Thus the designer s profit is Copyright 2015 by UBECO GmbH Iserlohn General 13 1 6 1 7 1 8 e better design because calculations are done with high accuracy input errors can be cha
288. lt Plasecs Sheet Metal Co C Profile 3 FEPO2G T300 22 06 95 M ller 29 07 2003 46 928 40 500 3 000 157 617 CAPROFIL324 A48655 Sheet Metal Co C Profile C40 3 FEPO2G T300 22 06 95 Miller 16 08 2003 40 000 38 000 3 000 117 549 CAPROFIL324 262500 Kolberg Drawer Slide 9 5t14 2G 250C 09 05 99 01 02 01 112 689 62 539 3 000 403 008 CAPROFIL324 zc3000 Kolberg Drawer Slide 3 st 2 24 T300 17 02 20 Brandegc 20 03 2003 30 000 20 000 1 000 66 444 C PROFIL32 43030 Steel Pipe Shield Profile 3 st 2 24 T300 16 09 02 Br 16 09 02 63 000 3 000 1 500 83 663 CAPROFIL324 07730 Winston kT 3305 la st14 T600 19 07 00 Brandear 19 07 00 120 081 72 162 4 000 436 495 CAPROFIL32A Metal Fo Shaped Tube Q 60 45 3 St2 24 T600 18 03 02 Brandeg 01 04 2002 34 000 22 000 3 000 91 881 CAPROFIL324 A Metal Fo Shaped Tube 10 60 4500 3 St 14 T300 25 02 00 28 02 2003 63 856 10 000 2 000 89 917 CAPROFIL324 x Only with option Database While dealing with an inquiry the designer needs calculation data from similar profiles that are produced in the past Designing new roll form projects should consider experience from earlier projects The profile catalogue gives a quick overview of all produced roll formed parts Any filters Copyright 2015 by UBECO GmbH Iserlohn 98 UBECO PROFIL Rollform Design Software can be defined named saved and reload
289. ly Bugfixes e No runtime error anymore while removing a roll and the Roll Tool Window is open e No sporadic error message anymore after opening a Profile Design Toolbox window e The Parts List in the Imperial System now contains blank sizes and bore diameter with two decimal places 1 12 Frequently Asked Questions Q The windows are too small some contents cannot be read A Please set the WINDOWS screen settings to Small Fonts Q In the print out vertical and diagonal dimension texts are absent A Some older printers support text angles of 0 only The same problem can occur in the landscape format Q If select another working diameter in the machine file the rolls move away from the profile How can modify the diameter afterwards without designing the rolls newly A Uncheck the box Keep Roll Data in Options Rolls previously Q During driver installation for the parallel hardlock got the error message System Error 1275 What is the reason A You tried to install a 32 bit driver in a 64 bit system This is refused by WINDOWS 7 We recommend to update to the topic PROFIL release by changing the parallel hardlock against an USB hardlock concurrently Q During bending with arc type A2 the profile form keeps unchanged only the material is moved to the neighbor arc A The profile is bent up only if the previous segment is a line So insert a line segment with length zero in front of the A2 arc
290. m width that has enough space for all fillet radii The result is rounded to 10 mm or 1 in e Fillet Radii R1 R2 Select a fillet radius at the inside at the tube and a fillet radius at the outside at the roll edges Working diameter and reference point are taken from the Machine Data Principle of operation After pressing the Ok button the roll is generated If a roll is yet existing it will be replaced 3 1 7 2 10 Break Down Pass Side Rolls E ee This function is a part of the Toolbox Tube Design and is used for generating the side rolls for a break down pass The shoulder is suited for leading the edge of the sheet to the correct position Calling the function Before calling this function you should have created a break down pass by using the Break Down Pass If you created the break down pass in another way pay attention that the profile list contains exactly 3 entries A1 A1 PS Only for such a tube profile rolls can be generated automatically Call this function by e E Button Break Down Pass Side Rolls from the Toolbox Tube Design The window Break Down Pass Side Rolls is opened Enter these parameters e Roll Diameter D If your entered diameter is too small that the roll cannot touch the tube an error message appears If it is too big the diameter is set automatically that both side rolls touch together e Total Width W If your entered value is too small the width is set automatically to a minimum width that
291. me roll corner point Hints e f you want to undo splitting use the function Join e To split a roll at a corner use the function Split at Corner Copyright 2015 by UBECO GmbH Iserlohn Reference 119 3 1 4 14 Join Use this function to join two rolls to one roll Calling the function Before you call this function identify the last Roll Corner Point of a roll which should be joined to the next one Or identify the first corner point of a roll which should be joined to the previous one Call this function optionally by e Main menu Rolls Join e Context menu right mouse button click on the certain corner point of the desired roll in the Drawing Area Join Principle of operation Two rolls with the same roll corner point are joined together to one roll Hints e f after joining a surplus roll corner point exists remove it with the function Roll Corner Remove e f you want to undo the joining use the function Split at Corner 3 1 4 15 Turn Use this function to turn a roll This means you take off a roll from the shaft and install it inverted Calling the function Before you call this function identify a roll by clicking any Roll Corner Point of the roll Call this function optionally by e Main menu Rolls Turn e Context menu right mouse button click on the certain corner point of the desired roll in the Drawing Area Turn Principle of operation The roll is turned by chan
292. mended to fill out the shaft data previously By appending side axles the data of the previous axle are copied The inclination angle however is modified in order to have the axle visible in the drawing area and selectable by mouse click Afterwards the user should set the desired inclination angle The drop down menu in the top and the buttons of the button bar can be used for Las Import a Machine File When you start with a new Project that does not contain machine data you can import machine data from a machine file m01 that you created with the function Export from another project previously m Export a Machine File The machine data from the current project are saved into a file m01 OF Append Forming Stand Behind the current stand marked in the Machine Explorer a new forming stand is created oc Append Calibrating Stand Behind the current calibrating stand marked in the Machine Explorer a new calibrating stand is created E Remove stand Pay attention to the sequence opposite the sheet running direction first calibrating stands afterwards forming stands F01 always is the last forming stand in sheet running direction the finishing stand in case of tubes the welding station CO1 is the last calibrating stand the finishing stand for shaped tubes Change Machine Data In case the machine data are changed and rolls already exist in the project the setting in Options Rolls Change Machine Data will be effectiv
293. ments without bending or unbending the segmenis Function File Save saves your profile project Use the function View Pass to view the drawing of the profile in the Drawing Area The Navigator helps you to zoom to move and to fit the drawing Transfer the drawing which is displayed in the Drawing Area to your CAD System by using the function Drawing gt CAD Use the function Calculate Statics to get a table of all static parameters of the cross sectional area So you can examine if your profile satisfies given static parameters The function View Statics generates a drawing of the profile and the statics Copyright 2015 by UBECO GmbH Iserlohn Tutorial 31 2 4 2 With the function Abs Angle you can examine if specific parts of your profile have the desired angle related to the horizontal line Hints e After designing the cross section of the final profile your profile project contains a profile list with the name L01 This name is shown in the Explorer e The next step is Designing the Flower Pattern By doing this the profile lists L02 LO3 etc are created The last profile list e g L16 should contain the flat strip as it is decoiled from the coil Numerical Method Use the numerical method to design a simple rectangular profile or a tube Because in this case you know all input data or you easily can calculate them Enter the Profile Elements directly and manually into the Profile List Windo
294. n Before you call this function activate either the left or the right corner of the roll to define whether the extension should be left or right Call this function optionally by e Main menu Rolls Cylindrical Extension e Context menu right mouse button click on the left or right corner of the desired roll in the Drawing Area Cylindrical Extension The input window appears and asks Give width for the cylindrical extension Select between relative By Width and absolute To Width In case of By Width the input can be negative in order to get a smaller roll Principle of operation The cylindrical extension will be attaches to the selected roll corner If the roll is not cylindrical Copyright 2015 by UBECO GmbH Iserlohn 112 UBECO PROFIL Rollform Design Software 3 1 4 7 before or behind the selected Corner Point a new corner point will be appended in the other case the selected corner point will be moved If further rolls exist they will be moved in case there is not enough space between the rolls The new coordinates of the Corner Point will be calculated Hint Alternatively you can append a Conical Extension or an Arched Extension Arched Extension lV If a roll has an arc with a radius at the beginning or the end it may be necessary to lengthen the arc instead of appending a conical extension A reason for it may be The surface of the sheet should not damaged by a roll corner This means the
295. n Part Previous Segment how much of the residual length should be added to the previous segment The rest is added to the next segment Track Holding Select arc type A4 and check in Options Calculate Arc Type A4 Track Holding The residual length is divided automatically to the previous and next segment that the strip is guided straightaway this means with constant intersection point of the tangents Select if the intersection point of the tangents inside or outside should be kept constant while bending Modify angle constant radius By using this setting A4 works like A2 and A3 by keeping the radius constant while modifying the angle Modify angle and radius radius angle method After entering a new angle an input window opens and asks for the desired new radius Firstly this method seems to be absurd because in sheet running direction a part of the arc after bending is pressed to flat again However the method can be chosen expediently in these cases e Existing rolls with certain angles and radii should be re used e Spring back should be compensated This works in the same way as the function Open Fold see chapter Why doesn t this fold spring up First in sheet running direction more material as necessary is bent to an arc In the last stand a part at the beginning and at the end of the arc is bent to flat again whereas the middle part is bent to the final angle During this operation all three part spring back The mi
296. n Calculate Plausibility Check and correct the roll data e Currently it is not possible to transfer all stands in conjunction with the formed sheet between all rolls This function is planned for future enhancement Use View PSA and Drawing gt CAD instead This function transfers the sheet without thickness e Select by View Show Spacer Rolls whether the 3D output should contain spacer rolls 3 1 8 4 Create Parts List No Designation Roll No Part No Mat Blank Size Bore Gross Fin Weight 2 Bushing 2080 D 76 0 x 28 0 50 0 1 0 0 4 2 Bushing 2080 D 76 0 x 56 0 50 0 2 0 1 0 1 Bushing 2080 76 0 x 65 0 50 0 2r 1 2 2 Spacer 2080 81 0 x 175 0 50 0 7 1 4 1 2 Spacer 2080 81 0 x 185 0 50 0 Typo 4 3 4 Spacer 2080 81 0 x 190 0 50 0 7 7 4 4 2 Spacer 2080 81 0 x 195 0 50 0 7 9 4 6 4 Spacer 2080 81 0 x 205 0 50 0 8 3 4 8 2 Spacer 2080 81 0 x 223 0 50 0 9 0 D2 4 Spacer 2080 g 81 0 x 225 0 50 0 9 1 54 3 1 TopRol 201 A4865 R02 01 2080 101 5 x 36 0 50 0 2 3 1 4 TopRol 203 A4865 R02 03 2080 101 5 x 36 0 50 0 273 1 4 TopRol 203 A4865 R01 03 2080 111 5 x 28 0 50 0 2 1 0 8 TopRol 201 A4865 R01 01 2080 111 5 x 28 0 50 0 2 1 0 8 LeftRoll 301 A4865 R01 L1 2080
297. n a separate column of the rolls Identification Groove Identification groove belongs to the roll data and is displayed in the Expanded Roll Tool Window Identification groove is the name of a file that e g contains these data GROOVEFILE Identification Groove 80 000 Diameter 8 000 Groove With 2 000 Groove Depth 80 000 Shoulder Angle To assign an identification groove to a roll click with the mouse cursor into the input field Select the desired identification groove file within the file select window If you want to create new identification groove files press Edit in the Expanded Roll Tool Window and select File Save as The data in the file currently are not yet utilized The identification groove file name can be used as a column of the Roll Parts List Material Material belongs to the roll data and is displayed in the Expanded Roll Tool Window Material is the name of an Additions File which is used to calculate the blank size from the finished size of a roll To assign a material to a roll click with the mouse cursor into the input field Select the desired additions file within the file select window If you want to create new additions files press Edit in the Expanded Roll Tool Window and select Copyright 2015 by UBECO GmbH Iserlohn 214 UBECO PROFIL Rollform Design Software 3 3 6 7 3 3 6 8 3 3 7 File Save as If you called the Expanded Roll Tool Window
298. n arc e Ifan angle entry is below a point header entry P or PS it is ignored Copyright 2015 by UBECO GmbH Iserlohn Reference 97 e Ifthe development table has more columns than the target profile list s count of profile elements if empty header entries exist the surplus columns are ignored e The existing target profile list LO1 keeps unchanged this means the first development table row is ineffective e f profile lists LO2 Lnn exist they are emptied e The profile list LO1 is copied and appended regards the count of rows of the development table and the table s angles and bending methods are set to the profile lists Angles in degree are set directly and angles in percent are transformed to degree related on the final angle in LO1 of the target profile list Appending profile list works dependent on the switch Insert Append in Options Profile List Development Table Bending Method The development table is able to show the Angles or Bending Methods as desired Toggle between both by using this function During automatic flower creation bending method entries are needed only if the method should deviate from the method in the target profile list LO1 or if a line should be converted to an arc Therefore if the develooment table does not contain a bending method the bending method from L01 is taken If there is no bending method in L01 A1 is taken Development Table Angel in To use the development tab
299. n older LS Dyna release Update to the solver R7 or later F am just designing a quite complicated profile with 32 passes The more rolls create the slower is the screen refresh after each roll modification How can accelerate it A Switch off the preview pictures in Options General Copyright 2015 by UBECO GmbH Iserlohn Tutorial 27 2 Tutorial 2 1 How to Work Profile design by CAD drawing Mumerical input Toolbox y o Pass discharged M Je Flower nested a Flower 30 To design the roll tools for an open cold rolled profile proceed the following steps e defining the desired Profile or Tube Cross Section and calculating the initial strip width e defining the Bending Steps Flower Pattern dependent on the permissible longitudinal strain e designing of the Roll Tools e if needed verifying the design by Finite Element Analysis e output of the Manufacturing Data To design the roll tools for a cold rolled seamed tube or a shaped tube use the Toolbox Tube Design Copyright 2015 by UBECO GmbH Iserlohn 28 UBECO PROFIL Rollform Design Software 2 2 Quality Management PROFIL has a three step concept for quality management asses eee stress of Band Edge Material 3 FE P02 G 275 NA Re 380 N mme2 Center Line Forming Ps Re 63 63 99 100 8 11 5 0 co 0 Om eof Stress of band edge as a bar diagram
300. n your initial work sheet Set up Columns Set up Columns After pressing this button the Set Up Parts List Columns Window opens Copyright 2015 by UBECO GmbH Iserlohn Reference 71 3 1 2 8 10 Set Up Parts List Columns Use this window to set up the columns of the parts list The window appears if you press button Set Up Columns in Options Parts List Parts List Columns available Count Designation Material Actual Diam Actual Width Blank Diameter Blank Width O Shaft Bore Hole Bushing Identification Gre Fertiqungsvertak Finished Weight available This list box shows which parts list columns can be selected Count Designation Roll No Part No Classification Material Actual Diam Width Blank Diam Width Shaft Bore Hole Bushing Identification Groove Treating Surface Addition Remark Blank Weight Finished Weight X lt User gt count of rolls with same visible parts list properties fixed text from table Designation from the Roll Tool Window from the Roll Tool Window from the Roll Tool Window name of the Addition File from the Roll Tool Window actual dimensions with additions from the Additions File that is set in Material Unit mm or inch from the Machine Data from the Expanded Roll Tool Window from the Expanded Roll Tool Window from the Expanded Roll Tool Window from the Expanded Roll Tool Window from th
301. nation The CAD system registers itself to WINDOWS with its Program ID This information is stored in the system registry of WINDOWS By this Program ID the connection to PROFIL is made PROFIL notices which CAD releases are registered and displays them in a drop down list when you click on the arrow symbol Open the drop down list and select one of the Program ID s e AutoCAD Application nn Connect to AutoCAD Release nn Use this Program ID if you have installed more than one AutoCAD Release and you want to select a special one AutoCAD 14 AutoCAD Application 14 AutoCAD 2000 AutoCAD Application 15 AutoCAD 2004 AutoCAD Application 16 AutoCAD 2005 AutoCAD Application 16 1 AutoCAD 2006 AutoCAD Application 16 2 AutoCAD 2007 AutoCAD Application 17 AutoCAD 2008 AutoCAD Application 1 7 1 AutoCAD 2009 AutoCAD Application 17 2 AutoCAD 2010 AutoCAD Application 18 AutoCAD 2011 AutoCAD Application 18 1 AutoCAD 2012 AutoCAD Application 18 2 AutoCAD 2013 AutoCAD Application 19 AutoCAD 2014 AutoCAD Application 19 1 etc e AutoCAD Application Connects to the topical AutoCAD Release this is the last installed one e SldWorks Application nn Connect to SolidWorks release nn Use this Program ID if you have installed more than one SolidWorks release and you want to select a special one SolidWorks 2003 SldWorks Application 1 1 SolidWorks 2004 SldWorks Application 12 SolidWorks 2005 SldWorks Application 13 SolidWorks 2006
302. nd flat or quite high and narrow Shaped Tube Calibration also by keeping the cross section of the shaped tube unchanged This means the shaped tube is formed as an open profile welded and then calibrated Beside the previous pass also the Next Pass can be inserted in the roll tool drawing New Variables for consecutive numbering of the rolls of a stand and of a shaft type Bugfixes The fixed scales in Print Preview and Roll Assembly Plan are adapted to DIN ISO 5455 PROFIL Rel 4 6 01 Dec 2009 New features Options Drawing Profile element separator lines can be switched off thus better manual extruding in 3D CAD Radius Dimension Function Move Dimension now also rotates dimension line and text Roll Read CAD Roll imports a complete roll from CAD and positions it on the selected shaft without modifications New Space Mouse integration with improved rotation function in 3D Output to CAD No layer name limitation to 8 characters anymore thus longer roll numbers possible Print Preview The pathname is displayed in short form in case it is too long Bugfixes No Stream Error anymore during loading INI files from older releases Automatic Flower Creation Alternating bending methods are handled correctly now PROFIL Rel 4 5 01 Dec 2008 New features Creating the profile pass the PSA model the roll tool stand or all stands as 3D models in STEP format in accordance with DIN ISO 10303 Extended Import fun
303. nd the width is mirrored at the roll reference point in addition Hints The function does not modify e The start Direction of the profile list If necessary modify it manually e The Machine Data If they are different in case of side rolls the roll may not touch the profile anymore Manual correction is necessary Modify Start Element The first profile element of the Profile List in the Profile List Window starts at the Reference Point X0 YO Define the reference point in the Window Read CAD Contour by selecting the marker Reference Point x0 y0 blue The reference point normally should be nearly the center of the profile s web Because both legs turn around the reference point during forming it is recommended to put it in such a position in order nearly to have equal leg heights on both sides also in case of a unsymmetrical profile Thus the Stress of Band Edge is distributed equally to both sides This also can be optimized by selecting a suitable Direction Calling the function Call this function optionally by e Main menu Profile Start Element e Context menu right mouse button click on a profile element in the Drawing Area Profile Modify Start Element After importing the profile cross section you can use this function to modify the profile element order and to select which profile element should be the first in the profile list Click on any drawing element of the current pass The nearest end point is caught It
304. ne left and tube forming machine right The machine explorer displayed in the left part of the Machine Window The entities in the table of stands are e F Forming Stand for open profiles and welded tubes e C Calibrating stand only for welded tubes The machine explorer is just as the Profile Explorer organized against the sheet running direction This means on the top is the last stand for the final profile A pure roll forming machine for open sections see left picture has only forming stands e g F01 F16 A tube forming machine for Welded Round Tubes or Shaped Tubes see right picture first against the sheet running direction has calibrating stands e g C01 C02 C03 Behind C03 comes the welding station F01 then the fin passes e g F02 F03 F04 then the forming stands or break down passes e g F05 F10 If you select a stand by mouse click the table on the right shows the belonging data Stand Name Distance to Next Stand for calibrating stands only Calibrating Factor Deformation Degree and the table with the data of the shafts axles Diameter Shaft Working Diameter Reference Point Inclination Angle If the stand has additional side axles you can see the data after mouse click on the additional axles symbol e G L2 The stand name first is F01 Fnn for forming stands and C01 Cnn for calibrating stands In the field Stand Name you can modify the name The new name is shown in the machine explorer
