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Round Tubes & Rectangular Tubes 
Shaped Tubes and Drawing Rings
COPRA® RF Software
User Manual  .  General Functions
 
 
© Copyright by data M Software GmbH  
 
 
© Copyright data M Software GmbH 
 
 
 
 
 
Unlawful reproduction, in any way, of this manual and its contents is strictly prohibited. 
 
data M Software GmbH makes no warranty, either expressed or implied, regarding 
these materials and makes these materials available solely on an "As is" basis. In 
no event shall data M Software GmbH be liable to anyone for special, collateral, 
incidental, or consequential damages in connection with the use of the materials 
provided. 
 
The sole liability to data M Software GmbH shall not exceed the purchase price of 
the materials described herein. 
 
Information in the manual is subject to change without notice and does not represent a 
commitment on the part of the vendor. The software described in this manual is furnished 
under a license agreement and may be used or copied only in accordance with the terms 
of the agreement. 
 
 
 
 
 
 
 
 
 
 
 
 
 
Copyright© data M Software GmbH 
All Rights Reserved 
data M Software GmbH 
Am Marschallfeld 17 
D-83626 Valley/Oberlaindern 
Germany 
www.datam.de  
 
Table of Contents 
© Copyright by data M Software GmbH  
 
I 
Table of Contents 
General Functions 
1 
1. Shortcuts 
1 
2. Entity Selection 
2 
3. COPRA® Memory 
2 
3.1. COPRA® Database 
2 
3.2. Computer RAM 
3 
3.3. The CPM File 
3 
3.4. Archive Files 
4 
4. 
The COPRA® Explorer with CADFinder 
5 
4.1. 
CADFinder/The box Project data 
5 
4.2. Flower 
6 
4.2.1. Flower data 
6 
4.2.2. Pass (x) 
6 
4.3. Rolls 
7 
4.3.1. Station 
7 
4.3.2. Axis 
7 
4.3.3. Roll Data and Attributes 
7 
COPRA® Basictools 
8 
1. The COPRA® toolbar 
8 
1.1. Starting COPRA® 
8 
1.2. Project Manager – Please do no longer use 
8 
1.2.1. Dialogue box: Project Manager 
9 
1.3. The Base Functions toolbar 
11 
1.3.1. Settings 
11 
1.3.2. 
Material Choice 
14 
1.3.3. 
Station Attributes 
15 
1.3.4. 
Roll numbering 
16 
1.3.5. COPRA® Zoom on/off! 
17 
1.3.6. Create Project Slide! 
17 
1.3.7. Save current Project! 
18 
1.3.8. Reload current Project! 
18 
1.3.9. Erase COPRA® Database 
18 
1.3.10. Erase Screen! 
18 
1.3.11. Create COPRA® Polyline 
19 
1.3.12. COPRA® Screen Menu 
19 
2. The COPRA® Database toolbar 
19 
2.1. View Flower 
19 
2.2. Get Pass 
19 
2.3. Save Pass 
20 
2.4. Delete Pass(es) 
20 
2.5. Append Pass 
20 
Table of Contents 
II 
 
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2.6. Insert Pass 
20 
2.7. Fade-in Profile 
21 
2.8. Fade in Rolls 
21 
3. The COPRA® Utils toolbar 
21 
3.1. COPRA® Copy 
21 
3.2. COPRA® Paste 
21 
3.3. COPRA® DB Undo 
21 
3.4. COPRA® DB Redo 
22 
3.5. COPRA® Redraw 
22 
3.6. Entity Information 
22 
3.7. COPRA®? 
22 
4. Machine file for bearing seats 
22 
4.1. Modify 
23 
4.1.1. Pre-settings for creation of drawing 
23 
4.1.1.1. Settings Assembly Plan Dimensioning 
23 
4.1.1.2. Breakdown/Fin Pass 
24 
4.1.1.3. Intermediate/Idler Pass 
24 
4.2. Copy 
25 
4.3. Delete 
25 
4.4. Identifications 
25 
4.5. Current Machine 
25 
5. Convert Database 
25 
5.1. Action 
26 
5.2. Reference 
27 
COPRA® Round & Rectangular Tubes 
28 
1. Archive Files 
28 
2. The Flower toolbar 
29 
2.1. Plane of Unfolding 
29 
2.2. Unfolding 
30 
2.3. Fold 
31 
2.4. Automatic Unfolding 
32 
2.5. Execute Unfolding 
33 
2.6. Dynamic Flower 
33 
2.7. Dynamic Unfolding 
34 
2.8. Dynamic Folding 
34 
2.9. Symmetrical Profiles 
34 
2.10. Calibrate 
34 
2.10.1. Constant Radius Method 
35 
2.10.2. Constant Length of Neutral Line Method 
35 
2.10.3. Track-holding Method 
36 
2.10.4. Angle/Radius Method 
36 
2.10.5. Power Bending Method 
37 
2.11. Reference Point 
38 
2.12. The Profile Utilities toolbar 
39 
2.12.1. Edit Profile Section 
39 
2.12.2. Move Profile 
43 
2.12.3. Rotate Profile 
43 
2.12.4. Split Entity 
44 
2.12.5. Join Entities 
44 
Table of Contents 
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III 
2.12.6. Join All Entities 
44 
2.12.7. Same Number of Entities for 2 Profiles 
44 
2.13. The Profil Utils toolbar 
45 
2.13.1. Write Part of Profile to File 
45 
2.13.2. Read Part of a Profile from File 
45 
2.13.3. Write a Sequence of Passes to File 
46 
2.13.4. Read a Sequence of Passes into Flower 
46 
2.13.5. Material Thickness 
46 
3. Tubemill map Selection 
47 
3.1. Selected Tubemill map 
48 
3.2. Import/Export 
48 
4. The Tubemill map Layout 
50 
5. Flower (round Tube) 
51 
5.1. List of Additions 
52 
5.2. Strip Width 
54 
5.3. Forming Steps 
55 
5.3.1. No. of Arcs 
55 
5.3.2. Calculations 
56 
5.3.2.1. Calculation Method 
56 
5.3.3. Ovalism 
57 
5.3.4. Angle 
58 
5.3.5. Radii 
59 
5.3.6. Fin Width 
59 
5.3.7. Arc Length 
60 
5.3.8. Profile Data 
61 
5.4. Use Calculations 
63 
5.5. Parameter 
63 
5.6. Replace Data 
64 
5.7. Constant Point of Gravity in sizing Stations 
65 
5.8. OK. 
65 
5.9. Flower 
65 
5.10. Flower and Rolls 
65 
5.11. And Project Slide 
65 
6. Flower (rectangular Tube) 
65 
7. Tubemill map Data 
67 
7.1. Machine File for Bore Details 
69 
7.1.1. The toggle: Name from Tubemill map 
70 
7.2. Type of Station 
70 
7.3. Horizontal Centres 
71 
7.4. Axes 
71 
7.5. Root Diameter 
73 
7.6. Minimum Roll Width 
75 
7.7. Diameter Defaults 
76 
7.8. Roll Distance and Gaps 
81 
7.9. Width Defaults 
82 
7.10. Parameter 
84 
7.11. The Block round Driven Rolls 
86 
7.12. The Block round Idler Rolls 
86 
7.13. The Block min. Gap 
86 
8. Tubemill map Roll Design Set-up 
87 
8.1. Type of Station 
88 
Table of Contents 
IV 
 