305. new roll is inserted at O width position Hints e The function Rolls Spacer Rolls Create fills a gap between rolls automatically with a spacer roll e f you want to undo the paste function use the function Roll Delete Copyright 2015 by UBECO GmbH Iserlohn Reference 123 3 1 4 21 Delete Use this function to delete a roll Calling the function Before you call this function identify the roll by clicking any Roll Corner Point of the roll Call this function optionally by e Main menu Rolls Delete e Context menu right mouse button click on the certain corner point of the desired roll in the Drawing Area Delete Principle of operation The roll is deleted irretrievably 3 1 4 22 Stock Management olx Roll Stock Management Fiter E Value Allowance 156 3 from the right too Width omers Width Max Shaft Stock Position User 1 65 000 159 666 50 000 0422 Maschine 4229 70 000 156 000 50 00 0422 Maschine 4229 70 000 156 000 50 000 0422 Maschine 4229 63 800 137971 50 0000422 Maschine 4229 13 000 109 000 50 00 0422 Maschine 4229 63 800 137 971 50 000 0422 Maschine 4229 58 000 137 100 50 000 0422 Maschine 4229 13 900 156 500 50 000 0422 Maschine 4229 Part No wp3591 3075 wp3591 3080 wp3591 3080 wp3591 3080 wp3591 1000 wp3591 3080 wp3591 2031 wp3591 2080
306. ng gt CAD to ME10 via MI file is now also possible if spacers exist on top or bottom shaft only PROFIL Rel 4 3 01 Dec 2006 New features e Plotting a standardized roll assembly plan without CAD by using a Drawing Template drawing frame with title block e Extended Variables for Number Keys in Options Rolls and Title Block in the Drawing Template e Context menu to speed up the profile and roll design and for adapting the machine parameters by using the right mouse button in the Drawing Area Copyright 2015 by UBECO GmbH Iserlohn General 19 Improved network support An opened project file can be opened by another user on approval see Open Project Partial Ellipse as a new component of the Profile Design Toolbox Read CAD Contour imports partial ellipses and converts them to arcs approximately Shaped tube calibration now also is possible behind round tubes calibration For it the Deformation Degree is set to 0 The Machine can be removed from the Project Data Window by using the Del key Drawing gt CAD creates a layer named Pass Number instead of Profile List Number if the Explorer is switched to pass number Improved editing functions of the numerical values in the input fields Scaling factor of the z axis in View Flower 3D can be preset Reversible zoom direction when spinning the mouse wheel See Options Mouse and mouse position dependent zoom Support of the Soace Mous
307. ng Area of the main window and can be set in Options Drawing too Copyright 2015 by UBECO GmbH Iserlohn Reference 255 3 8 5 Filter Define filters in the top area at the left of the Roll Stock Management Window for reducing the amount of displayed rolls in the Roll Table in the bottom area of the window Each filter consists of a set of filter conditions logical AND conjunction and can be stored and recalled again The filter conditions can be entered manually into the table or can be generated automatically from the data of a roll from the clipboard Filtering can be switched on and off Filter Click on the arrow on the right of the input field and a drop down list is opened which contains all existing filters Select one of them and the according filter conditions are displayed in the table Table of Filter Conditions Name Select from the drop down list the name of the filter condition The names are at first all columns of the Roll Table Roll No Part No Classification No of Corners Width Max Shaft Stock Position User 1 3 Furthermore all columns of the Roll Corner Table can be selected but limited to the corner numbers 1 8 Width 1 8 Diameter 1 8 Radius 1 8 Angle 1 8 Furthermore all columns of the Project Table can be selected Project Customer Description and Drawing No Value Enter the value of the filter condition If the filter name in the same row determines a numerical f
308. ng PgUp Dn on the keyboard Copyright 2015 by UBECO GmbH Iserlohn Reference 247 If the angle is modified the diameter of the next roll corner point is adapted Width and radius of the topical and the next corner point keeps unchanged Hint Alternatively the angle can be modified by using the function Clearance Angle In doing so the width of the corner points are modified 3 7 Profile Catalogue lt Profile Catalogue fi 215 x Allowance ir Radius Angle 15 500 L 1 500 30 000 1 284 31L 4 000 F ajar L 1 500 60 000 2 652 y RN QI Customer Descript Drawin Class Ma Material h Machin Date Height Thickt Strp Wic Direc Project Path lt Sheet Metal Co C Profile 3 FEPO2G T300 22 06 95 Muller 29 07 2003 46 928 40 500 3 000 157 617 CAPROFIL32 448855 Sheet Metal Co C Profile C40 3 FEPO2G T300 22 06 95 Muller 16 08 2003 40 000 38 000 3 000 117 549 CAPROFIL32 262500 Kolberg Drawer Slide g st14 zq250c 09 05 99 01 02 01 112 689 62 539 3 000 403 008 CAPROFIL32 263000 Kolberg Drawer Slide 3 st224 1300 17 02 20 Brandegr 20 03 2003 30 000 20 000 1 000 66 444 CAPROFIL32 43030 SteelPipe Shield Profile 3 stz24 raoo 16 0902 er 1608 02 63 000 3 000 1 500 83663 CAPROFIL32 07730 winston KT3305 la st14
309. ng and for tube calibrating A Shaped Tube Calibration C Welding Pass Fin Pass Break Down Pass Break Down Pass W Forming Section 2 contains functions for generating the rolls for tube forming Fin Pass Top Roll A Fin Pass Bottom Roll E Break Down Pass Top Roll Copyright 2015 by UBECO GmbH Iserlohn Reference 159 Break Down Pass Bottom Roll y Fin Pass Side Rolls A Break Down Pass Side Rolls Principle of operation e Preparing Create a new profile project by using File New Open the Machine Window and enter the machine data or import a Machine File that you exported from a previous project If the welded tube should be formed to a shaped tube the machine must contain calibrating stands e Defining the tube dimensions round tube Call the function Welding Pass of the Toolbox Tube Design and enter the diameter the sheet thickness and the necessary addition for welding e Defining the tube dimensions shaped tube Use the Toolbox Profile Design the Graphical Method or the Numerical Method to define the cross section of the shaped tube Afterwards call the function Shaped Tubes Calibration of the Toolbox Tube Design The cross section patterns for the calibrating stands and the welding stand are created automatically By using the function Welding Pass you can attach the addition for welding e Creating the passes For each stand create a pass by using the fun
310. nged at the stroke of a key e quicker design because calculation and drawing work is done in the background e safer design because simulations will find out critical points e reduce cost by more economical roll design e more systematic than pure experience e never repeat the same work use existing designs for easy modifications e improve the profile quality by having more time to consider the forming method while less time is spent on routine calculations The PROFIL Story PROFIL has been designed by UBECO in co operation with the German roll forming industry When it was presented at the Euro BLECH exhibition in 1986 the attendees were impressed by the capabilities of the software Soon PROFIL became a leading software for roll forming design in Germany The first version was running under MS DOS and HP UNIX Since 1997 the WINDOWS version has been available Because of its very easy to handle graphical user interface PROFIL became famous world wide Until now more than 500 systems have been sold Customers in more than 25 countries are using PROFIL for their design In 2001 the simulation of the roll forming process by using FEA Finite Element Analysis was possible for the first time in the designing office of roll forming companies This is a milestone in the development of design methods since user without FEA experience are enabled to get the benefit of the FEA simulation to enhance the product quality When later the P
311. ngle e Export of Additional Side Axles to the machine file now is possible e Dimensioning between different rolls on the same axle is possible again e Roll Read CAD Contour Contour tracking does not change the profile side anymore if a the end of a line touches another line PROFIL Rel 5 0 1 01 Feb 2013 Bugfixes e Roll Arched extension now works fine again e lf increment is selected in the roll number key in Options Rolls or Options Spacer Rolls the variable HRW now is replaced by the correct roll width e Inthe PROFIL LT version the Sheet Thickness can be modified again e Emptying Profile will not delete or modify roll dimensioning of the same pass anymore e f Use layer numbers instead of names is set in Options Files the spacer rolls now get the correct layer numbers e No runtime error anymore after deleting the first corner point of a roll Roll Comer Remove and after selecting other rolls by using the Explorer e PSA and View Flower 3D is now displayed correctly in case the function Modify Develop Point was used previously e Inthe Roll Assembly Plan all Spacer Rolls now are shown completely in case Use layer numbers instead of names s preset in Options Files Copyright 2015 by UBECO GmbH Iserlohn 16 UBECO PROFIL Rollform Design Software 1 10 PROFIL Rel 5 0 01 Dec 2012 New features e Modify Sheet Thickness with constant inner or outer radius consta
312. ngle and Width length and height will be calculated If you enter Angle and Height length and width will be calculated If you enter two of the three variables length width and height all other variables will be calculated If the angle is negative an arc to the right will be generated If width and or height are negative the matching direction will be calculated The insert point is the tangential point of the arc see drawing this means the length of the previous element will be shortened The width is measured in the direction of the previous element the height is perpendicular to it Principle of operation If you have selected a Profile Element previously the new profile elements will be appended to the selected one Otherwise they will be appended to the end of the profile Copyright 2015 by UBECO GmbH Iserlohn Reference 155 3 1 7 1 6 Stage 3 1 7 1 7 This function is a part of the Toolbox Profile Design and generates three new elements arc line and arc which represent a stage The dimension reference point is the intersection point of the tangents to the arc Calling the function Call this function by F Button Stage from the Toolbox Profile Design The window Stage is opened If you select Angle and lower Width the height will be calculated If you select Angle and Height the lower width will be calculated If you select Width and Height the angle will be calculated Angle and height
313. ngles inside the drawing and for creating various kinds of dimensioning Calling the function Call this function optionally by e Main menu Toolbox Dimensioning Button Toolbox Dimensioning in the Button Key Bar Content El Measure Horizontal Dimension 1 vertical Dimension W Parallel Dimension af Diameter Dimension 2 Radius Dimension in Angle Dimension Automatic Roll Dimension And you can modify dimensionings am Move Dimension a Delete Dimension Drag dimensioning When the dimension points are defined the complete dimensioning is already visible The dimension text sticks to the cursor can be moved across the drawing and positioned as desired Thus dimensioning is most comfortable Copyright 2015 by UBECO GmbH Iserlohn 170 UBECO PROFIL Rollform Design Software Associatively Dimension points are tied to the drawing elements When you modify the drawing elements the dimensioning will be modified automatically too Because of the associatively dimensioning cannot be positioned freely CAD transfer When dimensioned drawings are transferred to AutoCAD via the ActiveX interface genuine associative AutoCAD dimensioning is created By ActiveX transfer to SolidWorks non associative dimensioning is created While transferring drawings by Output Drawing gt CAD via other interface files DXF MI IGES the dimensioning is transferred too though it consist of l
314. nodes of the successor elements are guided In special cases e g if cut strips are roll formed it may be useful to switch off this guiding Please use this checkbox with care without guiding it may be possible that the strip is not threaded correctly like on a real roll former After pressing the Ok button these file are created lt project name gt inp lt project name gt in1 lt project name gt in2 lt project name gt in3 lt project name gt in4 lt project name gt in5 only if Check contact left and right sheet side only is set lt project name gt txt FE bat The first 5 files contain the FEA simulation model The txt file contains the documentation of the FEA settings FE bat is the batch file to start the ABAQUS Explicit solver Afterwards you can save all settings of the FEA parameters window into the project file by using the function Save Project If you later call Output FEA again all settings are displayed again and can be modified easily Hint e Before you create the FEA simulation model you should use the function Calculate Plausibility Check to check the whole profile project on errors Curve Generator Often the exact stress strain curve of the used material is not available and cannot be obtained shortly Nevertheless the designer wants to proceed a FEA simulation with approximate values The Curve Generator is a handy tool for creating a stress strain curve quickly by defining three characteristic curve point
315. now are dimensioned correctly e The diameter of the cross hair circle of the marked roll corner point now is independent of the zoom factor e Inthe Print Protocol of the rolls the widths now are related to the corner of the roll PROFIL Rel 3 0 14 Nov 99 New features e ActiveX Interface to AutoCAD 2000 e Fully associative Profile and Roll Dimensioning e Automatic Roll Dimensioning e Transfer of the dimensioning to AutoCAD R14 and 2000 via Activex e Extended functions for Tube Forming Welding pass fin pass break down pass automatic generation of rolls for all passes Copyright 2015 by UBECO GmbH Iserlohn General 23 e Roll tool Stock Management with quick searching for suited rolls for re use option e Project Select Window with graphic preview Interface to the FEA Technologic Processor of the Institute of Production Engineering and Forming Machines PtU Darmstadt Germany for FEA calculation e Maximum count of Profile Elements increased from 99 to 199 Presetting of the edge rounding radius in Options Roll Extended online help with new table of contents Button Save only enabled if the project was modified Single passes or rolls can be transferred to CAD Text height can be preset in Options Drawing If the input fields Top Roll Ref Point x y of the machine data window are empty the Roll Reference Point for the top rolls now is set to the upper side of the sheet automatical
316. ns the data of the geometry of the rolls in form of G01 G02 and G03 commands by DIN 66025 for the machine control Afterwards you can view it and append further machine commands to it if you confirm Yes to the question NC program has been created View now The text editor set in Options General will be opened with the NC file You can do the same with the function Edit NC Copyright 2015 by UBECO GmbH Iserlohn 184 UBECO PROFIL Rollform Design Software 3 1 8 7 Setup Output NE Program Build Program Number from F Rall Ho e Part Mo Create Separate Files Integer Decimal Places E Fath for Entire File CAPROFIL D ata Eng Path for Separate Files C NPROFIL DatasEng Define in Options NC the path for the file The file contains the NC programs of all rolls of the profile project If you want to generate a separate file for each roll you can select it in Options NC Representation of Values Integer Decimal Places fa a Metric N mm f Imperial lb ir Select in Options Calculate whether the representation of the values should be metric mm Kg or imperial in lb You can preset the Integer Decimal Places as well Hints e Select by View Show Spacer Rolls whether the NC output should contain spacer rolls e In order to create a set of different files sequentially use the Export function e Function File Print enables printing the NC program in combina
317. ns the project data the FEA parameterization and messages lt project name gt is the FEA Project Name defined in FEA LS Dyna Start Afterwards you can save all settings of the FEA parameters window into the project file by using the function Save Project If you later call Output FEA again all settings are displayed again and can be modified easily Starting the simulation e Run the LS Dyna Program Manager e Call Solver Start LS Dyna Analysis e Enter Input File lt project name gt dyn Copyright 2015 by UBECO GmbH Iserlohn 186 UBECO PROFIL Rollform Design Software e Check CASE run multiply load cases e Run Defining prepunched holes cut outs This function requires Automatic remesh and is currently possible only if the element type Shell is selected see Profile In a later version this function will be available for element type Solid too If prepunched sheet should be roll formed the holes cut outs simply can be defined in a 2D CAD drawing with any shape and position The simulation result shows if the shape and position is as desired in the final profile after leaving the roll forming machine After pressing the Ok button in the Output FEA LS Dyna window for the first time the DXF file lt project name gt dxf is created that contains the drawing of the flat sheet with the preset meshing Open this file by using your CAD system and attach the desired holes cut outs pattern Coo 4 ___ OH
318. nt neutral line or constant geometric center line e Modify Strip Width for the current pass or all passes of the whole flower pattern e Modify Reference Point for the current pass or all passes of the whole flower pattern e Expanded Undo Redo functions The function name of the next step is shown and the count of steps can be preset by the user e Spacer Rolls that are objects like forming rolls They can be dimensioned designated by a special number key and modified geometrically like forming rolls e Roll Angle in the Roll Tool Window can be modified e Clearance Angle can be defined relative to the actual angle or to the roll axle e Parallel Gap between roll and profile e Modify Roll Reference Point context menu Axial only radial only or both e Modify Develop Point in order to redefine the develop point during flower pattern creation e For Output 3D Model gt CAD via ActiveX the rolling direction can be selected Bugfixes e Undo Redo is available now for all commands that modify the project also after changing the view e Import Profile Lists Roll Tool Files now imports the machine data correctly What s new Releases 4 x PROFIL Rel 4 8 01 Dec 2011 New features e New snap points for setting the profile reference point in the Window Read CAD Contour Line Center Point Arc Quad Point 270 and 90 e Arc type A4 with modifying angle and radius see Arc Types e Draft Modus for modifyin
319. ntour or even penetrates it If it does you have to modify the Machine Data working diameter or reference point afterwards in order to get contact Whether a Contour File KTR format or a Contour File DXF Format is being read you select in Options Files from CAD If you have enabled the ActiveX Input from CAD in Options Activex the drawing is directly read from the CAD system If you want to read files with frequent varying file names instead of a temporary file with a constant file name better use the Import Function Copyright 2015 by UBECO GmbH Iserlohn Reference 107 3 1 4 3 Calling the function Before reading the contour select one of the center lines for defining whether a bottom a top or a side roll should be created The center lines are visible in the Drawing Area if you have selected View Rolls and the Machine Window contains machine data In case of rolls already exist on the shaft select any roll in order to mark the shaft Call this function by e Main menu Rolls Read CAD Roll The Window Read CAD Contour appears and you define the start green and end point red of the contour Because the whole half roll should be imported set both points on the centerline where left and right side flank intersect the centerline The blue line of the contour tracking must follow the outer roll contour If it doesn t click on the correct line near the start point to redirect the start direct
320. nts e Preset in Options Drawing the desired grid lines distance e Preset in Options Colors the desired color of the grid lines e In order to get the precise dimensions of the drawing objects use the Toolbox Dimensioning Copyright 2015 by UBECO GmbH Iserlohn Reference 151 3 1 7 Toolboxes 3 1 7 1 Profile Design Use the Toolbox Profile Design for quick and easy design of simple or standard profiles without CAD Calling the function Call this function optionally by e Main menu Toolbox Profile Design Button Toolbox Profile Design in the Button Key Bar Content Section 1 contains cross sectional elements for continuing the design these elements can be mounted together to the final profile Z Line A Arc lo Partial Ellipse A Arc lt 90 Line N Arc gt 90 Line vA Stage PX Trapeziodal Profile Section 2 contains basic profiles that can be extended afterwards by elements from section 1 A U Profile E c Profile 1 Hat Profile 7 Profile 3 1 7 1 1 Line Copyright 2015 by UBECO GmbH Iserlohn 152 UBECO PROFIL Rollform Design Software 3 1 7 1 2 This function is a part of the Toolbox Profile Design and generates a new element of type line Calling the function Call this function by A Button Line from the Toolbox Profile Design The window Line is opened If you enter one of the three variables Length Width and Height the other two will b
321. nts e lfthe start element should be a part of an existing profile element you can Split it previously Example A V profile should be formed upright e f you want to move the reference point develop point starting from a certain pass of the flower pattern use the function Modify Develop Point Modify Develop Point The Reference Point X0 Y0 of a profile is identical to the develop point i e the point the profile s legs turn around during developing the flower pattern _ y I some applications require to redefine the develop point in a certain pass in order to turn the profile s legs around a different point in the next passes see the example in the picture Calling the function Use this function in the desired pass during creation of the flower pattern The next passes against the sheet running direction should not exist If they already exist they should be deleted Call this function optionally by e Main menu Profile Develop Point e Context menu right mouse button click on a profile element in the Drawing Area Profile Modify Develop Point Copyright 2015 by UBECO GmbH Iserlohn Reference 87 3 1 3 6 Click on any drawing element of the current pass appropriately on the bottom side of the profile The nearest end point is caught Principle of operation The profile list will be re sorted similar to the function Modify Start Element additionally the Reference Point X0 YO an
322. odified dependant on the entered percentage Open the window Stress of Band Edge or toggle to PSA Profile Stress Analysis to view the effect of lowering to the profile stress Hints e In order to undo Center Line Forming call the same function again and enter the amount of lowering 0 e If the automatic assignment of lowering does not fit your needs you can set the YO coordinate of the Reference Point in the Profile List Window manually Copyright 2015 by UBECO GmbH Iserlohn 96 UBECO PROFIL Rollform Design Software 3 1 3 14 Development Table Development Table DevTable ii ioj x File Development Table evelopment T able ource C PROFIL32 DevT able pro 1 MEME AO a TE Leh E 10 Al 11 L 12 alla L 14 Al 7100 00 100 000 100000 100 000 100 000 100 000 100 000 100 000 66 667 100 000 100 000 66 667 100 000 100 000 33 333 100 000 100 000 33 333 100 000 100 000 100 000 100 000 83 333 68 889 _ 83 333 88 889 66 667 77 778 66 667 77 778 50 000 61 111 50 000 61 111 33 333 44 444 33 3331 44 444 5 9 16 667 27 778 _16 667 27 778 0 5 556 11 111 5 556 11 111 wolo u aom aanlal lnl The development table is the representation of the bending angle sequence of the flower pattern in tabular form It is created automatically f
323. of operation Renumbering works dependant on the Number Keys For the forming rolls the number keys in Options Rolls are used Number Keys Autom Increment fw RollNo fw Part No Bottom Fall PLu01 PR Ps PSut OO Top Rall PLotl SPRPSSPSOOT Left Rall PLIN SPRPSSPSHOT Right Foll A PRPs For the spacer rolls the number keys in Options Spacer Rolls are used Number kens Autom Increment p RollNo P PartNo Bottom Shaft SpsawssAl Top Shaft SpeRwxsAl During this operation the Variables are replaced by the corresponding project or roll data If single rolls are locked against number changes e g because they came from the roll database or from a partial project or numbers are modified manually you are asked One ore more rolls are locked against number change Unlock and renumber You can decide how the rolls should be treated 3 1 4 12 Split at Corner Use this function to split a roll at a Roll Corner Point Precondition The roll has 3 or more corner points Copyright 2015 by UBECO GmbH Iserlohn 118 UBECO PROFIL Rollform Design Software 3 1 4 13 Calling the function Before you call this function identify the desired split Roll Corner Point Call this function optionally by e Main menu Rolls Split at Corner e Context menu right mouse button click on the left or right corner of the desired roll in the Drawing Area Split at Corner Principle of operation The roll is
324. of stress e In order to get the stresses in the whole profile i e not only at the band edge use the function View PSA Profile Stress Analysis Center Line Forming Bottom line forming left and center line forming right with lowering to constant centroid s height 100 Center line forming also is called Downhill Forming or Natural Forming Center Line Forming is a checkbox in the window Calculate Stress of Edge For a preview switch the calculation method for the stress of the band edge from bottom line forming e constant level of the web of the profile to center line forming and back again So you quickly can check if center line forming solves a problem of excessive stress or if your machine has not enough stands Center line forming means to keep the Centroids of an Area of all passes on a constant level This is caused by decreasing the web from one stand to another And also the stress of the band edge normally will decrease This enables you to decide if center line forming solves a problem But remember that your machine only allows center line forming if the shafts are adjustable If you want to use this method proceed the final lowering by calling the function Center Line Forming See also Calculate Stress of Edge Copyright 2015 by UBECO GmbH Iserlohn Reference 131 3 1 5 3 Shaped Tube Calibration ir gt Shaped Tube OJ QA La a A CSI lt eeo can O amp
325. ofile first while the finished radius is formed at the outsides Calling the function Before calling this function you should created already some Break Down Passes Afterward use the function Profile Append for creating a profile list for the new break down pass Call this function by e Button Break Down Pass W Forming from the Toolbox Tube Design The window Break Down Pass W Forming is opened Enter the desired Angle and Radius for the first arc segment and the Radius for the second arc segment into the input fields If the message appears Incorrect Input the entered parameters are not suited for creating a break down pass the developed length of which is the same as the one of the previously appended profile list Principle of operation After pressing the Ok button the tube profile for the break down pass is entered into the profile list The first arc segment at the bottom has the desired angle and radius The second one at the outside has the desired radius and its angle is calculated on this way that the developed length of the whole profile is the same as the one of the previously appended profile list For generating the rolls for the break down passes use the functions Break Down Pass Bottom Roll and Break Down Pass Top Roll Hint e For creating the rolls for the break down pass use the function Break Down Pass Top Roll and Break Down Pass Bottom Roll Copyright 2015 by UBECO GmbH Iserlohn Referen
326. oftware 2 5 2 5 1 Flower Pattern Designing the Profile Flower Pattern For designing the flower pattern the Draft Modus must be switched off First define the Bending Method You can change the bending method A1 to A2 or A3 or A4 if you want to use a constant radius method The bending method affects the following bending Afterwards you can define the bending steps each for every stand Use the function Profile Append to create the next profile list for the next stand opposite the sheet running direction Activate an arc element either by clicking into the drawing or into the field Angle or Radius of the profile list Now select among 3 possibilities to bend up the arc e enter anew angle or radius into the field Angle or Radius of the profile list e press the buttons Pg Up Dn on your keyboard until the desired angle radius is obtained e select Angle or Radius in the Toolbox Modify click on the button smaller or 10x smaller until the desired angle radius is obtained If you have selected the bending method A2 or A3 or A4 the angle can be modified only After proceeding this for all bending steps use the function View Flower Nested to view the drawing of the flower pattern The function View Flower Separated gives to you a clearly laid out view of all bending steps The function View Flower 3D gives you a perspective view of the bending steps So you are able to examine if the course of the band edg
327. ohn 154 UBECO PROFIL Rollform Design Software 3 1 7 1 5 If you enter Angle and Length width and height will be calculated If you enter Angle and Width length and height will be calculated If you enter Angle and Height length and width will be calculated If you enter two of the three variables length width and height all other variables will be calculated If the angle is negative an arc to the right will be generated If width and or height are negative the matching direction will be calculated The insert point is the intersection point of the tangents to the arc this means the length of the previous element will be shortened The width is measured in the direction of the previous element the height perpendicular to it Principle of operation If you have selected a Profile Element previously the new profile elements will be appended to the selected one Otherwise they will be appended to the end of the profile Arc gt 90 Line This function is a part of the Toolbox Profile Design and generates a new element of type arc and a new element of type line The dimension reference point is the maximum point of the arc so this function is useful for arcs larger than 90 Calling the function Call this function by e N5 Button Arc gt 90 Line from the Toolbox Profile Design The window Arc gt 90 Line is opened If you enter Angle and Length width and height will be calculated If you enter A
328. oll Tool Window will be activated if the window Is open A right mouse button click on a drawing element opens the context menu Profile Design or Roll Design dependent on the kind of drawing Using this feature speeds up the design significantly By using the context menu Machine Parameters right mouse click on a shaft or roll centerline the working diameter reference point and the inclination angle can be modified Change Machine Dat In Options Rolls Keep Roll Data select if the roll properties should be retained or if they should be adapted by retaining the roll contour only Use the function View Show Dimensions to switch all dimensions temporarily off and on again Use the function Inspect to display the whole drawing in its defined colors A right mouse button click to the background causes this too If you want to expand the drawing area use the function Window Visible to switch off the windows Colors of Drawin Ausiliarny Line Main Line Profile Main Line Rolls Tert e Reset Select the drawing entity colors in Options Drawing Colors of Drawing Colors of Drawing rea Inactive Marked Background Profile Explorer e Reset Select the drawing area colors in Options Drawing Colors of Drawing Area View Flower 3D Co 45 go C 135 0 300 In case of a 3D drawing select the 3D view port angle and the z scaling in Options Drawing View Flower 3D z Scaling Tex
329. oll has a Working Diameter pitch diameter this is the diameter at the profile web the horizontal part of the profile see picture above If the Gear Transmission Ratio of the machine is 1 1 top and bottom rolls should have the same working diameter in order to have equal circumferential speeds and the profile is moved safely and free of slip Some machines have the transmission ratio 1 1 4 this enables forming open profiles with higher legs If e g the transmission ratio is 1 1 4 equal circumferential soeeds are possible if the working diameter of the top roll is set to 1 4 times the working diameter of the bottom roll But equal circumferential speeds only can be achieved at the web of the profile At the profile legs always friction arises enhanced roll wearing and sheet surface damaging will be incurred In order to minimize this experienced designers use a clearance angle Better flowing of the profile legs into the stand Imagine the flat sheets runs into a stand like in the picture above First it will get contact with the roll surfaces that have the largest diameters The top roll has its largest diameter at the center cylindrical part whereas the bottom roll has it at the side shoulders By turning on the top roll presses the sheet into the trapezoidal slot of the bottom roll and the profile legs are drawn over the shoulder edges of the bottom roll The shoulder edges should have a large fillet radius as shown in the picture in o
330. oll is yet existing it will be replaced Copyright 2015 by UBECO GmbH Iserlohn Reference 165 3 1 7 2 7 Break Down Pass Top Roll pee This function is a part of the Toolbox Tube Design and is used for generating the top roll for a break down pass Calling the function Before calling this function you should have created a break down pass by using the function Break Down Pass If you created the break down pass in another way pay attention that the profile list contains exactly 3 entries A1 A1 PS Only for such a tube profile a roll can be generated automatically Call this function by e B Button Break Down Pass Top Roll from the Toolbox Tube Design The window Break Down Pass Top Roll is opened Enter these parameters e Total Width W This input is only necessary if the roll should become smaller than the opening of the tube If your entered value too big your input is ignored and the width is set automatically to a maximum width by considering the desired air gaps at both sides if the edges of the tube are bent inside or the upper arc segment is lengthened to the vertical if the edges of the tube are bent outside e Fillet Radii R2 Select a fillet radius at the roll edges only if the edges of the tube are bent inside In the other case your input is ignored and the radius of the upper arc segment is taken e Air Gap AG Enter the desired horizontal air gap between the roll and the edge of the
331. ollform Design Software Time Interval View FEA ABAQUS 145 View FEA Result 143 Time Step Size 193 Title Block 232 Title of Column 69 Toolbox Modify 168 Toolbox Dimensioning Angle Dimension 174 Automatic Roll Dimensioning 175 Delete Dimension 177 Diameter Dimension 173 General 169 Horizontal Dimension 172 Measure 171 Move Dimension 177 Parallel Dimension 173 Radius Dimension 174 Vertical Dimension 172 Toolbox Profile Design Arc 152 Arc lt 90 Line 153 Arc gt 90 Line 154 C Profile 156 General 151 Hat Profile 157 Line 151 Partial Ellipse 153 Stage 155 Trapezoidal Profile 155 U Profile 156 Z Profile 157 Toolbox Tube Design Break Down Pass 161 Break Down Pass Bottom Roll 166 Break Down Pass Side Rolls 167 Break Down Pass Top Roll 165 Break Down Pass W Forming 162 Fin Pass 160 Fin Pass Bottom Roll 164 Fin Pass Side Rolls 166 Fin Pass Top Roll 163 General 35 158 Shaped Tube Calibration 131 Welding Pass 160 Top Roll Break Down Pass 165 Fin Pass 163 Top Bottom Side 214 Torsion Moment 129 Touching the Profile 214 Track Holding 66 Track Holding Method 238 Transfer to CAD 177 TransfertoNC 178 Transition Elements LS Dyna 187 Output FEA ABAQUS 194 Transmission Ratio 219 Trapezoidal Profile Forming 133 Toolbox Profile Design 155 Treating Expanded Roll Tool Window 211 Option Rolls 214 True Strain 199 Tube Design 35 158 Tube Forming Machine 218 Tube Shaped 221 Turn Roll 119 Type
332. ollowing types are possible L Line or S Strecke The profile element describes a straight part of the profile Further data are only the length of the straight part in the column Straight Lenth If the part is punched furthermore the columns Size and Position can be filled out A Arc or B Bogen The profile element describes a bent part of the profile The number behind the letter defines the Bending Method Further data are Direction Radius Angle Straight Lenth will automatically be calculated Not allowed are data in the columns Size and Position P Point The profile element describes the reference point of a non symmetrical profile Afterwards the description of the 2nd half of the profile follows Only one element P is allowed The point is also be used as Reference point by using the function Calculate Statics PS Symmetrical point Copyright 2015 by UBECO GmbH Iserlohn Reference 237 3 5 6 3 3 5 6 4 3 5 6 5 3 5 6 6 The profile element describes the symmetrical point of a profile Only one element P is allowed and must be the last element in the profile list The point is also be used as Reference Point by using the function Calculate Statics See also Profile List Direction The direction is a column of the table of the Profile Elements of the Profile List and marks whether a bent part turns left L or right R based on the reference point See also Profile
333. olor of the background of the drawing area Profile Explorer Color of the background of the Profile Explorer The selected colors will NOT be transferred into the CAD and NC output file Default All colors of the drawing area are reset to the default colors Color of Grid Lines Diff to Background Color fio Color of Grid lines Copyright 2015 by UBECO GmbH Iserlohn Reference 65 3 1 2 8 4 The color of the grid lines should differ only a little from the background color of the drawing area Select how much it should differ If the background color is dark the grid lines are shown ina color that is a little bit lighter otherwise darker Recommended is a value of 6 12 A larger value causes a more brightness distance Try a value that you just can see the grid lines they should not interfere with the drawing Profile List Use this function to set the parameters for the profile list Profile List winda Mas no at Same Time El Select the Max no at Same Time of Profile List Windows For example if you select 3 the 4th window closes the 1st again So you do not need to close superfluous windows by yourself Profile list window Insert Append f Previous Pass Select if the Profile List of Pass 1 or of the Previous Pass should be inserted appended when you call the function Profile Insert or Profile Append Layout Layou f Normal With Spring Back C With Holes Cut Outs
334. om the context menu by right click on the shaft centerline the data are saved into the machine file When machine data are modified in the Machine Data Window the project is updated by saving the machine data into the machine file Why changing this handling method The old handling method has the advantage that the machine data could be used for various profile projects for the same machine universally The bad thing about it is that modifying machine data may unnoticed impact other projects unintentionally This is why many users save the machine file in the project path But this does not meet the idea of the universal usage of the machine file New handling since PROFIL Rel 4 7 The machine data are handled in the profile project completely and are saved into the Project File pro They are shown in the Machine Data Window that is nearly unchanged against previous releases except in two items the load file and save file functions are replaced by import and export file functions for transferring machine data via m01 files to other projects The machine file is not saved anymore automatically but only by calling the function consciously In case of missing machine data e g not enough stands PROFIL shows a message in the bottom dialog line and the machine window is opened and the user is requested e g to append an additional stand This also occurs if a new project is created and it still has not machine data Then the user can enter
335. omatically to the layer that currently is within the rolls of the selected stand Precondition the layer exists in the FEA result To reset the selection click on the center button of the Navigator 3D Hints e The Navigator helps you to zoom to move and to fit the drawing e By using the Navigator 3Dyou can rotate the drawing and toggle to a 2D view e With the function Output Drawing gt CAD you can transfer the drawing to your CAD System Graph i loxi The graph shows the stress strain and thickness dependant on the position of the sheet in the machine in sheet running direction for LS Dyna simulation result only Calling the function an Graph This button is visible at the right corner of the PROFIL main screen after selecting a Copyright 2015 by UBECO GmbH Iserlohn Reference 147 LS Dyna simulation result by using the function View FEA Result LS Dyna The window Graph opens and shows stress strain or thickness of the FEA result Modifying the graph The graph drawing can be modified by e Selection Select if you want to see the Max tensile stress in transversal direction MPa the Max tensile stress in sheet running direction MPa the Max tensile strain or the Min sheet thickness mm each dependant on the sheet position in the machine mm 0 Pos of final stand Copy Snapshot to Assembly Window Opens the new window FEA Result Assembly into which all values are cop
336. on Fin Pass from the Toolbox Tube Design The window Fin Pass is opened Enter the Fin Width F into the input field or confirm the default value Copyright 2015 by UBECO GmbH Iserlohn Reference 161 3 1 7 2 3 Principle of operation After pressing the Ok button the tube profile for the fin pass is entered into the profile list The first arc segment at the bottom will be bent open by increasing the radius Then the angle of this arc is set to 90 thus the top and bottom rolls later will get one single radius only The second arc segment at the top keeps its radius constant the same radius as for the previous pass The angle however is modified in the way that the sheet width sum of all developed lengths is constant If the machine has more than one fin pass use this function for each fin pass For generating the rolls for the fin passes use the functions Fin Pass Bottom Roll and Fin Pass Top Roll Hint e For creating the rolls for the fin pass use the function Fin Pass Top Roll and Fin Pass Bottom Roll Break Down Pass This function is a part of the Toolbox Tube Design and creates the tube profile for a break down pass Calling the function Before calling this function you should have created a Welding Pass and have created one or more Fin Passes Afterward use the function Profile Append for creating a profile list for the new break down pass Call this function by e Button Break
337. on the current pass only or on all passes of the whole flower pattern Principle of operation The function Modify Strip Width enables to modify the strip width for the current pass or all passes This is achieved by lengthening or shortening the profile elements at both band edges Then the profile elements at the bad edge are corrected in the following way e Is the profile element at the band edge a line L it is lengthened or shortened e Is the profile element at the band edge an arc A the angle is increased or decreased by keeping the radius constant Is the profile list symmetrical i e it contains a symmetrical point PS the band edges are modified symmetrically Is the profile list asymmetrical i e it contains a point P the partition of the strip width modification to the left and right band edge can be preset in Options Profile List topic Modify Strip Width Sheet Thickness Modify Reference Point The Reference Point belongs to the Profile List data and defines the start point of the profile in the xy plane The reference point normally should be at or near the center of the profile s web on the sheet metal s bottom side Usually it has the same position as the Roll Reference Point in order to get roll diameters whose ratio is equal to the Machine Transmission Ratio The function Modify Reference Point enables to modify the x and y coordinates of the reference point either for the current pass or for all pa
338. ongs to the project data Enter the drawing number PROFIL saves the name in the project file for your information and for easier selection If needed the drawing number can be used as variable DR for the automatic roll numbering see Options Rolls See also Profile Project Material The name of the material belongs to the project data To select the material from the Material File click on the arrow button on the right and the table of materials drops down Select the desired material Dependent on material are the calculations of the Spring Back the Stress of Edge and PSA Profile Stress Analysis To edit or to enhance the material file use the function Options Calculate See also Profile Project Machine Sheet Running Direction gt This field shows the name of the machine You cannot modify it In order to modify the name click on this field and the Machine Window opens Modify the content Copyright 2015 by UBECO GmbH Iserlohn 208 UBECO PROFIL Rollform Design Software 3 3 2 6 3 3 2 7 3 3 2 8 3 3 2 9 3 3 2 10 of the Machine input field or load another machine file by using the import button See also Profile Project Date The date belongs to the machine data If you create a new project by using the function New Project the input field is automatically set with the current date See also Profile Project Name The project author s name belongs to the
339. or shortening the arc e Arched extension for rolls that end with an arc or a line In case of arc the arc is lengthened in case of line an arched extension with a selectable radius is added e Extended extension settings by width relative to width absolute and to diameter absolute e New Roll Properties separate for each roll Bore Hole Bushing Identification Groove Material Treating Surface Addition Remark Default values can be preset User defined composition of the Parts List Columns with selectable sorting and sum fields As well as rolls the parts list can contain spacers and bushing Rolls with same parts list data are summarized to one parts list entry if the column Count is selected The addition for calculating the blank size of the rolls is taken either from the intersection point of Copyright 2015 by UBECO GmbH Iserlohn 22 UBECO PROFIL Rollform Design Software the tangents or the actual maximum diameter by user preset see Options Parts List e The parts list can be transferred to MS Excel by ActiveX starting in the marked cell see Options Parts List e Bore hole designation is shown in the drawing all texts aligned left or center see Options Drawing e Selecting layer numbers instead of layer names when the output file is created Options Files e Improved online help e User defined text editor instead of NotePad see Options General Bugfixes e No sporadic er