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8.2. Roll Widths 
89 
8.2.1. Roll Width Top/Bottom Roll 
89 
8.2.2. Roll Width Side Rolls 
90 
8.3. 4 Axes Station 
91 
8.4. Relief Angles and Radii 
92 
8.5. Chamfers and Fillet Radii 
93 
8.5.1. From Parameter 
95 
8.6. Ø List Blanks 
95 
8.6.1. RDL 
96 
8.7. Parameter 
96 
8.8. Machine and Roll Data 
98 
8.9. Max. Wall Thickness 
98 
8.10. Replace Data 
98 
9. Parametric Roll 
100 
9.1. Machine Data 
100 
9.2. Roll Data 
100 
10. Special Solutions in the COPRA® Tubemill map 
101 
10.1. Symmetrical Turk heads 
101 
10.2. 4 Axis Sizing Pass 
101 
10.3. Split Bottom Rolls 
101 
10.4. Define welding point new 
101 
10.5. Which Station Types can be used when? 
102 
10.6. Placing the Dependencies for the Forming 
102 
10.7. How to form a Rectangular Tube? 
102 
10.8. Create Flower new 
103 
10.9. How to design oval Side Rolls in the Forming? 
103 
10.10. Which Profiles can be designed in the Tubemill map? 
103 
10.11. How to set the Gap between the Turk head rolls on zero? 
103 
10.12. How to append a Pass ( Straightener )? 
103 
10.13. How to increase the Forming Radius on the Breakdown Rolls? 
103 
10.14. How to set the Diameters D1 and D2 in the Fin Pass equal? 
104 
10.15. Why is there a Gap in the flower when the Roll is closed? 
104 
10.16. How to get 4 Axes in Sizing Pass? 
104 
10.17. How to set or change the Gap Width? 
104 
10.18. Structure of the Tubemill map 
104 
10.18.1. Project Manager 
105 
10.18.2. Tubemill map Selection 
105 
10.19. Which Role does the Writing of an Archive File have? 
106 
COPRA® Shaped Tubes and Draw-rings 
107 
1. The Special Shapes/Draw-rings toolbar 
107 
1.1. CAD Profile 
107 
1.1.1. Redefine welding point 
108 
1.2. Unfolding Plane 
108 
1.3. Execute Transformation 
109 
1.3.1. Angle Modification 
110 
1.3.1.1. The Block Shaping Steps 
110 
1.3.1.2. Distribution 
111 
1.3.1.3. Optimisation Settings 
111 
1.3.1.4. Compression 
114 
1.3.1.5. Compression settings 
114 
Table of Contents 
© Copyright by data M Software GmbH  
 
V 
1.3.1.6. Distribution in Profile 
115 
1.3.2. Theoretical Basic Knowledge 
116 
1.3.3. Entities of shaping Steps 
116 
1.3.4. Compression Factor 
117 
1.3.5. Optimising Methods 
118 
1.3.5.1. Power Fit 
118 
1.3.5.2. Best Fit 
120 
1.3.5.3. Angle Fit 
120 
1.3.5.4. Percent Range 
120 
1.3.6. Topographical 
120 
1.3.6.1. Curve of Contour 
121 
1.3.6.2. Fillet Radius 
123 
1.3.6.3. Curve Parameter b 
125 
1.4. Optimise one Pass 
126 
1.4.1. Close Section 
126 
1.4.2. Optimisation Settings 
126 
1.4.3. Modify Section 
126 
1.4.4. Change Bend 
131 
1.4.5. Change Radius tangentially 
131 
1.5. Create 3D Draw-ring 
131 
2. The Profile Utilities toolbar 
132 
2.1. Edit Profile 
132 
2.2. Move Profile 
136 
2.3. Rotate Profile 
136 
2.4. Split Entity 
137 
2.5. Join Entities 
137 
2.6. Join all Entities 
137 
2.7. Same Number of Entities for 2 Profiles 
137 
 
 
General Functions 
 
Shortcuts 
© Copyright by data M Software GmbH  
 
1 
General Functions 
 You will find important tips, which you should follow under this sym-
bol. 
 Under the star symbol you find useful tips. 
 
1. Shortcuts 
In the modules Profile, Flower, Rolls and NC Data’s the shortcuts "+", "-",  
"+-", "++" and "--" are available. 
 If changes are made you will be asked whether the changes should be sa-
ved in the last actual pass.  
Please note that that pass number 1 is the end profile, if numbering with 
passes is chosen. If numbering with stations is chosen station number 0 or 1 
(depending on your settings) is the flat strip. You may chose the numbering 
in COPRA® Settings – Pass- and Roll-numbering. . 
 
(+) 
The shortcut "+" loads the data of the next higher pass number from the data-
base. If the current pass is the last saved in the database, then pass number one 
will be loaded. 
(-) 
The shortcut "-" loads the data of the next lower pass number from the database. 
If pass number one is the current one, the highest pass number will be loaded. 
(+-) 
The shortcut "+-" loads the data of the current pass from the database. So all not 
yet saved changes in a pass will be reserved.  
(++) 
The shortcut "++" loads the last pass / end profile of the flower from the data-
base. 
(--) 
The shortcut "--" loads the first pass / first station of the flower from the database. 
General Functions 
 
Entity Selection 
2 
 
© Copyright by data M Software GmbH  
2. Entity Selection 
Some COPRA® dialogue boxes supply a list of entities for modification purposes. 
Entities can be highlighted in the list using the crosshairs and then be modified. To 
modify multiple entities in the same way it is possible to highlight all the entities to 
be modified in the list. 
 The limits of the, from and to values, are within the filter selection set. 
 If the Use Filter for bend angle and Use Filter for Radius are both se-
lected, only those entities will be taken care of when selecting the Select! or 
Deselect!, which match both the angle and the radius of the filter selection 
set. 
 
3. COPRA® Memory 
3.1. COPRA® Database 
All data of a project are saved in the COPRA® database on the hard disk of your 
computer. This is project information, common data and the geometry of sections 
and rolls of all passes. The database covers the COPRA® work files. 
 
The database consists of the following files: 
• ALLGEM.DB  
→ Project information 
• PROFIL.DB 
 
→ Section data of all passes 
• RAHMEN.DB  
→ intern data 
• VERWTG.DB  
→ Administration of the passes 
• WALZEN.DB  
→ Roll data of all passes 
 
All database files are saved in the project directory. To modify the data of a pass, 
they need to be loaded into the computer memory. After the current pass data has 
been modified, it is written to and updated on, the hard disk database. 
 
There are various possibilities to save the data of the current pass to hard disk: 
• The current pass is saved with the Save DB option. 
• A new pass is loaded into the computer memory with the Get Show option 
and the Save current pass is selected. 
• The Save current pass option is selected when exiting a module. 
General Functions 
 
COPRA® Memory 
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3 
3.2. Computer RAM 
In the computer memory, only the data of one individual pass are loaded. 
 Only the data of one pass can be loaded into the computer memory. 
This is the current pass. 
 In case of a computer breakdown only the modifications made to the current 
pass will be lost. 
 
Modifications made to a pass are only saved in the computer memory until a Save 
to database is being executed. 
 The design work made with COPRA® is very much faster if, in the first step, 
modifications are only made in the computer memory. 
 Exiting AutoCAD without saving the current pass may cause a loss of 
data that are only available in the computer memory. 
 