340. ou can enhance the material file by new materials You need to find out the material data by experiment and by material catalogue Or use a similar material from the file Copyright 2015 by UBECO GmbH Iserlohn 230 UBECO PROFIL Rollform Design Software 3 4 3 3 4 4 Factor File In the factor file PROFIL FKD you can define your own calculation methods for the developed length Decide first if you want to use a Factor Method or a Addition Method Paths to System Files Material Data CAPROFIL D ata Profil wwkd E dit User Def Calc Methods C PROFIL DataProfil fhd Edit Select the desired factor file by using the function Options Calculate User Def Calc Methods and open it with the Edit button The file has one or more lines with a leading N followed by the name of the method The letter indicates comment lines The line with leading N contains the name of the method with max 9 letters this name is displayed inside the Project Data Window For the Factor method there are now some lines with a leading F and the contents Column 1 F for the Factor Method Column 2 Limit of the relation inner radius sheet thickness for the factor of the position of the neutral line the correction addend and the correction factor Column 3 Factor for the position of the neutral line Column 4 Correction factor in pos or negative Column 5 Correction addend in mm pos or negative The l
341. outs are meshed automatically as well Check this box to enable remesh Automatic refinement currently is possible for shell elements only Solid element type with 4 solids in thickness direction e Solid The solid model is adequate for the forging process In a roll forming process this arises during deep drawing in case of intended sheet thickness modification and during bending 180 folds hems It needs larger calculation time than by using the shell model Automatic remesh and with it setting of bore holes and cut outs is currently not possible this is planned for a later release In sheet thickness direction Select the count of solid elements in sheet thickness direction that should be used for the simulation The count must be even the minimum count is 2 Copyright 2015 by UBECO GmbH Iserlohn Reference 189 3 1 8 8 1 2 Rolls This dialog window is called by Output FEA LS Dyna is used for parameterizing the meshing of the rolls in axial and radial direction alx E LS Dyna Profile M Meshing Rolls Axial Meshing Rolls Radial Line Segments 20 000 mm Angle Segments Count 180 Holes Cut Out Start Small Arc Seg 15 000 Material Large Arc Seg 2 000 mm Contact Others Def Large Arc Radius gt 10 0 mm X Cancel Help Meshing Rolls Axial Line and arc segments are meshed as follows e Line Segments Select the desired length of the shell
342. ow The machine file is a file with the extension M01 Select a short name of machine for file name to Copyright 2015 by UBECO GmbH Iserlohn Reference 231 3 4 5 3 4 6 allow easy identification Contour File KTR Format Use the contour file to transfer the geometry of a profile or a roll tool drawn in the CAD System to PROFIL The KTR format is a file format defined by UBECO For these CAD systems macros are available which generate a contour file PC DRAFT AutoCAD CADDA Please contact your dealer To generate a contour file proceed the following steps e Draw the contour in the CAD system Select a Reference Point this is mostly the center point of the lower line of the web of the profile and draw the lower line of the profile beginning in the reference point e Inthe CAD system call the macro which generates the contour file e In PROFIL select the Profile Element in the Profile Lists Window for the start of the contour The start point normally is element 1 except you read the 2nd half of an asymmetrical profile then the start point is the next element behind element P If you have selected the first element the reference point x0 y0 and the direction are set to the start point of the contour If you have selected another element the new profile elements will be appended to the existing ones without changing the reference point So you can append the second half of an asymmetrical profile b
343. ow 0 arc start point 100 arc end point 3 1 7 4 1 Measure K 5 17 mm Y 0 902 mm D 5 248 mm A 170 104 This function is a part of the Toolbox Dimensioning and can be used for measuring of e distances in x and y direction e distances diagonal e angles Calling the function Call this function by e Button Measure from the Toolbox Dimensioning After calling this function you are asked to identify two points Click on an element of the drawing and the next end point of the element will be identified Between the identified points a temporal line in the predefined mark color is drawn Principle of operation The results of measuring are displayed in the bottom status bar in the form MS VE US a We Between the identified points is e x the horizontal x distance e y the vertical y distance e d the diagonal distance e W the angle between the connecting line and the horizontal x axis The temporal line disappears again when you call another function Copyright 2015 by UBECO GmbH Iserlohn 172 UBECO PROFIL Rollform Design Software 3 1 7 4 2 Horizontal Dimension 3 1 7 4 3 45 pan EN i i Sa This function is a part of the Toolbox Dimensioning and can be used for a horizontal dimensioning between two dimensioning points Calling the function Call this function by e Button Horizontal Dimension from the Toolbox Dimensioning After calling this function
344. owed only in straight Profile Elements of type L For displaying the size in the Profile List Window select the layout With Holes Cut Outs in Options Profile List See also Profile List Copyright 2015 by UBECO GmbH Iserlohn 238 UBECO PROFIL Rollform Design Software 3 5 6 7 3 5 6 8 3 5 6 9 3 5 6 10 3 5 7 Position The position is a column of the table of the Profile Elements of the Profile List and defines the center of a hole or a cut out Holes Cut Outs are only allowed in straight Profile Elements of type L The position is related to the start point of the profile element For displaying the size in the Profile List Window select the layout With Holes Cut Outs in Options Profile List See also Profile List Straight Length The straight length is a column of the table of the Profile Elements of the Profile List and displays the length of a straight element or the calculated straight length of a bent element dependent on the selected Calculation Methods See also Profile List Stress The stress is a column of the table of the Profile Elements of the Profile List and displays the relative stress in transverse direction on the outer side of an arc in related to the fracture stress of the material If values are greater than 100 you must expect cracks Furthermore the Statics is not valid See also Profile List PE For future use only Arc Types PROFIL knows 4 various
345. p the FEA simulation If however the time interval is too large the FEA result may become invalid Select the desired time interval The recommended value for element type Shell is 1 2 us and for element type Solid 0 52 us see Profile Why the profile must be guided In reality the sheet metal strip has a quasi infinite length because it is decoiled from a coil However a sheet with an infinite length cannot be simulated because it would take infinite computing power or infinite time So for the simulation a section with a finite length is used instead setting in Profile Meshing in Sheet Running Direction The picture shows a length of about 2x distance between stands However the behaviour of this section if different to a sheet with infinite length Notably the front may push against a roll this causes unrealistic deformation of the front that do not appear in case of a sheet with infinite length That is why the tractive the guidance of the sheet in front of the section is absent In order to clone the reality at the best it is a good idea to replace the absent sheet by a guidance in the FEA nomenclature called a boundary condition Exception Blank manufacturing when cut and clipped sections should be roll formed In this special case the guidance can be switched off in order to simulate if the blank is fed correctly Dependant on the application the user can select between 3 different methods of guidance also a comb
346. peration All passes and all rolls of the project are checked When the first error is found the program breaks and shows a message in the bottom dialog line at the bottom of the screen At the same time the faulty pass or roll corner point is shown in the drawing area After correction the plausibility can be restarted in order to find more errors Hint e It is strongly recommended to check the project before creating the NC data and before starting the FEA simulation Otherwise implausible NC data could be created or the FEA simulation stops because solid bodies cannot be created from the transferred roll contours Copyright 2015 by UBECO GmbH Iserlohn 136 UBECO PROFIL Rollform Design Software 3 1 6 View 3 1 6 1 Pass 46 30 Use this function to display the drawing of the profile in the Drawing Area Calling the function Select the pass that should be displayed Call this function optionally by e Main menu View Pass e L Button View Pass in the Button Key Bar Principle of operation The pass is displayed graphically in the Drawing Area The switch Profile Loaded determines whether the pass is displayed discharged or loaded If you have entered Holes Cut Outs into the profile list they will be displayed too Setup Colors of rawin Ausiliarny Line Marn Line Profile Main Line Rolls Text e Reset Select the Auxiliary Line Color and the Main Line Color Profile in Options Drawing
347. perties of the BricsCAD interface Since PROFIL Rel 4 3 and BricsCAD Rel 15 this interface has been provided to transfer profile and roll tools drawings from PROFIL to BricsCAD and to transfer profile and roll contours from BricsCAD to PROFIL preliminary only for 2D drawings The extension to 3D models is planned for a later release e Before you transfer a drawing with Output Drawing gt CAD Profile Read CAD Contour or Roll Read CAD Contour select in BricsCAD COM ACAD Compatibility in Settings Settings Program Options System Program ID CAD Copyright 2015 by UBECO GmbH Iserlohn Reference 79 Program ID CAD System AutoCAD Application 16 only for AutoCAD Solidworks and LOGOCAD Trigal Determine the Program ID of the ActiveX target system For explanation The CAD system registers itself to WINDOWS with its Program ID This information is stored in the system registry of WINDOWS By this Program ID the connection to PROFIL is made PROFIL notices which CAD releases are registered and displays them in a drop down list when you click on the arrow symbol Open the drop down list and select one of the Program ID s e AutoCAD Application nn Connects to AutoCAD Release nn Use this Program ID if you have installed more than one AutoCAD Release and you want to select a special one AutoCAD 14 AutoCAD Application 14 AutoCAD 2000 AutoCAD Application 15 AutoCAD 2004 AutoCAD Application 16
348. porting external created programs use for the manual programming the roll data from the Roll Tool Window printed with function File Print Preview and File Print The data of the Roll Corner Points are suited for entering directly into the machine control 2 6 8 Saving the Rolls into the Roll Data Base Only with option Roll Stock Management Saving a single roll by using the clipboard For saving a single roll into the roll database by using the clipboard select the desired roll by a click in the Drawing Area and copy it by function Roll Copy to the clipboard After you have opened the Roll Stock Management press the button Insert Roll from Clipboard of the Roll Table Saving one or more rolls from the project Call the function Roll Stock Management Save and select if you want to save the previously marked roll all rolls of the marked shaft all rolls of the current stand or all rolls of the whole project Entering a roll from a paper drawing into the database Create a new record in the Roll Table of the Roll Stock Management by using the button Insert Roll of the database navigator and enter the roll data into the record Use the button Post edit to save the record While the new roll is still active for every corner or the roll create a new record in the Roll Corner Table of the Roll Stock Management by using the button Insert Corner of the database navigator and enter the Roll Corner Data into each record Width Diameter and Radius
349. proceed these steps to install the interface to ME10 e Extract file ProfilMe zip in a user defined file exchange path e g c profil e Modify the file Startup mac in the ME10 directory Open it with a text editor and append a new line at the end of the file Enter an input call of the file Customiz in the profil directory e g input c profil customiz Copyright 2015 by UBECO GmbH Iserlohn 262 UBECO PROFIL Rollform Design Software 4 6 e Edit the file Customiz in the profil directory and check the path name of the file exchange directory e Edit the file Profil mac in the profil directory and check the section Settings Enter the correct pathname of the file exchange directory e In PROFIL call Options Files and select ME10 and the operating system under which ME10 is running The CAD Output file must be Profil mi and the Contour Input file must be Profil ktr in the user defined file exchange path e Check the data exchange between PROFIL and ME10 Operating instructions for the transfer are in the WINDOWS Help file Profilme hlp Remarks You can also connect PROFIL to the HP UX version of ME10 Use the TCP IP protocol for connecting the WINDOWS PC to the UNIX Workstation Define two drive letters one mapped to the UNIX path of the data exchange profil mi and profil ktr and the second of the project files pro Enter in Options Files the drive letter and the file name for the CAD output file and the
350. r Defined Calculation Methods We recommend to you to use the Oehler method because it is most precise If you click on the arrow at the right side of the input field a box drops down and shows you the calculation methods Select the desired method by clicking lf you modify the calculation method the straight length of the arc elements will change as well as the Strip Width See also Profile Project Profile List ER ER Loi Pass Dist Stand 7 Pass l ki r m 300 000 90 150 000 Stp width 117 549 Direc Mo Top Di Radius dis_ chAnale StLenath Str ss 15 500 2 JAIL 1500 90 000 4 109 102 BRE a a AT L 3000 90 000 6 665 51 ye lees In this window the Profile List is shown and you can edit it Select in Options Calculate the number of decimal places and the unit mm or inch Layou Normal With Spring Back With Holes Cut Outs Furthermore select in Options Profile List Layout if the window should show not only radius angle discharged but also radius angle loaded With Spring Back or if also Holes Cut Outs should be visible Profile List winda Mas no at Same Time El Select in Options Profile List Profile List Window how many windows should be visible at the same time The coloured background in the columns Radius Angle shows the status of the menu switch Profile Loaded A zero is not displayed empty numerical fields contain 0 To modify a value
351. r Method 242 Straight Length 238 User Defined Calculation Methods 242 Development Table 96 Diameter Corner Point 246 Dimension 173 Expanded Roll Tool Window 211 Hole Cut Out 237 Roll Working Diameter 222 Set Up Parts List Columns 71 Shaft 212 Shaft Machine Window 222 Spacer Rolls 109 Spacers 220 Dimension Angle 174 Delete 177 Horizontal 172 Move 177 on off 203 Parallel 173 Radius 174 Roll Automatic 175 Vertical 172 Dimensioning 169 View Show 150 DIN 66025 73 6935 240 DIN ISO 10303 Export 51 Output 3D Model gt CAD Direction Profile List 237 Read CAD Contour 235 Discharged Profile List 94 Radius Angle 237 Distance between Stands Machine Data 221 Profile List 234 Double Fillet 113 Downhill Forming 95 Drawing gt CAD Output Drawing gt CAD 177 Plot 55 Roll Stock Management 252 Drawing gt NC 178 Drawing Area Main Window 214 Options Colors 64 Options Drawing 62 Profile Catalogue 250 Roll Stock Management 254 Drawing Number 207 Drawing Print 54 Drawing Scale Options Files 75 Plot 55 Drawing Template 232 Dreistern 135 Driven Expanded Roll Tool Window Roll 212 Driver Installation USB Hardlock 259 DXF Contour File 231 Export 51 Import 50 Options Files 75 Options NC 73 E Edge 214 Edge Rounding 67 Edit 179 211 Copyright 2015 by UBECO GmbH Iserlohn Index 267 Edit Arched 112 Copy 58 Conical 110 Curve Generator
352. r and safer design To achieve these aims the software must relieve the designer of tedious work e g calculating the developed length drawing the profiles and roll tools compiling the parts list etc So the designer is able to fully concentrate on the design A designer in most cases is not a computer specialist Therefore the software must speak the designer s language And the software must be easy to operate and easy to learn The software must fulfil practical requirements and must have great flexibility to adapt to specific requirements It also must contain the latest results of scientific research What does PROFIL do PROFIL performs these tasks e PROFIL supports the section definition Create new profiles by entering the data into the system by importing a CAD contour or by using the design toolbox for standard profiles or by combining these powerful tools to get your design e PROFIL works as your assistant while designing Besides determining the neutral line and calculating the developed length of the sheet metal PROFIL calculates all the important data for the bending process spring back statics and the stress of the band edge e PROFIL speeds up your work designing the flower Simply change angle or radius values with the editor or by using the modify toolbox to create the bending steps You may select constant developed length or a constant radius method e PROFIL supports modification and optimization of the f
353. r trapezoidal profiles the designer should attach a clearance angle for the first point For the rest a gap should be created by the function Roll Gap e Alternatively the angle to the next roll corner point can be modified by direct input in the Angle input field of the Roll Tool Window In doing so the coordinates of the roll corner point keep unchanged Copyright 2015 by UBECO GmbH Iserlohn 116 UBECO PROFIL Rollform Design Software 3 1 4 10 Gap Use this function to create or modify a parallel gap between roll and profile The gap can created between two Roll Corner Points or for the whole roll Application spectrum e Coated sheet metal should be processed e Raised cut outs should not be deformed e A horizontal sheet guide should have a gap in order to avoid pinching in case of sheet width allowances e A Clearance Angle should be continued in the successive profile segments e g for forming trapezoidal profiles e Already finished parts of the profile should not be touched by rolls anymore see picture Calling the function Before you call this function identify the previous Roll Corner Point of the two that should be treated If the gap should be applied to the whole roll select any corner point of the roll Call this function optionally by e Main menu Rolls Gap e Context menu right mouse button click on the corner of the desired roll in the Drawing Area Gap TS a Modify gap w
354. ration After confirmation by pressing the Ok button in the Window Read CAD Contour the position on the shaft is checked first e The position is free The new roll is inserted at the defined position The user has to check if there are remaining gaps between the rolls e A roll yet exists with same width and position The existing roll is replaced by the new one if the user agrees e An overlap occurs between an existing roll and the new one The existing rolls are moved by the overlap width if the user agrees Now a roll is created and displayed which has the same contour as the one prepared in the CAD system Afterwards you can modify the roll for your own needs by using the functions of the menu Roll Hints Further function for creating rolls are e Automatic creation by Scan Profile Drawing e Import an existing roll from CAD by Roll Read CAD Roll e Import roll from the Roll Data Base Read CAD Roll Use this function to import from the CAD System a roll that already exists but still is not available in a PROFIL Project File This is useful in case you want to import rolls from third party systems or if you want to reuse old rolls An important property of this function is that the roll keeps unchanged during positioning on the shaft centerline in contrast to the function Roll Read CAD Contour that adapts the diameter dependent on the machine data The consequence is that the imported roll possibly does not touch the profile co
355. rawing right the discharged or loaded state blue is shown Whether the pass is drawn discharged or loaded you define by setting this toggle switch The result of the switching is dependent on the selection before Discharged state Cross section of the profile without consideration of the spring back also the cross section of the final product with the desired dimensions Loaded state Cross section of the profile with over bent arcs in order to compensate the spring back After leaving the last stand the profile springs back and has the desired cross section of the discharged state afterwards Each arc has to be over bent at least in one stand In most cases this has to be considered in the last final stand In some cases the arc has to be over bent in a previous stand e g for complicated profiles if the rolls of the last stand cannot attack the arc Calling the function Before you call this function select the arc that should be toggled Or deselect all function Inspect in order to toggle all profile elements Call this function optionally by e Main menu Profile Loaded e Context menu right mouse button click on the arc that should be toggled in the Drawing Area Profile Loaded Principle of operation If a single arc of a pass is selected by clicking of the arc in the Drawing Area or in the Profile Window thus the arc is drawn in the mark color only the loading of this arc is switched on and off If no arc is
356. rched extension will be attaches to the selected roll corner If further rolls exist they will be moved in case there is not enough space between the rolls The new coordinates of the Corner Point will be calculated Hint Alternatively you can append a Cylindrical Extension or a Conical Extension 3 1 4 8 Double Fillet This function creates a double fillet at a roll corner with a larger and a smaller radius Both arcs have tangential connections Application spectrum e Avoiding track markers on the sheet surface caused by production tolerances of the rolls e g of split rolls large radius e Avoiding damage of the roll corners during handling operations small radius e Avoiding operator s hands injury during handling operations small radius Calling the function Before you call this function identify the Roll Corner Point that should be furnished with a double fillet Call this function optionally by e Main menu Rolls Double Fillet e Context menu right mouse button click on the corner of the desired roll in the Drawing Area Double Fillet ax Double Fillet dt 0 000 5 000 e 000 i X Cancel Help The input window appears and asks Double Fillet Width Enter the desired width between the start point of the large arc and the corner point of the roll s flange face Principle of operation Two fillet radii with tangential connections are applied to the selected Roll Corner Point The radii are
357. rder to prevent the sheet surface from damage In doing so the legs must be able to move horizontally they say they must flow This can be archived by using a clearance angle Without it the legs would wedge and the sheet would be stretched in transversal direction Very important are clearance angles for profiles with more than one bending zone per side and per stand Example Trapezoidal Profiles Often a full trapezoid that consist of four angles is bent per side Calling the function Before you call this function select the vertex of the clearance angle in the example the Roll Corner Point of the fillet of the top roll Copyright 2015 by UBECO GmbH Iserlohn Reference 115 Call this function optionally by e Main menu Rolls Clearance Angle e Context menu right mouse button click on the left or right corner of the desired roll in the Drawing Area Clearance Angle Enter Clearance Angle Degree Actual angle rel to the roll axle 1 000 Leg to the outside 45 i Leg to the ref paint 160 Opening Direction Input Angle i Leg points to the outside f Relative to the actual angle Leg points to the reference point Relative to the roll axle E x Cancel Help The input window appears and asks Enter Clearance Angle Degree Opening Direction In most cases the legs of the clearance angle point to the outside direction view from the reference point This direction Legs point to t