3.3. The CPM File 
When opening a new project from the project directory, a project file with the na-
me "PROJECT".CPM will automatically be created. In this project directory all 5 
files of the database with the extension *.DB are saved. 
 The 5 work files *.DB of the database are saved compressed in the project 
file. This saves a lot of disk space. To have access to the project data the 
project file has to be uncompressed. The database files will be created when 
uncompressing a project file. 
 
The project file should be used to save the latest design situation. 
 
 If a project file with the latest design situation is existing, it is possible to do 
test modifications on the project. If the modifications should be discarded, the 
original design situation can be reloaded from the project file. If the modifica-
tions are OK, the new design situation can be saved in the project file. 
 
The information of the current project is saved in the project file. When fin-
ishing a project, the data of the last design situation should be saved in the 
project file. All data concerning the section, the flower or the rolls can be 
used if later modifications of the project should be necessary. 
General Functions 
 
COPRA® Memory 
4 
 
© Copyright by data M Software GmbH  
3.4. Archive Files 
 
Function: 
Important design steps should be saved in Archive files 
An Archive file has the same file format as the Project file. 
 In Archive files the 5 database files *.DB are also saved compressed and 
therefore cannot be modified directly. 
 Opposite to the one Project file, as many as necessary Archive files may be 
created. 
 
The Archive files should be used to save important steps in the design. It is like a 
snapshot of the current design situation. Especially after having worked with the 
modules Profile, Flower and Rolls it makes sense to create an Archive file. 
 Archive files can be very useful if changes need to be made to the project or 
if a similar section has to be designed later. 
 
The project file is always located in the project directory. The project file-
name cannot be changed. The location of the Archive files, as well as the 
Archive file names, are defined by the user. 
 
The COPRA® database was changed several times since the first re-
lease. Therefore it may happen that an old database would have to be 
converted first. Archive files of previous releases can always be 
loaded. Therefore all COPRA® databases should also be saved as Ar-
chive files. Before old Archive files are loaded a new project should be 
created with the Project Manager. 
General Functions 
 
The COPRA® Explorer with CADFinder 
© Copyright by data M Software GmbH  
 
5 
4. 
The COPRA® Explorer with CADFinder 
 
Function: 
Quick navigation during design 
 
The COPRA® Explorer allows a quick navigation during design and provides a 
clearly-structured overview of the existing projects. With the help of files it is pos-
sible to page between the individual stations and to determine their profile and roll 
data. Radii, angles and neutral line can be checked quickly. Furthermore, you can 
select another option by clicking the mouse, e.g. a different pass number. The 
pass number incl. the required data will then be automatically displayed as the 
current pass. COPRA® Explorer can be switched on in the toolbar COPRA® Ex-
plorer. 
 
The COPRA® Explorer is divided into the main options Flower, Project, Rolls and 
CADFinder. 
4.1. 
CADFinder/The box Project data  
All data concerning your COPRA® project are displayed in this box. It can be o-
pened via the button “Projects” in Explorer. If you click the current project with right 
mouse key opens a window. Click on Properties (at the bottom of the box) to 
open the dialogue Project Properties .  
You may see and change the name of your project under Project name. Below 
the Project name is the Project path displayed. Click the button 
 in order to 
change the Project path. Next are the items Project comment and Document 
no.-prefix listed. 
A click on the button Attribute opens the dialogue Project attributes. You may 
define general Project attributes such as Company or Profile Number further 
you may modify COPRA® Project attributes as Sheet Thickness. Confirm with 
Accept for saving changes.  
What are the features of this solution? 
COPRA® CADFinder is a document management system that allows also to or-
ganise any files independent from a defined file structure on a storage device. To 
do so the user creates a nested project structure. The documents can then be 
assigned to a project in this structure via a document number. The organisation of 
the documents and the assignment to the physical file path is done by a data base 
server (e.g. MS SQL Server or an alternative data base with SQL and ODBC sup-
port for the multi user version or the MSDE data base in a single user environ-
ment). 
 
Furthermore user defined attributes can be linked with projects and documents. 
This ensures a fast retrieving of documents via specific search functions. These 
attributes in the COPRA® version of CAD-Finder may also be used to complete 
the title block information in an AutoCAD template. 
General Functions 
 
The COPRA® Explorer with CADFinder 
6 
 
© Copyright by data M Software GmbH  
Also a structured view of projects (project manager) and belonging documents as 
any number of flexible working catalogues are available for displaying different 
search results. From here the individual documents can be opened, modified, 
completed with new attributes, copied and moved very easy and comfortable. The 
design of the structured view is similar to the Microsoft Windows-Explorer in order 
to guarantee an intuitive working in a well known environment.   
 
A revision control and workflow system is also available for the individual docu-
ments. So an older version of a document may be – if desired – saved before 
modifying in order to have access to previous releases of this document. The his-
tory of a file may be saved. The link to the respective project is maintained. So for 
a document multiple work situations may be saved. The workflow system recog-
nizes if a user works on a document and sets the workflow status to "Modifica-
tion". In that case any other user may only view the document. When the modifica-
tions have been completed the status is set back and the document may be modi-
fied by another user. Any number of workflow situations maybe defined by the 
user. 
 
Please refer to the COPRA® RF CADFinder manual for a detailed explanation 
as well as further information. 
 
4.2. Flower 
By pressing the button "Flower" appears a list with all passes .  
4.2.1. Flower data 
The flower data box gives you information about the number of elements, outside 
and inside length of the profile, the length of the centre and neutral line - as well 
as the value oft strip width. 
4.2.2. Pass (x) 
All passes of the design are listed under Flower. Double click on a pass opens the 
pass automatically in model view. If you click on the + sign of any station a further 
list with all elements the profile consists of in the selected pass is displayed. You 
will get detailed information about the arcs and straight entities the profile consists 
of if you double click on any element. 
Arcs: 
Double clicking on an arc element opens a small box giving information about the 
neutral line, radii and angle. 
Lines: 
Double clicking on a line element opens a small box giving information about the 
length and the start angle of the straight element. 
General Functions 
 
The COPRA® Explorer with CADFinder 
© Copyright by data M Software GmbH  
 
7 
4.3. Rolls 
By click on "Rollers" are all Stations, their axes and rolls listed in a box. The button 
station attributes appears if you select a station and click it with right mouse key. 
Please refer to Station attributes for further information about station attributes. 
4.3.1. Station 
By double click on a station or by clicking on the + sign, all side, top and bottom 
axes are listed. 
4.3.2. Axis 
By click on Axis top/bottom/left or right opens a list with all existing rolls. The start 
and endpoint coordinates of the axis are listed. 
4.3.3. Roll Data and Attributes 
By click on any listed roll appears a list showing the following parameters under 
roll data: 
• 
Roll name 
• Maximum width 
• Maximum diameter 
• 
Number of entities 
• 
Roll type 
• Weight 
 
By click on any listed roll appears under attributes a list showing all available at-
tributes like: 
 
• Material 
• 
Roll bore 
• 
Keyway 
• 
Roll type top 
• 
Roll type bottom 
• 
Combination roll 
• 
Stamping number 
• 
Stamping groove width 
• 
Stamping groove depth 
• 
Inner diameter 
• 
Bearing 
• 
Roll number 
• 
Roll type  
COPRA® Basictools 
 
The COPRA® toolbar 
8 
 
© Copyright by data M Software GmbH  
COPRA® Basictools 
1. The COPRA® toolbar 
 
 
 
In the COPRA® toolbar the following functions are involved: 
  The icons containing a small black triangle in the lower right corner can be 
expanded with a click of the left mouse key so that additional information will 
be available.  
1.1. Starting COPRA® 
 
Function: 
Initialise the COPRA® Roll form Software, or flip back to the last, active screen menu page. 
During initialisation of COPRA®, the system checks whether the required settings 
are available. For example, all layers required by COPRA® will be created auto-
matically. If the AutoCAD commands of the Screen menu are used during design-
ing, it will always be possible to return to the last active screen menu.  
This has to be the first command after AutoCAD has been loaded or a new draw-
ing has been created. The last actual project is loaded automatically. 
1.2. Project Manager – Please do no longer use 
In previous COPRA® version was this function used to create an manage projects. 
But now COPRA®´s latest function, the COPRA® RF CADFinder may be used for 
that – see COPRA® RF CADFinder manual. The old COPRA® project manager will 
no longer be available in the next upcoming COPRA® version. . 
 If a project is set current in COPRA® CADFinder it will also be the current one 
in project manager and the other way round.  
 
 
Function: 
Create new, display or update existing projects 
The COPRA® Project Manager is a tool for easy project administration. All pro-
jects ever created with the Project Manager will appear in a project list.  
 One directory may contain one project only. 
COPRA® Basictools 
 
The COPRA® toolbar 
© Copyright by data M Software GmbH  
 
9 
1.2.1. Dialogue box: Project Manager 
Last current: 
Shows the current project and its path. 
Selected: 
Shows the selected project and its path. 
Project Mainfolder: 
Shows the selected main directory. An additional main directory for projects can 
be created. 
 COPRA® Setting files and prototype drawings should always be set.  
More: 
It can be used to reload projects, which have been removed from the project list. If 
selected, a file dialogue box for project files will be opened. Project files do have 
the extension .CPM. A double click on the filename or highlighting it and pressing 
OK, brings this project back into the project list. 
Sort Projects: 
The project list can be sorted in alphabetical, chronological order or in groups.  
New:  
A new project can be created when selecting this button. If the directory of the pro-
ject path selected does not yet exist the user has to confirm the creation of the 
directory. The project path defines the directory where the COPRA® database and 
its related files will be saved. If the directory was created, the Material’s dialogue 
box comes up and the coil material used has to be selected. It can be selected, 
either from the list box or, if a proper material is not yet available, be created by 
the user with the help of Create. The selected material is the default for all techni-
cal calculations like Spring-back and Deformation Technology. 
 
data M Software does not guarantee that the material properties ship-
ped with COPRA® are correct as the natural deviations of the coil ma-
terial may be quite high. 
 
After confirmation of the material, additional project information can be entered.  
This information is optional and may be left blank. 
COPRA® Basictools 
 
The COPRA® toolbar 
10 
 
© Copyright by data M Software GmbH  
Save:  
Compresses and saves the current design data of the COPRA® database to the 
project file. When exiting the modules Profile, Flower or Rolls, the project file 
may be updated automatically by appropriate selection. 
 This function can also be used outside the Project Manager by selecting the 
Save current Project, option from the pull-down menu. 
Modify:  
Project name and project directory can be modified. 
Copy: 
Copies an existing project to another directory, which can be selected.  
Remove:  
Removes the highlighted project name from the project list. The project data it-
self are not removed from the hard disk. A project that has been removed from 
the project list can be reloaded by using the <more...> button (see <more...>). 
Info:  
Information about the highlighted project will be displayed and can be changed if 
necessary. In the headline of the box selected Project name, Project path, Pro-
ject file and Material are shown. The additional information shown can be modi-
fied and customised. The material Thickness entered is the one used when de-
signing a new section. Customer, Product, Drawing Number, Design Date, De-
signer and Comment can be entered optionally. 
Material:  
Shows the coil material used for the highlighted project.  
COPRA® Basictools 
 
The COPRA® toolbar 
© Copyright by data M Software GmbH  
 
11 
1.3. The Base Functions toolbar 
 
 
 
 
Function: 
Lists all basic functions of COPRA®. See the following descriptions: 
1.3.1. Settings 
 
Function: 
Change the default settings of COPRA®  
Language: 
The desired language can be selected in the list box. Languages are connected 
with the unit (mm) except English (US), which is connected with the unit (inch). 
Centre of Profile: 
Displays the section’s centre line. 
Split Lines in Profile: 
If toggle is set, split lines between arcs and lines will be shown. 
Automatic Zoom:  
If selected, a ZOOM EXTENTS and ZOOM <FACTOR>x is done after every 
modification. The factor may be set to values between 0.5 and 1.0. If case the fac-
tor is set to 1.0 the ZOOM <FACTOR> option will not be executed. 
Automatic redraw:  
If selected, an automatic redraw is done when loading a new module. The screen 
is updated with the current section and/or rolls. The current drawing entities will be 
erased depending on the updating screen setting in the bottom of this dialogue 
box. 
Fade out Plane of Unfolding: 
If this feature is active, the plane of unfolding will be faded out.  
Fade in next Section: 
If selected, the next section saved in the COPRA® database is also being dis-
played on the screen. 
COPRA® Basictools 
 
The COPRA® toolbar 
12 
 
© Copyright by data M Software GmbH  
Fade in previous Section:  
If selected, the previous section saved in the COPRA® database is also being dis-
played on the screen.  
Pass and Roll Numbers:  
Gives access to all options regarding pass or roll designations. By selecting the 
Fade in spacer dimensions, option the widths and diameters of the space rings 
will be faded in. 
 Please refer to chapter Rollnumbering in COPRA® Rolldesign & Rolltechnol-
ogy manual, too.  
Numbering of the different Stations: 
The numbering with station provides with further options, like separate numbering 
with station types.  
Use COPRA® Numbering: 
The standard COPRA® numbering with passes or stations will be used. 
All continuing: 
If your stations should be numbered continuously select the button next to All 
continuing.  
The resp. stations separated: 
If you would like to have a separate numbering for each station type enable the 
checkbox The resp. stations separated, please. This means that the station 
types will have an own numbering within their group e.g. Turk head 1, Turk head 2 
and so on. 
 Please refer to the in following explained point “Rollnumbering”, too. You 
have got the possibility to create individual roll numbers. 
Idlerstations: 
Enable the toggle Idlerstations if you would like to have a separate numbering for 
the intermediate stations in addition to All continuing or The resp. stations 
separated. In this case the idler stations will be as such identifiable and their 
numbering will eg. be 1-2 . 
COPRA® Basictools 
 