358. reduced by Center Line Forming Principle of operation After checking if the given cross section is a trapezoidal profile i e it has horizontal top and bottom lines the function creates the flower pattern for a trapezoidal profile automatically either with cosine band edge course or linear course with user defined fillet radii as desired If passes already exist after the selected pass a dialog box asks if they can be removed Hints e In order to enable PROFIL to recognize the trapezoids correctly it is necessary that the trapezoids have a horizontal line or a tangential connection between two arcs at the top and the bottom of each trpezoid If they have not e g corrugated sheet simply split the arcs at the top and bottom point quad point 90 and 270 You can do this either in CAD before Reading the CAD Contour or in PROFIL by the function Profile Element Split e Sharp edges i e arcs with inner radius 0 should be avoided This is why the automatic trapezoidal profil forming works numerically and cannot find a proper solution if the function is Copyright 2015 by UBECO GmbH Iserlohn Reference 135 3 1 5 5 3 1 5 6 discontinuous Use radii not less than 0 2 mm inner radius instead Required Count of Stands During processing a quotation and a cost assessment the cost of a roll tool set or a roll forming machine must be estimated roughly The expected count of passes or stands for a given profil
359. refinement Automatic remesh and LS Dyna will remesh automatically Meshing Profile Cross Section Enter the count of FEA elements right column for each Profile Element left column of the Profile List individually L and A elements only P and PS elements are ignored The row numbering is the same as in the Profile List Window In case the project file still does not contain saved FEA parameter a proposed meshing is shown in the table You can modify it for your own needs Transit Elements possibly the FEA system wants to place an arc to a different position than you have planned it in your flower design To enable this transition elements can be set When a line segment touches an arc segment the beginning or the end of the line segment is divided in smaller items with the same shell element length as the neighbouring arc segment Select the count of transition elements 3 The picture shows a snap shot while simulating a hat profile When the sheet enters a roll stand not only the bending zones are bent blue correspondents to the profile elements Arc but also the parts of the profile that properly should keep unbent yellow correspondents to the elements Line The example shows in the top right bending zone the roll attacking point actually is outside the planned bending zone In order to enable the FEA system to calculate properly in this example Transit Elements 2 was selected small yellow items left and r
360. revious step in order to enable PROFIL to create the sheet thickness on the right side Principle of operation After confirmation by pressing the Ok button in the Window Read CAD Contour the profile list is created and the drawing of the profile is shown in the Drawing Area Now check e Does the imported profile coincide with the CAD drawing Use the function Output Drawing gt CAD to check Hint The transferred drawing is on layer L01 Or dimension the profile and compare the dimensions with the dimensions in CAD e Do arc elements with radius 0 and very small straight length exist in the profile list These are correction elements PROFIL inserts them if in case of not tangential connections of the elements in the CAD drawing It is strongly recommended to avoid this because the correction elements have to be handled and developed during flower design as well If rolls are derived from such contours maybe they will cause grooves in the sheet surface Correct the CAD drawing empty the profile list and import again the contour By using the switch Profile Loaded you can define whether the contour is read into the columns discharged or loaded of the profile list normally discharged The other columns are calculated dependent on the spring back of the selected material The status of the switch is displayed by a coloured background of the table fields in the profile list window possibly select with spring back Copyright 2015 by UBECO
361. ribes either a straight not bent or a bent part of the profile or a reference or a symmetrical point The column Type marks whether the profile element describes a straight or a bent part or a point The straight part is represented by a L Line in the column Type and the length in column St Length The bent part is represented by an A Arc in the column Type and a following number which defines the Bending Method In column Di Direction the bending direction is displayed L for left and R for right Further data are the Radius the Angle and the St Length that is calculated by different Calculation Methods P is the reference point of an asymmetrical profile and marks the start of the second half of the profile PS is the reference and symmetrical point of a symmetrical profile You have to enter data for one side of the profile only P and PS will be used as a Reference Point for the function Calculate Statics Number The number is a column of the table of Profile Elements of the Profile List and numbers the profile elements continuously If you modify the number of the profile elements e g by using one of the functions Element Insert Element Append or Element Remove the profile elements will be automatically renumbered See also Profile List Type The type is a column of the table of the Profile Element of the Profile List and marks whether the profile element is a straight or a bent part of the profile The f
362. ricscadApp release nn Use this Program ID if you have installed more than one BricscadApp release and you want to select a special one BricsCAD Release 15 BricscadApp AcadApplication 15 0 e BricscadApp AcadApplication Connects to the current BricscadApp release this is the last installed one If the drop down list is empty no AutoCAD or SolidWorks or BricsCAD release is installed on your computer Enable ActiveX Input from CAD Copyright 2015 by UBECO GmbH Iserlohn 80 UBECO PROFIL Rollform Design Software Active np e Enable Actives Input from CAD disables File Input from CAD This function enables the ActiveX input and switches the function Profile Read CAD Contour and Roll Read CAD Contour and the matching button on the Button Key Bar to ActiveX At the same time the file input see Options Files will be disabled Enable ActiveX Output to CAD Actver Outpu e Enable Actives Output to CAD disables File Output to CAD This function enables the ActiveX output and switches the function Output Drawing gt CAD and the matching button on the Button Key Bar to Activex At the same time the file output see Options Files will be disabled Hint Select by View Show Spacer Rolls whether the ActiveX output should contain spacer rolls 3 1 2 8 14 PSA Use this window to set up the PSA Profile Stress Analysis Meshing Transv Meshing Trans Line Segments 4 000 mm Small Arc Seg 20 000
363. rofile Element Abs Angle Principle of operation If you have selected a profile element Line the absolute angle is displayed only without edit feature If you have selected a profile element type Arc you can modify the absolute angle between given limits Valid limits are corresponding to a relative arc angle from 0 180 The displayed absolute angle is always the angle at the exit of the arc Remark The column Angle of the Profile List is the relative bending angle related to the previous profile list entity In order to determine the absolute bending angle the relative bending angles up to this point must be added regarding its sign The simplifies the function Absolute Angle 3 1 3 16 2 Open Fold FP Problem The band edge should be folded to a hem by 180 degree with inner radius zero The sheet surfaces should touch closely and should not spring up No solution If the fold is roll formed until the sheet surfaces touch the spring back of the material causes the fold to spring up This is not the desired result Not possible Usually a bending zone is over bent in order to compensate the spring back If this is tried with the 180 degree bend the sheet would penetrate itself This is not possible Copyright 2015 by UBECO GmbH Iserlohn 100 UBECO PROFIL Rollform Design Software 2D Solution In the previous pass the fold is opened to a small inner radius by keeping the angle of
364. rofile lists were saved in separate files for each profile list These files had the extension Lnn To import such files use the function File Import Profile List Pass The pass belongs to the profile list data Other names for the pass are station stand Profile lists are always numbered opposite the sheet running direction LO1 finishing stand In the input field Pass you can automatically number the passes in sheet running direction Enter into the input field Pass of any profile list e g the scheme Pass or Stand Press ENTER and in all profile lists your input appears at the same time is replaced by the pass number in sheet running direction If the first pass is flat i e has no arcs it becomes number 00 for the flat sheet Use this function when all passes are complete If additional profile lists are inserted in a profile project the numbering in the field Pass is not renewed automatically So it is necessary to renumber the pass number like this Point to the arrow down key select from the drop down list the desired numbering scheme and press ENTER In order to delete an item from the list press the Backspace key If needed the pass number can be used as variable PS for the automatic roll numbering see Options Rolls The pass number can be displayed in the Profile Explorer to name the profile lists in sheet running direction Toggle by using the function Edit Explorer See also Profile List Copyright
365. rom an existing flower pattern or can be created and edited manually It can be saved to a file and can be reopened again The development table can be used for the Automatic Flower Creation for a similar profile Calling the function Call this function optionally by e Main menu Profile Development Table e Context menu right mouse button click on any profile element of any pass in the Drawing Area Profile Development Table After calling the function the window Development Table appears with an empty table first The window contains Editor for your remarks on top Add your own remarks or edit and modify the automatic created remarks from the source profile Example kind of profile the development table applies to Bending angle table and bending method table at bottom The header contains the profile element numbers and types of the currently opened profile list L01 this means each column represents a profile element The left column shows the pass number 1 L01 etc this means the table rows represent the forming passes stands The table fields show the Angles in degree or percent toggle by Development Table View Angle in or the Bending Methods toggle by Development Table View Bending Method Menu Functions File New Open Save Save as Development Tables are saved to a file with the file extension dtf By using these functions you can manage the existing development tables in files and reuse them later for
366. ror message anymore when removing a profile list e Bug fixed When splitting a roll between corner points the input of the limits sometimes is not possible e No sporadic error message anymore during the function 3D Stand gt AutoCAD PROFIL Rel 3 2 01 Nov 2000 New features e Creating a Photo Realistic Image of a stand or of the profile if PROFIL is connected to AutoCAD R14 or higher suited for demonstrating the company s products e g in presentations offers and advertising brochures e Wheel mouse support using the wheel to Zoom and Move the drawing in the drawing area Output of the roll drawings in Separate DXF Files with polylines suited for interfacing to an NC programming system Improved path selection in the Options Window PROFIL Rel 3 1 15 May 2000 New features e Automatic roll design for any kind of profile folded and complicated too and for every kind of shaft without using CAD The new function is called Roll Scan Profile Drawing replaces the function Roll Read Profile List and proceeds a hidden line algorithm for the drawing in the drawing area Existing rolls on other shafts are considered too In the roll tool drawing the Previous Pass can be inserted This is useful for checking out if the incoming profile is treated correctly by the rolls and if no conflict occurs e Inthe Print Preview now any user defined scale can be selected Bugfixes e Side rolls with an inclination angle
367. rs Poisson Ratio 0 280 Density 7 8500 Kg dm3 Stress Strain Curve 0 0001 0 0007 0 0023 0 0053 0 0102 0 0172 0 0268 0 0392 0 0549 y Import TXT Curve Generator X Cancel 7 Help Material File Select the name of the material file All material data of this tab window are read from this file and are saved into this file The file name extension is mat Material Name Description for describing the material Young s Modulus Poisson Ratio Density Enter the material properties Stress Strain Curve Enter the points of the stress strain curve The left column Stress should contain the true stress related to the current area not to the original area of the tensile test specimen The right column Strain contains the true logarithmic plastic strain this means the true strain minus the elastic strain Get more detailed information from the LS DYNA KEYWORD USER S MANUAL VOLUME ll Material Models A A N Import TXT Imports a stress strain curve from a text file e g from a tensile test according DIN standard Each line of the file must contain a pair of values either strain stress or stress strain of one curve point Either decimal numbers are possible with dot or comma as decimal separator or numbers in exponential notation The delimiter between the values can be space or tabulator After Copyright 2015 by UBECO GmbH Iserlohn 192 UBECO PROFIL
368. rs This is important in order to minimize the unwanted stress of band edge Copyright 2015 by UBECO GmbH Iserlohn 140 UBECO PROFIL Rollform Design Software 3 1 6 6 Calling the function Call this function optionally by e Main menu View Flower 3D E7 Button View Flower 3D in the Button Key Bar Principle of operation The flower pattern 3D of the project is displayed in the Drawing Area Settings are the same as described in View Pass Setup View Flower 30 Cor aros e 135 0 300 Select the view port angle and the scaling factor of the z axis in Options Drawing The settings also can be modified in the context menu right mouse button z Scaling Hints e The Navigator helps you to zoom to move and to fit the drawing e By using the Navigator 3Dyou can rotate the drawing and toggle to a 2D view e With the function Output Drawing gt CAD you can transfer the drawing to your CAD System e Another kind of displaying the flower pattern is View Flower Nested View Flower Separated Roll Tools LIL LO ILeY Ra1r 01 1r1 Ra1u 01 Use this function to display the roll tools of a stand in the Drawing Area Calling the function Select the roll stand that should be displayed Call this function optionally by e Main menu View Roll Tools e Tl Button View Roll Tools in the Button Key Bar Principle of operation The roll tools of t
369. rst column contains the blank diameters and the second the related finished diameters The meaning is in the second column the value is searched that is yet larger or equal to the finished diameter of the roll in the case of fillets the intersection point of the tangents The related value in the first column is the matching blank diameter the bar diameter Section Roll Width The first column contains the finished diameters and the second the related additions for the width The meaning is in the first column the value is searched that is yet larger or equal to the finished diameter of the roll The related value in the second column is the matching addition for the width which is added to the finished width and is rounded to full mm respectively 0 1 inch The name of the additions file is the name of the roll material with the file extension add e g 2080 add if you have selected in Options Profile List the representation of values Metric All values are in mm If you have selected Imperial the file name has the extension adi and all values are in inch The name of the roll material is copied into the column Mat of the parts list Use the function Edit in the row Material in the Expanded Roll Tool Window to edit the additions file and to adapt it to your own needs Drawing Template The drawing template is a DXF file that contains a drawing frame a title block and Variables It is used by the function File Plot in order to send a s
370. rugated sheet screen doors wall and roof cladding roof bows and trusses panels gutters purlins fence posts greenhouse profiles grape stakes logistic tracks drawer slides studs beams beads shelf racks sheet piling guard rails seat tracks bumpers truck and trailer components window guide channel seal retainer cross members heat transfer pipes garage doors rack beams duct flanges drywall profiles cable trays Copyright 2015 by UBECO GmbH Iserlohn 10 UBECO PROFIL Rollform Design Software Machine Sheet Running Direction gt The roll forming machine consists of a machine base with a set of roll forming stands arranged in series Mostly between 6 and 32 stands are needed dependent on the complexity of the profile Stand Each stand has a driven top and bottom shaft with force fit tied roll tools Often non driven side rolls with vertical axis are used these side rolls are fastened on special auxiliary holders within or behind the stand Acommon motor drives the top and bottom shafts of all stands via a gear box behind the machine In order to allow adjusting the vertical position of the rolls the shafts of the stands are connected to the gear box by using cardan shafts If the gear transmission ratio between top and bottom shaft is 1 1 then the top and bottom rolls have the same working diameter pitch diameter in order to have the same circumferential speed at the profile
371. s The three points are Yield point tensile breaking stress point anda medium point that controls the bulge of the curve The curve has a tangential connection to the Hookean line defined by the Young s modulus and is continuous rising with rising strain Copyright 2015 by UBECO GmbH Iserlohn 200 UBECO PROFIL Rollform Design Software gg Curve Generator i 10 x I Edit 7 Help x Cancel Calling the function e Main menu Output FEA LS Dyna or Output FEA ABAQUS In the tab Material press the button Curve Generator The window Curve Generator opens and first shows the stress strain curve that is selected in Material Material File If no material file is selected an example curve is shown Modifying the stress strain curve You can modify the curve in this way e Edit Press the Edit button 3 curve points are shown e Select the Yield Point left Move the point up and down in order to modify the yield stress Or enter the desired yield stress in the input field Stress in the header bar The belonging elastic Strain is calculated dependant on the Young s modulus e Select the Tensile Breaking Stress Point right Move the point in any direction in order to modify stress and strain at the breaking point Or enter the desired value in the input field Stress or Strain in the header bar e Select the medium point Move the point left and right in order to modify the bulge of the curv
372. s 40 Function 114 Clipboard Copy Drawing 58 Curve Generator 199 Element Append 103 Element Copy 104 Element Insert 103 Filter Roll Stock Management 255 Graph 146 Options General 61 Plot 55 Plot Copy Drawing 55 Roll Copy 122 Roll Cut 121 Roll Paste 122 Roll Stock Management 252 CNC Lathe 73 Coated sheet metal 116 CoCreate OneSpace Designer 261 Copyright 2015 by UBECO GmbH Iserlohn Index 265 Cold roll formed Profiles 11 Color Assign Options PSA 80 View FEA ABAQUS 145 View FEA LS Dyna 143 Color Select 226 Colors of Drawing 64 Column Properties 71 Combining Projects 50 Conical Extension 110 Constant Radius Method 238 Constant Straight Length Method 238 Contac pressure 194 Contact ABAQUS 194 LS Dyna 192 Contact at Top Bottom Side or Edge 214 Contents of the Disks 259 Contour 226 Contour File DXF Format 231 KTR Format 231 Contour Tracking 226 ConvertLtoA1 101 Copy Element 104 Roll 122 Copy to clipboard Curve Generator 199 Edit Copy 58 Element Copy 104 Export 51 Options General 61 Plot 55 Roll 122 Roll Stock Management 252 Corner Point Append 124 Remove 125 Roll 245 Corrugated Sheet 133 Cosine Course of Band Edge 133 Cost Assessment 135 Count Last Opened Projects 61 Stands 135 Undo Redo Steps 61 C Profile 156 Create Arched Extension 112 Assembly Plan 55 Automatic Flower Pattern 37 Clearance Angle 114 Conical Extension 110 Cylindri
373. s Drawing Printing of the drawing that is visible in the Drawing Area is switched on and off Contents Profile Roll List Printing of the current profile roll list is switched on and off Copyright 2015 by UBECO GmbH Iserlohn 54 UBECO PROFIL Rollform Design Software 3 1 1 10 Whether the Spring Back or the Holes Cut Outs will also be printed out you select in Options Profile List Bold print style for radius angle marks the loaded discharged state A Contents Statics Printing of the table of statics is switched on and off only if a profile list is selected The table is identical with the table called by the function Calculate Statics e Contents Stress of Band Edge Printing of the diagram of stress of band edge is switched on and off only if a profile list is selected The table is identical with the table called by the function Calculate Stress of Band Edge Contents NC program Printing of the NC program is switched on and off requires View Rolls and Contents Roll List is switched on Page If the print out has more than one page select the desired one Scale The drawing can be printed out by using one of the following fixed scales 20 1 10 1 5 1 2 1 1 1 1 2 1 5 1 10 1 20 Select the scale from the drop down list so that the drawing fits the sheet If you don t find a practical scale select User and enter the desired scale into the input window e g 3 000 for scale 3 1 0 2
374. s constant Is the profile list symmetrical i e it contains a symmetrical point PS the band edges are modified symmetrically Is the profile list asymmetrical i e it contains a point P the partition of the strip width modification to the left and right band edge can be preset in Options Profile List topic Modify Strip Width Sheet Thickness The method is useful in combination of the selection Constant Inner Radii or Constant Outer Radii for checking if existing rolls are suited for various sheet thickness Another application is to learn how to design rolls for a sheet thickness interval Pay attention by using this method The profile elements in the flower pattern do not have the same developed length anymore The possible result may be that a part of an arc is formed and in a later stand pressed to flat again After changing the sheet thickness the new thickness is shown in the field Thickness of the Project Window Restrictions Limits of the operating method e The operation method No Rolls Existing is applicable only if no manual modification is made in the passes e g inserting correction elements These will be lost during changing the sheet thickness by using the development table Both operation methods cannot be applied for shaped or round tubes in calibration stands C02 Cnn and in the subsequent welding station because a closed tube is then not closed anymore It can be used however if only the final shaped tube exis
375. s in reality The same applies to cut outs in the sheet it is also recommended to round out sharp corners e The file lt project name gt txt contains the project data the FEA parameterization and the messages Max aspect ratio of mesh elements Profile Max aspect ratio of mesh elements Copyright 2015 by UBECO GmbH Iserlohn Reference 187 Rolls and Displacement guide curves Furthermore the number of the profile element or the width position of the roll respectively where the maximum ration occurred 3 1 8 8 1 1 Profile This dialog window is called by Output FEA LS Dyna is used for parameterizing the meshing in profile cross section and in in sheet running direction LT Ax LS Dyna Meshing Profile Cross Section Meshing in Sheet Running Direction Ralls Length 1 500 mm Holes Cut Out Start Analysis Count 200 Material Contact Others Element type C Shell V Automatic Remesh Solid a In sheet thickness direction Transit Elements X Cancel Help Meshing means the strip is divided into small rectangular faces shell or solid elements The smaller the faces are the more precise the calculation is but the more calculation time is needed So select the meshing as fine as necessary Possibly select a more coarse meshing in profile parts that are less interesting LS Dyna is able to correct in case the faces are too large Check the box Adaptive
376. s the Machine Window which shows the machine data from the current Project Calling the function Call this function optionally by e Main menu Edit Machine e Es Button Machine in the Button Key Bar Hints e For designing the profile and the flower pattern the Distances between Stands are needed e For designing the roll tools further machine data e g Working Diameter Shaft Diameter and Working Width are needed Window visible Use this function to select if you want to see the Project Data Window the Profile List Window and the Roll Tool Window on the screen The status of this switch is displayed by a little hook Calling the function Call this function optionally by e Main menu Edit Window visible 8 Hd Button Window visible in the Button Key Bar Hints e Decide by your own if you prefer to work numerically in the profile list the drawing is always be displayed in the background or graphical only in the drawing In this case you can switch off the windows to get an extended Drawing Area Preset in Options Profile list Profile list window how many windows you want to see Copyright 2015 by UBECO GmbH Iserlohn 60 UBECO PROFIL Rollform Design Software 3 1 2 6 Draft Modus The Draft Modus switch can be used to toggle between bending an arc while Designing the Flower Pattern and modifying an arc while Designing the Profile Example In the draft modus angles and radii can be
377. se in Options Stock Management 3 8 1 Roll Table The lower area of the Roll Stock Management Window displays the table of the roll data This table contains all rolls if the filter is switched off or a subset of the rolls if the filter is switched on Each row of the table displays the data of one roll At first there are the data from the top of the Roll Tool Window Roll Number Width Part Number Max Diameter Classification Diameter Shaft Number of Roll Corner Points These data are automatically transferred when a roll is inserted into the database or when a roll is taken from the database Furthermore the roll table contains some data which are to be entered by hand in case of need e Stock Position Enter the location of the roll in the stock User def col of the roll tabl Tithe of column 1 User Title of column 2 User 2 Title of column 3 User 3 e User 1 3 Define the meaning of these columns by yourself Enter suitable titles for these columns in Options Stock Management The roll corner points of the selected roll are displayed in the Roll Corner Table The belonging projects of the selected roll are displayed in the Project Table Use a Filter to reduce the amount of displayed rolls The drawing of the selected roll is displayed in the Drawing Area The top bar of the roll table contains these indicators and buttons Number of rolls displays the number of all rolls in the database if the fil
378. shing B75 Edit Identification Groove Ge Edit Material jo Edit Treating M Surface Po dl Addition o A Remark Touching the Profile at fy Top Bottom Side Edge I Cancel Hilfe This window appears if you press the key More in the Roll Tool Window It is effective both for forming rolls and for spacer rolls For each roll you can enter these additional properties Diameter Shaft Driven Bore Hole Bushing Copyright 2015 by UBECO GmbH Iserlohn 212 UBECO PROFIL Rollform Design Software 3 3 6 1 3 3 6 2 3 3 6 3 Identification Groove Material Treating Surface Addition Remark Touching the Profile at The entries in the fields Bore Hole Material are file names After mouse click in one of these fields the file select window opens and you can select a file name The keys Edit call the text editor set in Options General that opens the file with the file name in the belonging input field The entries Treating Surface Addition and Remark are user defined concerning field name and field content The drop down boxes opened by a mouse click on the arrow symbol contains recent user inputs This makes new input easier The same window appears too when you press the button More in Options Rolls or in Options Spacer Rolls You can enter default values that are copied into a roll dataset when you create a new roll by Roll Read CAD Contour or Roll Scan Profile Drawing or a
379. should be a simple disc you simply can produce it by using the Split at Corner function at each edge of the fin Copyright 2015 by UBECO GmbH Iserlohn 164 UBECO PROFIL Rollform Design Software 3 1 7 2 6 Fin Pass Bottom Roll This function is a part of the Toolbox Tube Design and is used for generating the bottom roll for a fin pass Calling the function Before calling this function you should have created a fin pass by using the function Fin Pass If you created the fin pass in another way pay attention that the profile list contains exactly 3 entries A1 A1 PS Only for such a tube profile a roll can be generated automatically Call this function by Button Fin Pass Bottom Roll from the Toolbox Tube Design The window Fin Pass Bottom Roll is opened Enter these parameters e Total Width W If your entered value is too small the width is set automatically to a minimum width that has enough space for all fillet radii The result is rounded to 10 mm or 1 in e Fillet Radii R1 R2 Select a fillet radius at the inside at the tube and a fillet radius at the outside at the roll edges e Half Air Gap AG Enter the desired vertical air gap between the roll and the center of the tube more exact center of the first arc segment of the tube profile Working diameter and reference point are taken from the Machine Data Principle of operation After pressing the Ok button the roll is generated If a r
380. should be transferred into a predefined work sheet of MS Excel by the function Output Create Parts List Program Id Excel Select from the drop down list the Excel release for the ActiveX transfer The list shows all installed Excel releases the transfer is possible to release 8 or higher Excel Application means the topical release last installed Text File f In Output Path CAPROFIL D atatEngh In Project Path Parts List to Text File Check here if a text file should be created by the function Output Create Parts List The name of the text file is always the same as the project name but has the extension txt In Output Path Enter the path of the path for the parts list text file if necessary also with a drive letter e g c PartsLi In Project Path Check here if the parts list text file should be created in the same path of the belonging project file Heading for Parts List to Text File only 7 without i Top i Bottom Without Top Bottom Select the position of the heading top suitable for printing or bottom suitable for transferring the parts list into the CAD drawing or without heading for transferring into a spreadsheet or an ERP system Edit By clicking this button the text editor set in Options General is opened with the file PROFIL leg This file contain 1 line exactly with the heading for the parts list Modify the heading for your needs In case of Excel please define the heading withi
381. sible if the parts list is created as a text file not for transfer to Excel Priority of Sorting Enter priority 1 highest if this column should be sorted If rolls exist with same values in this column the priority 2 can be set for another column Then rolls with same values are sorted in this column Designation Bottar all Bottom F TopRoll Top Roll LeftRolt Leon RightRolt Right Roll Spacer Spacer Bushing Bushing Designation The text that appears in the parts list column Designation can be user defined dependent on the type of roll bottom top left and right roll Furthermore the text can be defined for spacers and Bushing Parts List contains e Roll Tools e Autom Spacers e Bushing Parts List contains Roll Tools Autom Spacers Bushing Select what kind of entries the parts list should contain Hint Select by View Show Spacer Rolls whether the parts list should contain spacer rolls The difference between automatic spacers and spacer rolls is discussed in Tutorial Roll Tools Creating Spacer Rolls Diameter from ntersect Prit f Actual Max Diameter from Intersection Point Actual Maximum Select if the maximum roll diameter is calculated from the intersection point of the tangents Roll Corner Point or from the actual diameter on the fillet The calculation of the Additions and with it the blank diameter is dependent on this selection Copyright 2015 by UBECO GmbH
382. so Partial Project Save as Partial Project Add On A project file pro can contain not only a complete Profile Project but also a Partial Project e g the left or right side only the pass only or a subset of the stands only By using the function Partial Project Add On you can add such a partial project to your currently opened project During this operation it is essential that the objects of the added project overwrite the objects of the current project So it is a good idea to save the project previously The Machine Data are not added so they have to be transferred separately Copyright 2015 by UBECO GmbH Iserlohn Reference 49 Calling the function Call this function by e Main menu File Partial Project Add On y Partial Project Add On aj x From file 44865 From pass LO To pass Los To curent project A172 From pass LO1 To pass Los Warning Existing data will be owersrittenil i X Cancel Help After calling the function Partial Project Add On and after selecting the file that has to be added the dialog window opens and the source and target passes can be defined From file From pass To pass The selection boxes show the passes of the selected project file If needed you can select a subset To current project From pass To pass Select the target position in the current project where the added passes should appear Please consider that the new passes are no
383. spacer roll by Roll Create Spacer Roll Furthermore you can preset the field names of Treating Surface Addition and Remark in this window If the window is opened from Options Spacer Rolls the field Material in inactive because the material for spacer rolls is preset in the Machine Window The same also applies to the field Diameter Shaft for forming rolls and spacer rolls Diameter Shaft The diameter shaft belongs to the roll data and is displayed in the header of the Expanded Roll Tool Window It is read out of the Machine Data when a roll is created and can be changed subsequently The bore hole can be displayed in the roll tool drawing select this in Options Drawing Driven Driven belongs to the roll data and is displayed in the Expanded Roll Tool Window A roll is driven if it has form fit with the shaft e g by a key Driven rolls move the sheet through the machine Otherwise it is an idle free rotational roll the soeed of which is caused by the friction with the sheet When creating bottom and top rolls they are marked as driven and side rolls are marked as not driven first These settings can be reversed manually if necessary If a Bushing is selected for a roll the mark Driven is removed Bore Hole Bore Hole belongs to the roll data and is displayed in the Expanded Roll Tool Window Bore Hole is the name of a file that e g contains these data BOREFILE Bore Hole 75000 Diameter H7 Fit 16 000 Key
384. sses Calling the function Call this function optionally by e Main menu Profile Modify Reference Point x0 or y0 e Context menu right mouse button click on a profile element in the Drawing Area Profile Modify Reference Point x0 or y0 e Profile List Window Enter the value in the input field x0 y0 Copyright 2015 by UBECO GmbH Iserlohn Reference 91 3 1 3 9 TS as Enter new reference point coordinate yi 152 000 C for the current pass only t for all passes x Cancel Help After calling this function a dialog window is opened Enter the desired new reference point coordinate and select whether the modification should be effective on the current pass only or on all passes of the whole flower pattern Principle of operation The function Modify Reference Point enables to modify the x and y coordinate of the reference point mutually independently Afterwards the drawing is moved to the new position Hints e In case the drawing of the profile has disappeared from the view port of the Drawing Area you can make is visible again by the button Fit of the Navigator e Select View Flower Nested in order to check all passes for proper position Insert eL U30x20 a LO Use this function to insert a new Profile List at the current position This means to insert a stand Calling the function Before you call this function select the pass at whose position a new prof
385. t 90 and 270 Q How can avoid the springback of the profile after leaving the machine A By overbending each arc in that pass in which it is bent to the final angle Another smart measure is to use the Arc Type A4 with the Modify angle and radius option in an additional calibrating stand at the end of the forming process This method overbends parts of the arc and bends them to flat again in order to compensate the spring back If the corner of the profile should be formed to a hem 180 fold with inner radius 0 use the Open Fold function in order to avoid spring back Q How can avoid the end flare effect after cutting the profile A End flare means one end opens and the other closes after the split cut In order to decrease this effect use smaller bend angle change from pass to pass i e use more stands Another measure is to insert side rolls between the stands They prevent spring back of the profile legs between the stands Also using of the Arc Type A4 with the Modify angle and radius option decreases the end flare effect F The ME10 macros do not work under PTC Creo Elements Direct Drafting rel 19 What can do A Inrel 19 new internal variables are used whose names conflict with macro names The new adapted macro rel 2 4 is available in the download section http www ubeco com F The LS Dyna simulation modifies the sheet thickness although the roll gap equals the sheet thickness Why A You are using a
386. t 2015 by UBECO GmbH Iserlohn 224 UBECO PROFIL Rollform Design Software reference point is on the roll contour and the working diameter can be measured at the roll X0 Pic 2 The roll reference point is in the centroid of the profile For special applications the roll reference point PO can be set to any point e g to the centroid of an area of the profile cross section as shown in pic 2 for a round tube Also in this case the Working Diameter DO 2x working radius RO is related to this reference point Pay attention that the working diameter cannot be measured at the roll This principle also is valid for top and side rolls For each shaft type a separate column exist in the Machine Window with reference point coordinates and working diameter YO XO Pic 3 The roll reference point is at the top side of the sheet For top rolls it makes sense to set the roll reference point PO to the top side of the profile i e to the point that is moved upwards from the Reference Point X0 Y0 by the sheet thickness see pic 3 Thus the Working Diameter DO 2x working radius RO can be measured at the roll But the disadvantage is that the machine data have to be adapted to varying sheet thickness This can be avoided by proceeding in the following way 50 000 Ref Pointx 200 000 200 000 200 000 Ref Pointyw 150 000 150 000 150 000 Incl Anales Pic 4 Empty input fields x y cause moving the
387. t displayed in the Drawing Area not transferred to CAD Drawing gt CAD and not printed Print Inspect If you have selected a pass or a roll in the Drawing Area by mouse click all other parts of the drawing appear in the inactive color and are not transferred to CAD by Drawing gt CAD The selection can be suspended by Inspect Calling the function Call this function optionally by e Right Mouse Button click into the background of the Drawing Area e N Button Inspect in the Button Key Bar Principle of operation Use the function Inspect to deselect the pass or the roll again and to display the whole drawing in its default colors for better inspecting Copyright 2015 by UBECO GmbH Iserlohn 204 UBECO PROFIL Rollform Design Software 3 2 4 3 2 9 Navigator Use the Navigator in the upper right corner to modify the view port of the Drawing Area It contains the following buttons Left Right Up Down E E 57 Use these buttons to move the view port left right up and down If you use a wheel mouse you can move the view port by moving the mouse while the wheel key is pressed If you use a space mouse from 3DConnexion press the cap to the left or right or to the front or back O Fit Use this button to fit the drawing into the view port In case of a space mouse use function key 1 SN a Zoom Use these buttons to zoom the view port If you use a wheel mouse you can zoom b
388. t inserted or appended however they overwrite the existing passes instead If the new passes e g only contain the left side of the profile the right side of the current project will remain unchanged However if you want to insert instead please create the desired count of passes by using the function Profile Insert or Profile Append and overwrite these passes with Partial Project Add On Principle of operation The partial project is added from the selected project file by using the settings to the current project These cases are handled specially e Different sheet thickness in the current and the added project A dialog window appears with the question Target project s sheet thickness differs from the add on project Adapt the target project The user should decide if it makes sense to agree e Rolls already exist For each roll a dialog window is opened with the question Roll already exists Overwrite The user decides if he wants so It is also possible to remove surplus rolls later These cases are not handled by PROFIL e Different strip widths in certain passes especially if a subset of passes is added The user should check this and correct it if indicated by modifying certain profile elements e Penetrations between rolls passes Also this should be checked and corrected by the user e Different machine data This causes that rolls of the added project do not touch the profile or penetrate the profile The reason is that mac
389. t precise method in case of pure bending DIN 6935 Method 0 9 0 8 0 7 0 6 0 5 0 4 0 3 0 2 0 1 Calculation by formula Fm ee A 2 S Determining from table ri s gt 0 65 1 0 gt 1 0 1 5 gt 1 5 2 4 gt 2 4 3 8 gt 3 8 f 0 6 0 7 0 8 0 9 1 0 Copyright 2015 by UBECO GmbH Iserlohn 242 UBECO PROFIL Rollform Design Software 3 5 10 3 5 11 with f Factor for the position of the neutral line ri Inner radius S Sheet thickness DIN 6935 is a practical calculation method as a function of inner radius ri and sheet thickness s for pure bending too Select in Options Calculate if it should be calculated by table or by formula In the diagram both alternatives are shown Because the DIN method has only two parameters it is less precise than the Oehler method However because it is quite simple to use especially by handling the table it is the preferred method for manual determining the straight length User Defined Methods Use your own User Defined Calculation Methods based to your experience especially for not pure bending Hints e Select the desired method in the Project Data e Do not modify the calculation method if your project already has more than one stands or the flower pattern is already completed Thus you would get different strip widths in the passes User Defined Calculation Methods In addition to default methods of Oehler and DIN 6935 you can enhance PROF
390. tandardized assembly drawing to the output device You can use any DXF file as drawing template Use the button Open Template in the Plot Assembly Plan window to open one of the existing templates or define a template by yourself by using any CAD system You also can modify an existing template for your needs by e g separating the rolls in the Assembly Plan window and by saving the template afterwards PROFIL is able to fill out the title block automatically if the drawing template contains Variables Position and text height are considered Variables that represent drawing objects are replaced by the ones from the current drawing Copyright 2015 by UBECO GmbH Iserlohn Reference 233 3 5 3 5 1 Profile List The profile list describes the geometry of the profile for one pass The name of a profile list ends always with Lnn while nn is the number of the pass and L01 is the last pass finishing pass The numbering is opposite the sheet running direction The profile list data are Pass Dist stand Strip width Reference Point X0 YO Direction and a table of maximum 199 Full Version or 15 LT Version Profile Elements In conjunction with the profile list data these data describe numerically the geometry of the profile The table of profile elements has the following columns Number Position Straight Lenth Stress Comment for users of updates from earlier versions of PROFIL In earlier versions the p
391. ted because the straight length calculated by the Oehler method is dependent on the arc angle Hint Redo joining by the function Profile Element Split 3 1 3 16 6 Insert Stich xD 200 000 Stich x0 200 000 Geriistab 300 000 y0 150 000 Gerustab 300 000 y0 150 000 Bandbreite 62 887 Richt Bandbreite 62 887 Richt i Radius entl Winkel entl gestrLa Bel Radius entl Winkel entl gestr L Bel 11 000 11 000 2 000 90 000 4 444 61 16 000 2 000 90 000 4 444 16 000 Use this function to insert a new empty Profile Element or a set of profile elements from the clipboard at the current position Numbers of the following elements will be increased by the count of inserted profile elements Calling the function Before you call this function select the profile element Call this function optionally by e Main menu Profile Element Insert e Context menu right mouse button click on the profile element in the Drawing Area Profile Element Insert Principle of operation If you call this function and the clipboard contains profile elements you are asked Clipboard contains profile element s Paste and in the next line a list of element types are shown e g L A1 L If you press Yes all profile elements from the clipboard are pasted Otherwise an empty line is inserted Hints e To append a