The COPRA® toolbar 
© Copyright by data M Software GmbH  
 
13 
Attach stationtype to profilenumber: 
Enable the toggle Attach stationtype to profilenumber in order to make the sta-
tion type always visible. Thereby the chosen station type (eg. calibration idler sta-
tion) will be attached to the profile number when updating screen.  
Layer Control: 
Allows modification of all COPRA® layers according to his/her requirements. 
COPRA® Paths:  
Provides an overview of all paths used by COPRA® for the current project. Names 
can be modified according to your requirements. 
Technology: 
Determines the decimal signs used during export. 
COPRA® Options: 
Provides the option to fade in dialogue boxes for the selection of functions. Fur-
thermore, the settings for automatic background backups can be defined. Up to 30 
archive files can be backed up, i.e. the 31st file will overwrite the first file etc.  
Contours as Polylines: 
If selected, all section and roll contours are drawn as polylines.  
Clear only COPRA® Layers when updating Screen: 
If selected, all drawing entities placed on COPRA® layers will be erased when a 
COPRA® Redraw (C Redraw) or any other updating of the screen is being made, 
e.g. when using the command Get&Show. 
If not selected, all drawing entities will be erased when a COPRA® Redraw (C Re-
draw) or any other refreshing of the screen is being made, e.g. when using the 
command Get&Show. 
This option is very useful when e.g. designing the rolls. For the construction lines a 
layer of its own can be created. If selected, all construction lines will still be visible 
after the COPRA® Redraw or Get&Show command has been executed.  
A typical example is to connect the endpoints of the roll axis with a construction 
line and use this to create the necessary offset lines to get e.g. even spacer ring 
dimensions. 
Clear also COPRA® help layers when updating screen: 
Deletes all drawn lines on COPRA® layers including the help layer during a re-
draw. 
COPRA® Basictools 
 
The COPRA® toolbar 
14 
 
© Copyright by data M Software GmbH  
Automatic redraw when changing project: 
A redraw will be done automatically when enabling this option and changing into 
another project and the project will be displayed. If there is actually no data in this 
project the screen will not change. It is recommendable to enable this toggle.  
Delete X-References: 
COPRA® works with X-references when creating assembly plans and/ or when 
defining individual roll- and station-attributes. It is recommendable to enable this 
toggle because then the external AutoCAD drawings will be only loaded as indi-
vidual roll- or station-attributes when you browse between passes. If an X-
reference is saved to network another user may have changed it, so enabling this 
toggle guarantees that you have always the latest version loaded on screen. Fur-
ther you do not have to delete the X-references from the assembly plans manually 
if you enable this toggle.  
 
The dialog box roll information: 
Show info in Rolls: 
It is possible to show raw diameter, weight, sequential number for top/bottom rolls, 
sequential number for side rolls, material and rolls type in the rolls.  
Alignment: 
Show the info on the left, right or center position. 
Description: 
The roll info described above can be set on none, as prefix or as suffix. 
 
1.3.2. 
Material Choice 
 
Function: 
Select the material you want to use 
You may choose a material in a dialogue box, further you may edit material or 
create a new one and its properties. In the past this could only be done via the 
Project Manager.   
COPRA® Basictools 
 
The COPRA® toolbar 
© Copyright by data M Software GmbH  
 
15 
1.3.3. 
Station Attributes  
 
Function: 
Station types can be individually named 
For each station can be defined which station type it is, e.g., a driven station, side 
rolls or a welding station or a drawing die and so on. 
 COPRA® takes automatically the station types from tube mill map layout eg. 
turk heads if a flower design exists. This needs to be taken into account when 
working with the COPRA® Module M3 (Automatic tubemill map. The listed 
station types can not be modified if there is data in tube mill map de-
fined. If there is no data in tubemill map COPRA® shows you in the dialogue 
box Station Attributes a hint: There is no data available in tube mill map. 
 
The single stations of your design are listed in a table. In order to link any specific 
attribute click it with left mouse key, please. At the very left of the table is the Sta-
tion numbering with COPRA® displayed, on the right next to it the numbering 
with machine. 
Station type: 
You may choose between the attributes main, idler, Turk head, welding, drawing 
die, lineal and strip guide.  
Inserted station: 
If you have later inserted a station - mark the check box Inserted station , please. 
Then already existing roll numbers will not be changed. The roll number of the 
later inserted station will be marked with an A. If you want you may adapt these 
roll numbers via the individual roll attributes.  
Station sub type: 
Depending on the chosen station type are additional attributes as pre bending, or 
calibration available that may be linked to the station.  
Station: 
You may define the corresponding number that the station has got on machine 
here.  
COPRA® Basictools 
 
The COPRA® toolbar 
16 
 
© Copyright by data M Software GmbH  
1.3.4. 
Roll numbering 
 
Function:  
Function:  
Individual roll numbering global for all or for single projects 
 You may define an own roll numbering for your company here. The settings 
are either valid for all projects or for the current one – depending on your set-
tings. 
 
A dialogue opens if you click the icon Roll numbering. 
 
*ATTENTION* – Please take care whether main- or idler station is chosen (see 
left side on top of the box). Depending on your choice either the numbering for the 
main or the idler stations may be defined.  
 
The column Selection: 
Please select here which information you want to add to your individual roll num-
ber. Furthermore the option „Delimiters“ is available. You may add e.g. a hyphen 
between two chosen information in roll numbering.  
The column Format: 
Depending on your needs you may add the information complete or as short cut. 
E.g. drawing number (complete) or DNo. (abbreviated). Æ see also „Abbrevia-
tions“ 
Selected elements: 
Your selection is displayed here. The line Example at the bottom of the dialogue 
gives you a preview on how your roll number will look like later.  
 
If you need to delete an element from list mark it, please (e.g. Pass number| Ara-
bic number) and click this symbol 
, the symbol is available between the Format 
and Selected elements column. 
 
Click this symbol 
 for deleting all available elements at once the symbol is a-
vailable between the Format and Selected elements column. 
 
For changing the sequence of two chosen elements in top direction you may use 
this symbol: 
 .The symbol is available between the Format and Selected ele-
ments column. If you want to change the sequence in bottom direction you may 
use this symbol 
. The symbol is available between the Format and Selected 
elements column.  
COPRA® Basictools 
 
The COPRA® toolbar 
© Copyright by data M Software GmbH  
 
17 
Short cuts: 
You may adapt short cuts to your needs using this function. Just click the respec-
tive button and a dialogue listing all available short cuts will open.  
User defined text: 
By right mouse key click in the column "Format" you may enter a user defined text 
if you have chosen this option. The information may then be linked to your roll 
number.  
It can be linked to roll number if you mark it and press this button
. The user 
defined text may be deleted in the column "Format" by pressing the "Delete" key.  
 
ATTENTION when deleting user defined text! 
If user defined text is deleted from "Format" column it automatically disappears at 
the right site in the column "Selected elements". 
Set as Default: 
The user defined roll number will be used global, for all projects.  
Set for Project: 
The user defined roll number will be used for the current project.  
Numbering of later inserted stations: 
Please refer to station attributes (point 1.3.2). 
 
1.3.5. COPRA® Zoom on/off! 
 
Function: 
Switches the automatic COPRA® Zoom on or off 
1.3.6. Create Project Slide! 
 
Function: 
Exchange automatically created project slide by customised one 
After the Strip Width Calculation a project slide is automatically being created 
showing the final section in the preview of the COPRA® Project Manager. With the 
Create Project Slide function this project slide can be replaced by a user defined 
one. The content of the screen is independent of any restrictions. It may be the 
flower, a 3D wire-frame model or even a roll form simulation picture including the 
rolls. 
 In case it should not be possible to create a project slide, check whether the 
project name contains a dot. 
COPRA® Basictools 
 
The COPRA® toolbar 
18 
 
© Copyright by data M Software GmbH  
1.3.7. Save current Project! 
 
Function: 
Save the design data of the current project 
All design data of the current project can be saved in a project file. Project files 
have the extension CPM (COPRA® Project Manager). The contents are the same 
as in Archive files.  
Opposite to the Archive module the user does not have to enter a filename. The 
filename is put together automatically from the project name. 
The Project file should not be used to replace the Archive files! With the Archive 
files a history of the design process can be created. In a Project file only the last 
design situation is being saved! The Project file is only an additional option to save 
the design data. When exiting the modules Profile, Flower or Rolls the Project file 
can be updated by crossing the respective toggle. 
1.3.8. Reload current Project! 
 
Function: 
Load the design data from the Project file into the current project 
The content of the latest saved Project file is loaded into the COPRA® database. 
An existing database will be overwritten. 
1.3.9. Erase COPRA® Database 
 
Function: 
Erase the COPRA® database files from hard disk 
The design data of the current project are saved in the COPRA® database files. 
These database files are work files that should be saved as an Archive or Project 
file. Sometimes it is necessary to have more than one flower in a project. In this 
case the COPRA® database files can be erased from hard disk and a new section 
can be designed. Before the COPRA® database files are being erased their con-
tent can be saved in the Project file. If the design data are not saved in the Project 
file, an additional user confirmation is necessary. 
1.3.10. Erase Screen! 
 
Function: 
The content of the screen is erased depending on the Delete options setting 
If the Clear only COPRA® layers when updating screen is selected, then all 
drawing information placed on COPRA® layers will be erased. The names of the 
COPRA® layers are set in the Settings. If the switch is set to all active layers, all 
drawing information will be erased. 
COPRA® Basictools 
 
The COPRA® Database toolbar 
© Copyright by data M Software GmbH  
 
19 
1.3.11. Create COPRA® Polyline 
 
Function: 
Design of the outside, inside or centre section contour as a polyline 
The final section of roll formed profiles is very often dimensioned by its contour in-
tersection points. When using the standard design possibilities of a CAD system 
this can be a lot of work. The contour needs to be designed with the help of con-
struction lines and then has to be redrawn. 
1.3.12. COPRA® Screen Menu 
 
Function: 
Loading the COPRA® Screen Menu 
In contrast to the OEM standalone version, this function is currently still available 
in AutoCAD. 
 
 
2. The COPRA® Database toolbar 
 
 
 
The COPRA® database toolbar includes the following functions: 
2.1. View Flower 
 
Function: 
Display flower of the current project 
This function is an easy way to display the flower of the current project. It is avail-
able at any time and shows all passes saved in the COPRA® database. With the 
Selection of passes option the passes to be displayed can be selected. 
2.2. Get Pass 
 
Function: 
Load a new pass from the COPRA® database and save the actual one 
Before a new pass will be load from database the actual pass can be saved by 
this function. A dialogue box with all necessary information will be displayed. 
COPRA® Basictools 
 
The COPRA® Database toolbar 
20 
 
© Copyright by data M Software GmbH  
2.3. Save Pass 
 
Function: 
Save the current pass in the database 
The Save DB function saves the module specific data of a pass in the COPRA® 
database. 
2.4. Delete Pass(es) 
 
Function: 
Delete a selection of passes from the database 
The number of passes deleted will reduce the number of passes. The pass num-
bers following the deleted ones will be reduced by the number of passes deleted. 
If rolls are already available, it is for example, possible to delete the tools only. 
 
The actual pass number can only be deleted if it was selected.  
2.5. Append Pass 
 
Function: 
Append the current pass to the database 
The number of passes is increased by one. 
Example: 
The number of passes saved in the database is 5. The current pass number 3 is 
appended to the database. The new number of passes is 6 and pass number 6 
will be the current one. The contents of pass number 3 and 6 are identical. 
2.6. Insert Pass 
 
Function: 
Insert the current pass into the database 
The Insert pass function will insert the data of the current pass as a new pass in 
the COPRA® database. The number of passes is increased by one. 
Example: 
The number of passes is 5. The current pass number 4 is inserted as pass num-
ber 2 in the database. The new number of passes is 6. The new current pass is 2 
and is identical to pass number 4. The pass numbers 3 to 5 are moved one posi-
tion upwards. 
 See also station attributes for retraining of already existing roll numbers.  
COPRA® Basictools 
 
The COPRA® Utils toolbar 
© Copyright by data M Software GmbH  
 
21 
2.7. Fade-in Profile 
 
Function: 
Fade-in a selected section 
Allows to fade-in any section from the database. The current pass will thereby be 
maintained. 
2.8. Fade in Rolls 
 
Function: 
Display rolls for a station 
The rolls for the section can be faded in for any station. 
 
 
3. The COPRA® Utils toolbar 
 
 
 
3.1. COPRA® Copy 
 
Function: 
Copy rolls or sections  
Rolls or sections have not to be designed anew. Instead, existing rolls or sections 
can be copied.  
3.2. COPRA® Paste 
 
Function: 
Insert copied rolls or sections  
The copied roll or the copied section can be inserted in any pass. Rolls can be 
inserted at any position, for example, top rolls can be used as left or right rolls or 
as bottom rolls. However, you have to choose the respective COPRA® module at 
first.  
3.3. COPRA® DB Undo 
 
Function: 
Reset commands 
This function is similar to the "Undo" in AutoCAD. Up to 5 steps can be reset pro-
vided that the data was not saved beforehand. 
COPRA® Basictools 
 
Machine file for bearing seats 
22 
 
© Copyright by data M Software GmbH  
3.4. COPRA® DB Redo 
 
Function: 
Reactivate changes 
This function allows you to reactivate the last 5 steps provided that the data was 
not saved beforehand. 
3.5. COPRA® Redraw 
 
Function: 
Redraw drawing 
3.6. Entity Information 
 
Function: 
Opens a dialogue box with the entity data of a previously selected entity  
All data associated with an entity can be checked and loaded in a dialogue box. 
The roll data can be displayed on screen with function key F2 (Test Window). 
3.7. COPRA®? 
 
Function: 
Opens the Online Help. The language depends on what was selected under Settings 
If selected the Online Help will be loaded. The language thereby depends on what 
was set under Settings. 
 
4. Machine file for bearing seats 
The relation of the rolls with the machine axes is defined in machine files. 
These machine files are used in the following modules: 
• Single Roll dimension 
• Automatic contour dimensioning 
• Assembly plan 
• Dimensioned assembly plan 
The selection of the machine and modifications of the bearing seats are possible 
after selecting the Machine option in the main dialogue boxes of those modules. 
 If a machine is set as the current one in one module then this machine is 
also the current one in other modules. 
 Verify that the settings are not contradictory. For example, the diame-
ter of bore must not exceed the inner diameter of stamping groove for 
roll numbers (Settings for drawing generation). 
COPRA® Basictools 
 
Machine file for bearing seats 
© Copyright by data M Software GmbH  
 
23 
After selecting the Machine, option the Machine data dialogue box is loaded: 
Machine: 
All existing machine files are listed here. In order to set the current machine or to 
modify one, it has to be highlighted in the list. 
 
4.1. Modify 
The settings of the machine picked in the machine list can be modified. 
4.1.1. Pre-settings for creation of drawing 
After selecting the Modify..., the Settings dialogue box will be opened, in which 
the values for the borehole chamfer and stamping groove are defined. 
 
 
Fig. 1   Bore for pass number 
 
The inner ∅ of the stamping groove has to be greater or equal to the ∅ 
of the borehole plus twice the chamfer of the borehole. The ∅ of bore 
for (T/B) can be found in the Breakdown/Fin Pass. The ∅ of bore for 
(L/R) can be found in the Intermediate/Idler Pass. 
 