392. ter is switched off or the number of filtered rolls if the filter is switched on ma A Database Navigator for switching to the first previous next last roll for inserting deleting and editing a roll for posting and cancelling the edited data and for refreshing the data e g if in a network several designers use the same database D Insert Roll from clipboard transfers a roll from the clipboard to the database The roll can be copied to the clipboard from the current project by using the function Roll Cut or Roll Copypreviously CAD Insert Roll from CAD Copyright 2015 by UBECO GmbH Iserlohn Reference 253 3 8 2 reads a roll from a CAD drawing and inserts it into the database This function is useful if older rolls should be inserted that are existing as a CAD drawing only not in a profile project Pay attention that the contour in the file has to start and to end on the centerline of the roll in contrast to the function Roll Read CAD Contour e AutoCAD R14 or higher or SolidWorks 2003 or higher or SolidEdge ST7 or higher or BricsCAD rel 15 or higher Precondition In Options ActiveX Enable ActiveX to CAD is selected The Window Read CAD Contour appears see picture you can select the layer of the desired roll and define the contour of the roll by setting the start green and end point red of the contour the intersection point of the edges and the center line in each case e ME10 or On
393. th the same sum of developed lengths If a round tube is created in the welding station use the function Welding Pass in order to attach the addition for welding Otherwise increase the ends of the profile by modifying the profile elements in the profile list Also the function Profile Modify Strip Width can be used for this purpose The Reference Points x0 y0 both for the shaped tube and for all calibration passes are modified in this way that the centroids of the area are in the center of the round tube of the welding station Hints e f you created a round tube use for the tube forming the functions Fin Pass Break Down Pass Break Down Pass W Forming e Create the rolls for the calibrating stands by using the functions Roll Scan Profile Drawing Roll Read CAD Contour e Create the rolls for the tube forming passes by using the functions Fin Pass Top Roll Fin Pass Bottom Roll Copyright 2015 by UBECO GmbH Iserlohn Reference 133 3 1 5 4 Break Down Pass Top Roll Break Down Pass Bottom Roll Fin Pass Side Rolls Break Down Pass Side Rolls e Another method is to handle the shaped tube as an open profile This means it becomes the desired final shape already in the welding station Afterwards it can be calibrated in order to get a shaped tube with small allowances Trapezoidal Profile Forming When wide sheet metal strips are roll formed to a trapezoidal profile the course of the band edge
394. that can be reversed next Setup Menus 20 Count of recent projects on file menu E Count of Undo Redo steps Select in Options General Menus how many steps should be available for Redo Hints If you did this in error you can 1 Undo the commands Copy Use this function to copy the drawing from the Drawing Area as a bitmap to the Windows clipboard This is useful to transfer the picture to any Windows application e g Word Paint and others by using the function Edit Paste in the other application Calling the function Call this function optionally by e Main menu Edit Copy Setup Because of conversion of a vector graphic to a bitmap the width of the lines is one pixel exactly This is why it is not recommended to zoom the picture in the target application afterwards if you do so you will get improper results Copy drawing to clipboar Resolution 300 250 Background color Poo Better set a practical Resolution in Options General Copy Drawing to Clipboard previously to get the desired size of the picture The drawing will always fit to the bounds of the picture not dependent on the zoom scale in PROFIL Furthermore you can set the desired Background Copyright 2015 by UBECO GmbH Iserlohn Reference 59 3 1 2 4 3 1 2 5 Color of the picture Hint In order to save the drawing to a bitmap file bmp use the Export function Machine This function opens and close
395. the friction coefficient can be set Contact pressure reduction factor for thin sheet Contact pressure is set in order to have necessary pressure between the contact surfaces The preset pressure is optimized for normal sheet thickness of 0 5 5mm Select the Reduction Factor 1 0 for normal sheet thickness For thin sheet the preset pressure possibly is too big If you see shooting out nodes in the FEA result caused by too high pressure decrease the pressure by using the reduction factor Recommended value is 0 1 for sheet thickness lt 0 3 mm Others Copyright 2015 by UBECO GmbH Iserlohn Reference 199 3 1 8 8 3 Meshing Transv Meshing Long Files Machine Material Contact Others Mass Scaling Time Interval 500 ns Recommended 1 37 ns Guided Nodes Jv First Row Y Last Row x Cancel 7 Hilfe Mass Scaling Time Interval Mass Scaling is useful for speeding up the FEA simulation If however the time interval is too large the FEA result may become invalid see View FEA Result Mean Energy Ratio Select the desired time interval The recommended value behind the input field is calculated dependent on the smallest shell element edge length and the material data Guided Nodes First Row Last Row To consider the real environment infinite long strip while the FEA simulation with a relative short strip the first row of nodes of the predecessor elements and the last row of
396. the profile Reference Point In order to keep the circumference speed of both top an bottom roll constant adjustable top and bottom shafts are needed not possible by all machines Bottom Line Forming means in contrast to Center Line Forming The coming flat strip has the same height as the leaving web of the final profile In principle any amount of lowering is possible Lowering to a constant height of the Centroid is often used This enables regular distribution to the whole profile cross section Calling the function Call this function optionally by e Main menu Profile Center Line Forming e Context menu right mouse button click on any profile element of any pass in the Drawing Area Profile Center Line Forming Cs a Amount of lowering in for Center Line Forming 100 000 1 x Cancel Help After calling this function a dialog window asks Amount of lowering in for Center Line Forming Enter e 100 if you want all centroids to have the same height e 0 if you want no lowering or if you want to reset to Bottom Line Forming e A negative value if you want the strip moving upwards for special application e g if the profile is open at the bottom side e A value greater than 100 if extreme bottom line forming is needed for special application e g if the distance between stands is extreme small Principle of operation The Y coordinates of the Reference Point of all passes except LO1 are m
397. the target profile list It is also possible to convert a line element from L01 to an arc element in Lnn Copyright 2015 by UBECO GmbH Iserlohn 38 UBECO PROFIL Rollform Design Software 2 6 2 6 1 2 6 2 By using this feature in the course of time you will get a collection of development tables for various kinds of profiles which contain your individual know how This enables you to quicker react on inquiries for new profiles Roll Tools Designing the Roll Tools Select among 3 various methods automatically with the help of the CAD system or by re using of existing rolls from the roll stock management Precondition for both methods is you have prepared a machine data in the Machine Window e Choose the Roll Design using the Profile Drawing if PROFIL should suggest a roll for your profile pattern automatically It is the fastest method for designing rolls e Choose the Roll Design using the CAD System if you want to give the rolls an individual form e Choose the Search for existing Rolls if you want to re use existing rolls from the roll stock management for reducing costs Roll Design using the Profile Drawing Choose this method if PROFIL should suggest a roll for your profile pattern automatically It is the fastest method for designing rolls The profile drawing displayed in the Drawing Area is scanned Only the contour of the profile and other yet existing rolls is considered that is
398. tial Proje r Add Oneni see dubia shen veusenty oc 48 Panal PYOIECES AVC ASren aE EOE aia 50 IMPON o E A E a E TI a 50 EXPO um ca 51 PEP REVI Wi A ences ess Bae 53 mA o 54 PIE ias 55 EME austin da a dls diia ee 57 Ed ii 57 UNJO desmarca danna led io dida aaa 57 E a ia nsebeeecaneaeeaeh antaseanstaueanwenee 58 COPY nr in kee E 58 Machine aia 59 WINCOW WVISIDlS lt costosas id iia 59 BA cos ca a O A A E E E A EE 60 EXPO aa a asa 60 A a hs eee eee E E A OA 61 General egs E E E E 61 DAWNO sarsan E E e E E 62 E ar eet eee go a a a a E ee re eee eter ee me eer 64 Pronte sti a 65 CANCUN AMA o A A ele 66 A dos eseai essen le ce gepoenasnoenemacwoousswceu cee E ane EE E 67 Spacer dls laica tasih 68 DAMAS nico 69 PAS E ER A on 70 Sep Pars List COlMMs it 71 ING gae cece recht caret e a A O 73 PUGS OS 75 ACUVOA dali inicial otero 77 AN 80 1 AAA o Ge danas a aa A ee 81 MOUSE ernn a doc ea a sasha Gaeek eases meets nesenas dessa aw eee entaeeeeeeeoee 82 A E E E E A E N induc vey E E E E E T E A E E TE 82 REJO GAD GOMMONI a een E A A eee NINE 82 EMPU Dir ii S 84 MIO so 84 MOGIiy Start El Mel sicarios as ladridos 85 MONDO PO 86 Modiiy Shest THICKNESS ica is da ia a id ds 87 Mody SURO MOI eines acre catenin te cae hands Pa Sec sev nasties teenies a dens esiabic yexeeeemet oeks 89 M dify Reference Poll sicario nata 90 EP aE E O EI 91 ADDON O OT 92 PACINO Cs A A aes ees es Bee 93 LOaded serssi na maldicion ladilla ata 94 Center
399. tial Project Add On Added rolls are locked against automatic roll renumbering Bugfixes Output FEA LS Dyna No Runtime error anymore in case a roll has no bore hole NC Program The G code is now correct if a roll has an edge fillet radius and a neighboring roll exists Creating Roll Extensions and Roll Move do not move the next roll anymore if enough space exists between the rolls PROFIL Rel 5 2 01 Dec 2014 New features Postprocessor to the FEA systems LS Dyna from Livermore Software Technology Corp The FEA result can be analyzed in PROFIL directly Graph for Stress Strain Sheet Thickness shows the LS Dyna simulation result dependant on the sheet position in the machine Importing a stress strain curve from a text file e g from a tensile test in Output FEA Options Files Presetting a drawing scale while importing a profile or roll contour Roll Double Fillet Creating rounded roll corners with two radii and tangential connections The context menu of the Machine Window and the Profile List Window enables copying of certain parameters to the corresponding items of all other stands or profile lists Copyright 2015 by UBECO GmbH Iserlohn General 15 e The input field Working Diameter of the Machine Window enables parameterizing of increasing diameters for keeping the strip under tension e During processing a quotation the approximate Required Count of Stands for a given profile is calcu
400. tings Menus Menus 20 Count of recent projects on file menu E Count of Undo Redo steps Count of recent projects on file menu Set the number of recently opened projects on the menu File Enter a number between 0 and 20 Count of Undo Redo steps Select the count of steps for the functions 1 Edit Undo and Edit Redo Copy drawing to clipboard Copyright 2015 by UBECO GmbH Iserlohn 62 UBECO PROFIL Rollform Design Software 3 1 2 8 2 Copy drawing to clipboar Resolution 300 250 Background color EJ Resolution Set a practical resolution of the bitmap to get the desired size of the picture if you use the function Copy to copy the drawing from the Drawing Area as a bitmap to the Windows clipboard Background color Select the desired background color of the copied picture INI File Settings INI File Settings Manage INI file settings always automatically g El INI file name CAPROFIL D atas Profil ini All system and user settings are saved in the WINDOWS Registry at program exit and are loaded at program start automatically For special purposes you can manage them in an INI file as well e g e f you want to transfer the settings to another computer e lf you use different computers and you always want to work with the same settings Manage INI file settings always automatically Settings are saved in the WINDOWS Registry in any case at program
401. tion File Partial Project Add On In order to open a PROFIL project pro use the function File Open Project Copyright 2015 by UBECO GmbH Iserlohn Reference 53 3 1 1 9 Print Preview E P rome Preck bow Profes lic Prodle Preci CAP AOF IL Dalbi Egia iS pro Cie lomer Precision Prodles irc Dak 2206 55 hescap l C Prodle Mame Sml hi Drewding Mo 24371230545 Rey 06 2012 Makiz FE PO2G 275 MA Thickresz 3000 Mahire Roller T300 Calc M Deher Pare T Pee xO 200 O 615 Skrad 300 0001 yO 130 000 Shp iid hi 117 545 Direc Shere of Bard Edge Makia FE PO GAS MA Ae S50 Mimi Re i Bago o D oa am ine Wi um O ih 0 BS Gg LL LAA LL Use this function to open the window Print Preview on the screen Calling the function Call this function by e Main menu File Print Preview The displayed sheet shows you the print out of the drawing and the data of the profile project If the print preview contains more than one page you can browse by using the page selector in the top button bar Principle of operation You can call these functions from the menu or the button bar of this window Printer Print The print out is started e Printer Setup Select the printer the paper size and orientation e Printer Font Select font color and size Contents Headline Printing of the headline description on the left and customer on the right is switched on and off E Content
402. tion with the roll drawing Preset is in File Print Preview Edit NC Use this function to view the NC program and to append further machine commands to it Calling the function Precondition You have generated the NC program by using the function Output Create NC Select View Rolls Call this function by e Main menu Output Edit NC Principle of operation The text editor set in Options General will be opened with the NC file Hint e Because the text editor is an independent program it must be closed manually Otherwise it will keep open in the background Copyright 2015 by UBECO GmbH Iserlohn Reference 185 3 1 8 8 3 1 8 8 1 FEA LS Dyna Use this function to create the simulation model for the FEA Simulation which can be processed by the FEA system LS Dyna Calling the function Precondition You have created roll tools for all stands see How to Work LO1 contains the final profile and the last pass Lnn contains the flat sheet normally without rolls Call this function by e Main menu Output FEA LS Dyna Fen parameters ts ovna O E LS Dyn Profile Rolls Holes Cut Out Start Material Contact Others Meshing Profile Cross Section Meshing in Sheet Running Direction Lenath 1 500 mm Analysis Count 200 Element type C Shell J Automatic Remesh Solid a In sheet thickness direction Transit Elements
403. tire file After clicking into the input field the file select window appears Path for Separate Files Enter path for the separate files The filename is built automatically by using roll number or part number After clicking into the input field the Explorer appears Hint Select by View Show Spacer Rolls whether the NC output should contain spacer rolls Copyright 2015 by UBECO GmbH Iserlohn Reference 15 3 1 2 8 12 Files Use this function to select by mouse click the file format the file name is always PROFIL If you want to use another name another path or another drive enter the full path into the input field Pay attention that the path exists and the extension is correct If you have a network you can enter a network path too Also a network path to a UNIX server is possible If you double click into the input field the file select window opens and you can search for the desired path Input from CAD Input from CAD C KTR File CAD Drawing Scale 1 00 1 00 f DxF File Contour lnputhile CostmpsProfil dat Select the path the name and the format of the input file which your CAD System generates by transferring a profile contour or a roll tool contour to PROFIL This file is be read by PROFIL if you use the function Profile Read CAD Contour or Roll Read CAD Contour Select among the following possibilities KTR format file format defined by UBECO see Contour File KTR Format Use t
404. tive or negative see picture e Context menu right mouse button click on a roll or shaft dash dot centerline in the Drawing Area Modify inclination angle Copyright 2015 by UBECO GmbH Iserlohn 226 UBECO PROFIL Rollform Design Software 3 3 9 TS a Mew Inclination Angle Right Side Roll 30 000 30 000 30 000 Keep Rall Data f Adapt rolls by keeping working contour x Cancel Help After calling the function the input window appears with the question New inclination angle and an admissible range of values for the input Furthermore the topic setting of the switch Changing Machine Data Keep Roll Data in Options Rolls is shown and can be modified Read CAD Contour Scan Profile Drawing The Window Read CAD Contour appears if you have called one of the functions Profile Read CAD Contour or Roll Read CAD Contour or Roll Read CAD Roll or Insert Roll from CAD of the Roll Table The Window Scan Profile Drawing has the same appearance and appears if you have called the function Roll Scan Profile Drawing for creating a roll automatically from the profile drawing in the Drawing Area In the first case creating profile list or roll by reading the contour from CAD the whole drawing is read from CAD and displayed in the window this can take some seconds The progress bar at the bottom shows the status In the second case creating a roll by scanning the profile drawin
405. tor in any numerical input field In case of table fields please double click to change to the Edit modus Principle of operation The current value of the input field is copied to the calculator s display These basic arithmetical operations are possible addition subtraction multiplication and division Furthermore inversion percentage calculation square root and memory functions After pressing the OK button the result from the display is copied into the input field the calculator was opened from Hit Enter or Tab and the new value will take effect Global Memory Functions If you save a value to the memory function MS M M you can recall it for later calculations function MR This also is possible if you closed the calculator and reopen it again in another input field except you deleted the memory function MC Thus the content of several input fields can e g be multiplied by the same constant value Windows Profile Explorer oe g E On En Sees gt gt e L03 aC Pass 7 al Fin Pass 2 ad Lud ca Pass b ae Fin Pass 1 aA LOS at Pass 5 al Breakdown 5 aN LOB HN Pass 4 H A Breakdown 4 The Profile Explorer on the left side of the screen clearly shows the passes stands and rolls of a profile project It can be used for quick navigating between all objects of the project The tree diagram contains the project name the pass numbers L01 etc the roll number and a small icon that shows the preview of the ob
406. tore the final pass of one or more projects into the profile catalogue e Current Project The currently opened project is stored e All Projects of a Path The path selection window appears and all projects of the selected path are stored If the window Profile Catalogue is not yet open it will be opened after calling one of these functions Setup Roll Database and Profile Catalogue Path for Database CAPROFIL D ata Set the path to the database in Options Database 3 1 3 16 Element 3 1 3 16 1 Abs Angle CA a Absolute Angle Related to m rz 5 000 175 000 32 000 DE i x Cancel Hilfe The absolute angle is the angle of any Profile Element related to the x axis Use this function to display the absolute angle of a profile element Furthermore you can bend the profile by modifying the absolute angle Copyright 2015 by UBECO GmbH Iserlohn Reference 99 Application spectrum e Checking if a certain profile flank fits to the requirement e g a surface should be precisely horizontal e For the flower pattern standard rolls with given flank angles should be used Calling the function Before you call this function select the profile element in the column angle discharged or angle loaded inside the Profile List Window Call this function optionally by e Main menu Profile Element Abs Angle e Context menu right mouse button click on the profile element in the Drawing Area P
407. transfer Machine Data created in a previous project to a new project in case the roll tools should be designed for the same machine Parts List Files Sawing List Files txt Generates a parts list sawing list of the rolls of your Profile Project The parts list contains all rolls of all stands of the roll forming machine See Options Parts List for the set up of the parts list The function Output Part List does the same the name and the path of the output file however are taken from the name of the current project NC Program Files G Codes G00 Generates the NC programs for all rolls of your Profile Project See Options NC for the set up of the NC output The function Output NC does the same the name and the path of the output file however are taken from the name of the current project Windows Bitmap Files bmp Copies the current drawing shown in the Drawing Area into the Windows clipboard and saves it to a bmp file See Options General for the set up of resolution and background color See also Edit Copy FEA Input Files ABAQUS Explicit inp Creates the simulation model for the FEA Simulation which can be loaded from the FEA system ABAQUS Explicit See also Output FEA ABAQUS FEA Input Files LS DYNA dyn Creates the simulation model for the FEA Simulation which can be loaded from the FEA system LS Dyna See also Output FEA LS Dyna Hints In order to import a partial project file pro use the func
408. ts in the calibrating stand C01 or a round tube exists in the welding station F01 Modify Strip Width After defining the desired profile cross section the strip width of the flat sheet is defined too sometimes the question comes up whether an already existing strip with a differing width can be used for forming this profile or whether a strip with a standard width can be used Another important application is If the roll tools are already designed the designer wants to know how a strip behaves between the rolls in case the width allowances are at the minimal and maximal limits For this purpose the function Modify Strip Width is provided It shortens or lengthens the profile elements at the left and right band edge in order to get the desired strip width Calling the function Call this function optionally by e Main menu Profile Modify Strip Width e Context menu right mouse button click on a profile element in the Drawing Area Profile Copyright 2015 by UBECO GmbH Iserlohn 90 UBECO PROFIL Rollform Design Software 3 1 3 8 Modify Strip Width e Profile List Window Enter the new width in the input field Strip Width TS a Enter new strip width 0 000 55 000 for the current pass only i for all passes X Cancel 7 Help After calling this function a dialog window is opened Enter the desired new strip width and select whether the new strip width should be effective
409. tube that has the same moments of inertia as the designed profile with any cross section The inertial radius is displayed separately for the X and Y direction the lower value is used to calculate the slenderness ratio of profiles that are loaded by longitudinal compression Imin A 1 min minimum inertial radius A Area of cross See also Statics 3 1 5 1 9 Area of Cross The area of cross is calculated by multiplication of strip width sum of all straight lengths and sheet thickness See also Statics 3 1 5 1 10 Weight The weight per meter is calculated by multiplication of the Area of Cross and density of the selected material for example steel 7 85 kg dma3 The calculation needs a valid material selection inside the Project Data Window In other case you will get a null weight Holes cut outs are not considered since input of count and length is not supported See also Statics 3 1 5 1 11 Principal Axes Angle The principal axes angle is the angle between the x main axis axis of maximal loading and the horizontal x axis of the drawing For symmetrical profiles the principal axes angle is either 0 or 90 dependent on the maximum length in x or y direction For asymmetrical profiles the principal axes angle can be any value between 45 and 135 See also Statics 3 1 5 1 12 Vault resistance If the load is not applied in the shear center point a vault of the profile will appear and this