4.1.1.1. Settings Assembly Plan Dimensioning 
 
Illus. 2   Settings Assembly Plan Dimensioning 
COPRA® Basictools 
 
Machine file for bearing seats 
24 
 
© Copyright by data M Software GmbH  
4.1.1.2. Breakdown/Fin Pass 
Here, the details for the boreholes of the top and bottom rolls can be set. 
These are the values for the borehole details of top and bottom rolls. 
 
The inner ∅ of stamping groove (T/B) must be greater or equal to the 
∅ of the borehole in the driven passes plus twice the borehole cham-
fer.  
 
 
Illus. 3   Borehole details of the driven passes 
A:  ∅ of bore 
B:  ∅ of undercut 
C:  Supporting width (2x) 
D:  Fillet of undercut 
x:   Depth of keyway 
y:   Width of keyway 
4.1.1.3. Intermediate/Idler Pass 
These are the values of the side roll borehole details. 
 
Illus. 4   Choose the machine for single roll dimensioning 
A:  ∅ of bearing 
B:  ∅ of borehole 
C:  Depth of bearing set 
D:  Fillet of bearing set 
COPRA® Basictools 
 
Convert Database 
© Copyright by data M Software GmbH  
 
25 
 
The inner ∅ of the stamping groove (L/R) must be greater or equal to 
the ∅ of the borehole in the intermediate passes plus twice the bore-
hole chamfer. 
4.2. Copy 
The data of the machine highlighted in list are copied to a new machine. The 
name of the new machine has to match the file format. 
4.3. Delete 
The machine highlighted in the list will be removed from the list. The correspon-
ding machine file is deleted. 
4.4. Identifications 
The name of the machine has to match the file format. Only 8 characters are al-
lowed. In the identification a detailed description of the machine is possible. 
4.5. Current Machine 
Displays the designation of the current machine. 
Load of COPRA® Set: 
Loads the plant data from the COPRA® Set file. 
Save to COPRA® Set: 
Copies the machine data to the COPRA® Set directory. 
 
5. Convert Database 
 
Function:  
Modify elements of construction 
 
It can additionally convert axes or rolls for example, via a dialogue box. 
Current: 
Shows the actual pass. 
Existing Profiles: 
Provides information about the existing number of profiles. 
Axes: 
Displays the number of axes. 
COPRA® Basictools 
 
Convert Database 
26 
 
© Copyright by data M Software GmbH  
Selection: 
This opens the Selection of Stations, dialogue box. The number of existing pro-
files and axes is displayed. By Max select, the selection of single, multiple or all 
passes for a defined number of stations are possible. 
Tool: 
By Tool, it is possible to choose between top, bottom, left or right roll. Later the 
selection will be modified. 
Objects: 
By activating this toggle the profile will be modified later. 
Tool: 
Axes and rolls can be enabled for modifying here. 
 
5.1. Action 
Offers the following options: 
• Mirror horizontal 
• Mirror vertical 
• Move 
• Convert 
Depending on selected action the under objects chosen elements can be modified 
respectively the action. 
The different Actions: 
Mirror horizontal: 
The profile, axes and rolls can be mirrored horizontal. The action can be done by 
point of unfolding, plane of unfolding or free point. 
Mirror vertical: 
The profile, axes and rolls can be mirrored vertical. The unfolding point, plane of 
unfolding or free point, can do this. 
Move: 
The profile, axes and rolls can be moved. A vector of P1-P2 can be used. The 
input of the x and y co-ordinates can be done by their values or by the selection of 
the points by crosshairs. For selecting by crosshairs, use the buttons ->P1 and -
>P2. 
COPRA® Basictools 
 
Convert Database 
© Copyright by data M Software GmbH  
 
27 
Convert: 
By entering a convert factor, the profile, axes and rolls can be enlarged or made 
smaller by any value. Furthermore, conversion elements from mm to can be ma-
de. 
 
5.2. Reference 
Here is the reference point for the selected action, thus, different reference points 
are offered. Refer to the next point for a detailed description. 
The different References: 
Unfolding Point: 
The unfolding point is used as the actions basic point. 
Unfolding Plane: 
The unfolding plane is the actions basis. 
Free Point P1: 
By defining the x and y co-ordinates any point can be selected as the actions ba-
sic point. 
Vector P1-P2: 
Two points that define the basis of the action can be selected with are two possi-
bilities: 
1. By P1 (x1) (y1) to define the co-ordinates of the first point, and P2 (x2) (y2) 
to define the co-ordinates of the second point. 
2. Or click at the buttons ->P1 and ->P2. Then the points can be selected by 
crosshairs. The co-ordinates of the selected points are automatically taken 
into the dialogue box. 
Convert Factor: 
By entering a convert factor, objects can be made larger or smaller, or be con-
verted from mm to inches. 
COPRA® Round & Rectangular Tubes 
 
Archive Files 
28 
 
© Copyright by data M Software GmbH  
COPRA® Round & Rectangular Tubes 
1. Archive Files 
 
Function: 
Important design steps should be saved in archive files 
 
An Archive file has the same file format as the Project file. 
 The 5 database files *.db are also saved and compressed in the Archive 
files, and therefore cannot be modified directly. 
 In contrast to only one Project file, as many Archive files as necessary may 
be created. 
 
The Archive files should be used to save important steps in the design. It is like a 
snapshot of the current design situation. Especially after having worked with the 
Profile, Flower and Rolls modules it makes sense to create an Archive file. 
 Archive files can be very useful if changes need to be made to the project or 
if a similar section has to be designed later. 
 
The Project file is always located in the project directory and its filename 
cannot be changed. The user defines the names and location of the Ar-
chive files. 
 
 The COPRA® database has changed several times since its first re-
lease, so older versions may have to be converted first. Archive files 
of previous releases can always be loaded. Therefore all COPRA® da-
tabase should also be saved as Archive files. Before old Archive files 
are loaded a new project should be created with the Project Manager. 
COPRA® Round & Rectangular Tubes 
 
The Flower toolbar 
© Copyright by data M Software GmbH  
 
29 
2. The Flower toolbar 
 
 
 
The Flower toolbar contains all functions required to create a flower. 
2.1. Plane of Unfolding 
 
Function: 
Define plane of unfolding 
Before a flower can be created, the plane of unfolding has to be defined. If the 
Flower function is opened for the first time in the current project, a defining the 
point of unfolding dialogue box appears automatically: 
Entity Centre: 
Allows you to pick the respective entity with the crosshairs. The point of unfolding 
is positioned in the middle of the selected entity. 
Before Entity: 
Allows you to pick the respective entity with the crosshairs. The point of unfolding 
is positioned at the point of separation from the selected entity. COPRA® direction: 
from left to right. 
After Entity: 
Allows you to pick the respective entity with the crosshairs. The point of unfolding 
is positioned at the point of separation after the selected entity. COPRA® direction: 
from left to right. 
Point picked by Cursor: 
Allows you to pick a certain point within an entity. The point of unfolding is at the 
defined point. The proposed point, which is marked with a cross, reflects the cen-
tre of strip width.  
COPRA® Proposal: 
COPRA® proposes to select the point of unfolding on a long straight part. The re-
spective legs are directed to the top.  
Rotate Profile: 
After having selected the point of unfolding, the section can be subsequently ro-
tated by a defined angle. The defined point of unfolding thereby serves as a refer-
ence point. If no point of unfolding is defined, the centre of the strip width will be 
assumed to be the reference point.  
COPRA® Round & Rectangular Tubes 
 