410. ulation The LS Dyna Solver creates a set of d3plot files one for each stand that is opened with View FEA Result Open the project file pro that contains the belonging project Call this function optionally by e Main menu View FEA Result LS Dyna e ER Button View FEA Result in the Button Key Bar Principle of operation The FEA result is displayed as a 3D graphic Select the initial view port angle in Options Drawing or modify the angle by using the context menu right mouse button The button bar on the right enables you to modify the view Color Assign E Axl Assig Sho t All CO dy Stress 2 Stress 7 Strain Sheet Thickn amp Sheet Center Miror Symm l Color Assign By pressing this button the window Color Assign is opened By moving the tabs you can assign the colors blue and red to any strain stress and sheet thickness Furthermore you can select whether all 5 layers within the sheet thickness should get different colors Assign All or if the color of all layers should be assigned to the stress strain thickness of the centerline of the sheet Assign Sheet Center The last one is useful if you do not want to see the desirable stress and strain on the sheet top or bottom surface but only the undesirable deformation of the sheet center In case of a symmetrical profile only one half is simulated for optimizing the calculation time Select if the result should be mirrored automatically Mirror Symm Autom
411. unction activate either the left or the right corner of the roll to define whether the extension should be left or right Call this function optionally by e Main menu Rolls Conical Extension e Context menu right mouse button click on the left or right corner of the desired roll in the Drawing Area Conical Extension The input window appears and asks Give width for the conical extension or Give diameter for the conical extension In case of Width you can select between relative By Width and absolute To Width In case of By Width the input can be negative in order to get a smaller roll Principle of operation The conical extension will be attached to the selected roll corner If further rolls exist they will be moved in case there is not enough space between the rolls The new coordinates of the Corner Point will be calculated Hint Alternatively you can append a Cylindrical Extension or an Arched Extension Cylindrical Extension Use this function to add a cylindrical extension to the beginning or the end of a roll This will be regularly necessary if you created the roll with function Scan Profile Drawing and the roll set should have more width than the profile itself The extension can be negative in order to geta smaller roll Cylindrical means that start and end of the contour will be lengthened parallel to the axis You define the amount either or e by width relative e to width absolute Calling the functio
412. ur to read the contour file and to generate a Profile List In case of a symmetrical profile append a profile element PS in case of an asymmetrical profile enter P instead and repeat contour import for the second half of the profile as described above Before reading the contour file activate the next row behind P If you use the ActiveX interface both halves and the point P are created at the same time Example You create the following drawing inside your CAD system After reading the contour into PROFIL and after appending a profile element PS at the end of the profile list you get the following profile Searching for similar profiles If a similar profile is manufactured already in the past the designer wants to base upon the experience To find quickly the older profile project the profile catalogue is helpful To search for a similar project proceed as follows Open the Profile Catalogue and create a Filter with the desired filter conditions e g outer dimensions or classification key If a suitable filter already exists you only need to select it from the drop down list See Filter for more info After defining the filter click on the button Filter On This causes the profile catalogue to show only the profiles that match the filter conditions Browse through the filtered profiles and select a suitable one Click on Open Profile Project Copyright 2015 by UBECO GmbH Iserlohn 34 UBECO PROFIL Rollform Design S
413. ut If this option is checked together with Create ODB file the data are written into the ODB file and can be evaluated by ABAQUS CAE Machine Meshing Transv Meshing Long Files Machine Material Contact Others Rolling Speed 37 000 m min x Cancel Hilfe Rolling Speed Select the strip speed of the roll forming machine Material FEA Parameters ABAQUS q 2 x Meshing Transw Meshing Long Files Machine Material Contact Others Stress Strain Curve Material File C PROFIL32 ST14 mat Stress Strain a Material Name st1 4 377 0 ES 382 2 0 0001 Description Bemerkungen 0 0003 Young s Modulus 207000 N mm 6 0 0028 Poisson Ratio 0 280 MSS 3 0 0115 Density 7 8500 Kg dm3 0 01 92 3 0 0294 Import TXT Curve Generator 5 0 0425 y Material File Select the name of the material file All material data of this tab window are read from this file and are saved into this file The file name extension is mat Material Name Description for describing the material Young s Modulus Poisson Ratio Density Enter the material properties Stress Strain Curve Enter the points of the stress strain curve The left column Stress should contain the true stress related to the current area not to the original area The right column Strain contains the true logarithmic plastic strain this means the true strain minus the elastic strain Get more
414. view the file based parts list to change it and to print it Calling the function Precondition You have generated the parts list by using the function Output Create Parts List and in Options Parts List is checked Parts List to Text File select View Rolls Call this function by e Main menu Output Edit Parts List Principle of operation The text editor set in Options General will be opened with the parts list Hint e Because the text editor is an independent program it must be closed manually Otherwise it will keep open in the background Create NC 0A4865 R01 U1 N10 G71 N20 G01 XO ZO N30 G01 X98 Z0 N40 GO3 X100 Z 1 10 K 1 N50 G01 00 Z 9 5 01 Z 10 10 5 KO 27 Z 11 10 K 1 20 G02 X100 Z 50 5 10 K 0 5 I 1 KO 60A4865 R01 01 N10 G7 N20 G01 XO ZO N30 G01 X105 4 ZO N40 G03 X107 4 Z 1 I0 K 1 N50 G01 X107 4 2 22 N60 G02 X107 4 Z 23 IO K0 414 N70 GOL X0 2 23 N80 M30 Use this function to generate the NC programs for all rolls of your Profile Project Calling the function Before you create NC data you should use the function Calculate Plausibility Check to check the whole profile project on errors Select View Rolls Call this function by e Main menu Output Create NC Principle of operation A text file will be created with the name of the profile project but the file extension G00 The file contai
415. visible from the shaft A roll is created that touches the complete visible contour First open the Machine Window and enter the machine data Select the desired profile pass and define by using the function Profile Loaded whether you want to design the rolls for the discharged state or the loaded state This is useful to compensate the spring back Copyright 2015 by UBECO GmbH Iserlohn Tutorial 39 2 6 3 Select the drawing of the rolls by using function View Rolls Now the center lines of the shafts will be displayed Select one of the center lines for defining the type of roll Afterwards call function Roll Scan Profile Drawing lt W je Now a roll is generated and displayed that touches the complete visible contour of the profile and also existing rolls on other shafts Roll Design using the CAD System Choose this method especially if you want to give the rolls an individual form Preparing the roll contour inside the CAD system First draw the desired roll contour inside your CAD system It is very useful if you transfer the drawing of the profile pass to the CAD system function Drawing gt CAD if you use the contour of the pass for your drawing If you plan to design split rolls also create a contour line for all rolls of a shaft together You can proceed the splitting later Do not draw the roll edges the first and the last radial line of a roll and the center line these will
416. w Example 1 A profile U 50x20x2 50 wide 20 high 2mm sheet thickness 1mm inner radius is described by the following input into the profile list For explanation L LineLength 50 2 2 1 22 A Arc Left 1mm inner radius 90 degree L LineLengih 20 2 1 17 PS Point symmetrical Example 2 An unsymmetrical hat profile 45x24x2 45 wide 24 high 2mm sheet thickness 2mm inner radius is described by the following input into the profile list Thickness 2 L Length 10 A1 L Radius 2 Angle 90 L Length 16 Copyright 2015 by UBECO GmbH Iserlohn 32 UBECO PROFIL Rollform Design Software a AAA L Length 11 For explanation P Point unsymmetrical below it is the description of the left half Example 3 18 856 32 196 In case of a profile with oblique angles not 90 you normally do not know the lengths of the line segments Enter estimated values for x y and z Thickness 2 L Length x A1 L Radius 2 Angle 60 L Length y Afterwards dimension the profile as it is dimensioned in the specification drawing Now modify the lengths of the line segments by using the Toolbox Modify or by pressing the Pg Up Dn keys of the keyboard until the shown dimensions fit to the specification drawing If necessary set a small Step Interval Length in Options Mouse in order to reach the desired value exactly After the input of each profile element the drawing of the profi
417. w and can be set in Options Drawing too Filter Define filters in the top area at the left of the Profile Catalogue Window for reducing the amount of displayed profiles in the Profile Table in the bottom area of the window Each filter consists of a set of filter conditions logical AND conjunction and can be stored and recalled again Filtering can be switched on and off Filter Click on the arrow on the right of the input field and a drop down list is opened which contains all existing filters Select one of them and the according filter conditions are displayed in the table Table of Filter Conditions Name Select from the drop down list the name of the filter condition The names are at first all columns of the Profile Table Profile project Customer Descript and so on Furthermore all columns of the Profile Element Table can be selected but limited to the profile element numbers 1 8 Type 1 8 Dir 1 8 Radius 1 8 Angle 1 8 Size 1 8 Posit 1 8 St Length 1 8 Value Enter the value of the filter condition If the filter name in the same row determines a numerical field e g width the value has to be numerical too e g 156 3 In the other case an alpha numerical value can be entered e g Classif U100 50 Allowance Enter the allowance for the filter value Example If the filter value is 100 and the allowance is 0 1 all entities between 99 0 and 100 1 stay visible The column Allowance is only evaluat
418. w displays the data of one roll Copyright 2015 by UBECO GmbH Iserlohn 124 UBECO PROFIL Rollform Design Software e Roll Corner Table in the middle left can be switched to the Project Table This area displays the data of the roll selected in the roll table e Drawing Area top on the right This area displays the drawing of the roll selected in the roll table e Filter top on the left Any filters can be defined for reducing the amount of displayed rolls Stock Management Save Use this function to store selected rolls into the roll database Which rolls are stored you define by selecting one of the following sub functions and by marking a roll in the Drawing Area respectively e Roll The marked roll is stored e Shaft All rolls of a shaft are stored Define the shaft by marking any roll of the shaft e Stand All rolls of all shafts of one stand are stored e Project All rolls of all stands of the whole project are stored If the window Roll Stock Management is not yet open it will be opened after calling one of these functions Setup Roll Database and Profile Catalogue Path for Database CAPROFIL D ata Set the path to the roll database in Options Stock Management 3 1 4 23 Corner 3 1 4 23 1 Append Rolls are built of a count of Roll Corner Points that are shown in the Roll Tool Window Use this function to append a corner point to a roll e g if you want to modify the contour of a roll
419. w possibly shows not all stands of the machine but only the stands that are used in the project In this case the appropriate machine file should be imported first Both the import and the export function open the file selection window and show the machine file name that belongs to the project as default file name Further Import and Export functions for machine files are in the file menu of the PROFIL main window However the default file name here is the recently used file name for these functions The stand that is shown in the machine data window is linked up both with the stand that is selected in the explorer and that is shown in the drawing area in the main window So the stand can be selected in any of these three items the other two are updated This takes affect also for the selected shaft Because the machine data are handled within the project also the undo and redo functions are available Interactive operation The machine window works interactively with the drawing area similar to the profile list and roll tool window This means the effect of data modifications are shown in the drawing immediately Vice versa if the user selects or modifies drawing entities the content of the data windows is updated Multi Axles Additional Side Axles In order to form more complex roll formed profiles on a roll forming machine it often is necessary to have additional side axles with inclined angles that plunge into the open cross s
420. web at least Mostly however the transmission ratio 1 1 4 is used in order to have a larger top roll diameter bottom roll diameter x 1 4 This enables to produce profiles with larger vertical legs Roll Design Profile design by CAD drawing Numericalinput Toolbox Pass discharged Flower nested Flower 3D Dr Roll dy wren fes Parts list Sawing list NC program Each profile cross section needs a customized set of roll tools First after defining the final profile cross section the flower pattern has to be designed This means starting with the final section the cross section of the profile in each stand is defined by unbending the arcs Afterwards the rolls have to be designed by deriving the roll contour from the profile contour in each stand A special roll forming problem is the longitudinal strain within the sheet see below To avoid remaining strain and unwanted deformations it is necessary to check just in time if the longitudinal stress does not meet or exceed the yield stress During flower pattern creation the stress can be checked approximately by the Stress of Band Edge Calculation or by the Profile Copyright 2015 by UBECO GmbH Iserlohn General 11 Stress Calculation PSA After completion of the roll design the FEA method can be used for a final check It also helps to evaluate if the designed roll tools are able to form the desired profile with the given allowances Th
421. y attention that all materials have an increasing number for later identification The input field in front of the Edit button is useful for selecting the path to the material file e g if the file should be installed in a network path for common access User defined calculation methods Use the Edit button to call the text editor set in Options General with the Factor file Inside this file you can set User Defined Calculation Methods if you are not satisfied with default methods of Oehler or DIN 6935 With first installation of the system you will find two methods User1 and User2 The first one is an example for a factor method and the second for an addition method You can modify them for your own needs The input field in front of the Edit button is useful for selecting the path to the factor file e g if the file should be installed in a network path for common access Hint e Because the text editor is an independent program it must be closed manually Otherwise it will keep open in the background Arc Type A4 Arc Type 44 e Track Holding inside f outside Addition Part Previous Segment 50 Z Remainder West S f Modify angle constant radius C Modify angle and radius While bending the arc type A4 constant radius method see Arc Types the residual length is added to the previous and the next segment Select how the length should be partitioned Track Holding The length is partitioned automatically that the strip
422. y turning the wheel If you use a space mouse from 3DConnexion press the cap down or draw it upwards a Zoom Window Use this function to zoom by clicking two opposite corners of a rectangle for the new view port After clicking the first point a drag box is displayed in the predefined color for marked elements S Previous Zoom Use this function to recall the previous zoom You can repeat it 10 times Navigator 3D gt The Navigator 3D appears on the right side if you call View PSA Profile Stress Analysis or View FEA Result Use the arrow buttons to rotate the 3D view port The center button resets to the initial view port Setting in Options Drawing View Port Angle By clicking on the background area you can switch to the 2D view Zoom Pan left right Fan up down at a Tilt Spin Roll Space Mouse If you use a space mouse from 3DConnexion the motion controller allows pan zoom and rotate the model simultaneously The function keys are allocated by Key 1 Fit Navigator Key 2 Reset the initial view port Navigator 3D Key 3 Front view Key 4 Not allocated Key 5 Top view Key 6 Side view from the right Key 7 Side view from the left Copyright 2015 by UBECO GmbH Iserlohn Reference 205 3 2 6 Calculator 3 3 3 3 1 Cancel a The calculator can be opened from any input field s context menu Calling the function Call this function by e Right Mouse Button Calcula
423. y while designing step 2 can be called by key stroke in critical situations and step 3 should be used at the end of the design process for a final check if the designed roll tools are able to produce the desired profile FEA Finite Element Analysis Result of an FEA simulation shown in LS PrePost the user interface of LS Dyna Result of an FEA simulation shown in ABAQUS CAE the user interface of ABAQUS The simulation of the roll forming process by using FEA is the third step of the three step Quality Management concept The FEA Finite Element Analysis simulation gives the designer very precise information about stress and strain within the whole profile and about the cross sectional pattern of the final profile This enables him to validate and optimize his roll form design at an early stage before the rolls are manufactured to ensure that the final product meets the particular needs To proceed this very precise calculation of the stress and the longitudinal deformation within the Copyright 2015 by UBECO GmbH Iserlohn 30 UBECO PROFIL Rollform Design Software 2 4 2 4 1 whole profile an interface has been provided to the leading FEA systems LS DYNA from Livermore Software Technology Corp and ABAQUS Explicit from SIMULIA Dassault Syst mes The necessary steps are e Design the profile the flower pattern and the roll tools afterwards create the interface files by using the function Output FEA LS
424. you are asked to enter e 1 Dimension Point afterwards a drag line appears between the selected point and the cursor position e 2 Dimension Point afterwards a drag dimensioning appears between both selected dimensioning points and the cursor position as dimension text position e Dimension Text Position Afterwards the dimensioning appears Hint e See Toolbox Dimensioning for further information Vertical Dimension This function is a part of the Toolbox Dimensioning and can be used for a vertical dimensioning between two dimensioning points Calling the function Call this function by 1 Button Vertical Dimension from the Toolbox Dimensioning After calling this function you are asked to enter e 1 Dimension Point afterwards a drag line appears between the selected point and the cursor position e 2 Dimension Point afterwards a drag dimensioning appears between both selected dimensioning points and the cursor position as dimension text position e Dimension Text Position Afterward the dimensioning appears Hint e See Toolbox Dimensioning for further information Copyright 2015 by UBECO GmbH Iserlohn Reference 173 3 1 7 4 4 Parallel Dimension 3 1 7 4 5 s5 This function is a part of the Toolbox Dimensioning and can be used for a parallel dimensioning between two dimensioning points parallel to any drawing element for profile dimensioning only Calling the function C
425. you can change the path or drive if needed Project Preview On the right you see a quick preview of the profile and beneath it Customer Description and Drawing No and on the right the count of passes Principle of operation After selection the Project Data Window for the selected profile project and the Profile List Window for the first bending step finishing step appear The Drawing Area displays a preview of the drawing of the profile You get a message if you try to open a project that already is opened by another user Then the project is opened on approval only shown in the top line and you cannot save the file In order to edit the file reopen it after the other user has saved it lt is possible to use Save As to save the project under a different file name Setup i Open Project and Explorer with preview While working with larger projects the screen refresh takes more time because of the refresh of Copyright 2015 by UBECO GmbH Iserlohn 48 UBECO PROFIL Rollform Design Software 3 1 1 3 3 1 1 4 3 1 1 5 the preview This may impede quick working Simply switch off the preview in Options General Hint See also Partial Project Add On Save Project Use this function to save the Profile Project after designing or after modification The project is saved into the project file that is displayed in the top bar of the main window Calling the function Call this function
426. you can copy it to another position in order create the detailed part At the same time the dimensioning appears if you attached dimensioning in the Drawing Area of the main window previously If you pick up an object which is copied already it is now moved in order to position it precisely e Right mouse button The context menu drops down and you can select if all objects should be moved or how a single object should be handled copy move rotate mirror or delete Furthermore you can switch on and off the dimensioning of an object a Open template Open a DXF file that contains a Drawing Template this is a drawing frame and a title block Use one of the existing templates or define a template by yourself by using any CAD system If the template contains Variables they are replaced by the drawing objects or texts of the current drawing or project m Save template Save the current Drawing Template to a DXF file with any name The drawing frame the title block and all fixed texts are saved to the file The drawing objects and the variable texts are not saved instead of them Variables are saved which are replaced by the belonging drawing objects or texts when the template is reopened from another stand or project Copy drawing to clipboard Use this button to copy the whole assembly drawing to the Windows clipboard see also Edit Copy E Plot To Scale The plotting scale of the drawing template always is 1 1 The content of the

PROFIL User Manual

Contents

Download Pdf Manuals

Related Search

Related Contents