The Flower toolbar 
30 
 
© Copyright by data M Software GmbH  
Mirror Profile: 
After having defined the point of unfolding, the section can be subsequently mir-
rored at the defined point. If no point of unfolding is defined, the centre of the strip 
width will be assumed to be the reference point. 
Rotate Profile Automatically: 
When selecting an entity, that is not positioned on the horizontal plane, the section 
will be rotated in such a way that the entity is in a horizontal position. 
 After selection, the point of unfolding is displayed and the system asks you 
whether you are satisfied with the plane of unfolding.  
Yes: 
If you confirm with Yes, the process is finished and the plane of unfolding defined.  
No: 
If you enter No the system asks you whether the pass should be recreated. If you 
confirm with Yes, the defining the plane of unfolding dialogue box reappears. 
Cancel: 
If the procedure is cancelled, no plane of unfolding will be defined. 
2.2. Unfolding 
 
Function: 
Step-by-step unfolding of individual bending steps with user-defined settings 
After having selected the icon the system asks you to select the arc to be unfolded 
with the help of the crosshairs. Do so and the Interactive Unfolding dialogue box 
appears: 
Current Entity Parameters: 
The current entity data are displayed for the purpose of information. 
Bending Parameters: 
Displays the defined bending data. 
Bending Angle: 
Shows the value for the angle to be unfolded. 
Bend Angle: 
Shows the value of the arc angle after unfolding of the arc by the value of the 
bending angle. 
COPRA® Round & Rectangular Tubes 
 
The Flower toolbar 
© Copyright by data M Software GmbH  
 
31 
And/Or: 
This function is only available, if the Constant Length calibration method was 
used. When activating this option, a new inner radius can be applied manually. 
Length Neutral Line: 
Defines the length of the neutral line in the selected arc. 
Calculation Method: 
The selected method for strip width calculation is displayed for the purpose of in-
formation. 
Select Entities: 
Refer to, General Information point 2. 
 
 If unfolding is repeated, always the last applied selection of entities is 
active. 
Join Equal Entities automatically: 
All equal entities will be joined automatically.  
Calibrating Method: 
Allows you to choose from different calibration methods. For detailed information 
refer to, Calibration Methods. 
2.3. Fold 
 
Function: 
Fold individual bends step by step with customised settings 
Normally, flower creation starts from the final section and is unfolded step by step 
,or automatically, to the flat strip. But sometimes it may be necessary to continue 
folding the strip, e.g. to create a section with over-bent angles and radii or to fold a 
straight. 
The following is a short description of the differences between the Fold and Un-
fold option. 
Folding with Angle/Radius Calibrating Method: 
The Angle/Radius calibrating method cannot be used for folding an arc. If the 
Angle/Radius calibrating method is used for continuous folding of a bend, the 
Calibrating Method/Length Compensation dialogue box will be loaded with the 
calibrating methods Angle/Radius and Power Bending being both disabled. To 
modify both angle and radius for continuous folding, use the Power Bending cali-
brating method. 
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Bending Straights: 
For better access to undercut bends it may be necessary to over-bend straights. 
Splitting Straights for Over-bending Purposes: 
If a straight is over-bent, the complete length will be converted to a bend. If only a 
part of the straight should be bent, it can be split into two parts by using the Split 
entities function from the Profile Utilities toolbar. 
 
2.4. Automatic Unfolding 
 
Function: 
Automatic unfolding of bends with pre-defined bending sequences 
Today, more and more roll formers use standard rolls to save the costs for making 
new rolls. Above all, standard sections are very often created with combination 
rolls. The angles of these rolls are known which makes it possible to automatically 
create a flower for these sections if there is a possibility to enter the bending se-
quence of the rolls. This tool is provided by the automatic unfolding command in 
COPRA®.  
After having selected the icon, the system asks you to select the arc to be un-
folded with the crosshairs. The Automatic Unfolding dialogue box is opened. 
Similar to the Interactive Unfolding dialogue box the following functions are 
available: 
Initial Step: 
Normally, this value should be 1. However, if several bending sequences are 
combined, the initial step has to be defined accordingly. 
End Angle: 
Allows you to define a certain final angle. 
No. of Steps: 
Defines the number of unfolding steps. 
Or Angle: 
Defines the unfolding angle. 
View Window: 
Shows the selected bending sequence. 
Bending Sequence: 
A dialogue box is opened allowing you to select an existing bending sequence: 
Adjust, Create, Modify, Copy or Delete. 
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Bending Sequence Trapezoidal: 
The system calculates a bending sequence whereby calculation aims at obtaining 
an even inlet for the strip edge. For detailed information refer to, Trapezoid. 
Bending Sequence: 
Shows the selected bending sequence. 
Angular Sum: 
Shows the total sum of the angles. 
Sequence of Angles: 
Displays the angle steps. 
All other functions see, 2.2 Unfolding. 
 
2.5. Execute Unfolding 
 
Function: 
Execute the bending parameters entered and save new section in COPRA® database 
 
2.6. Dynamic Flower 
 
Function: 
Predefine dynamic step-by-step unfolding or folding  
This feature allows you to fold or unfold arcs dynamically. After having selected 
the icon, the Dynamic Unfolder dialogue box is opened: 
Pass Data: 
Shows the current pass data for your information. 
View Window: 
Displays all entities and their respective values.  
Entity Selection: 
See chapter, General Information. 
Calibration Method: 
Allows you to choose from several calibration methods. 
Increment (Angle >0): 
The value by which, the arc is to be unfolded. 
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Increment (Angle <0): 
The value by which, the arc is to be folded.  
Unfold/Fold: 
The arc is unfolded or folded by the entered value. Check the value in the view 
window. 
 
2.7. Dynamic Unfolding 
 
Function: 
Dynamic unfolding 
This function allows you to unfold the arc by the entered value to the desired posi-
tion. This feature is very helpful, for example, for checking accessibility of the rolls. 
2.8. Dynamic Folding 
 
Function: 
Dynamic folding 
This function allows you to fold the arc by the entered value to the desired posi-
tion. This feature is very helpful, for example, for checking accessibility of the rolls. 
2.9. Symmetrical Profiles 
 
Function: 
Split symmetrical sections 
Symmetrical sections can be split to make design faster by unfolding only one half 
of it. COPRA® automatically recognises whether a certain profile is symmetrical 
and loads the required dialogue box.  
2.10. Calibrate 
 
Function: 
Select the default calibrating method 
The calibration method depends on the section to be formed. In practice, the cali-
bration methods constant length of neutral line or constant radius are the most 
common ones. However, some roll forming processes require more advanced 
methods. Each bend is described by the inner radius Ri, the bend angle α and the 
length of neutral line LNL. 
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COPRA® provides 5 different Calibrating Methods: 
• 
Constant radius 
• 
Constant length of neutral line 
• 
Track holding profiling 
• 
Angle/radius profiling 
• 
Tube profiling/power bending 
 
2.10.1. Constant Radius Method 
This calibration method uses a constant radius among all forming steps. This 
means that the material has to be taken from the inner, the outer or from both 
legs. By the term legs, we understand the non-bent neighbour entities. When un-
folding starts from the final section, this process is inverted: the material may be 
distributed to the inner, the outer or to both legs. The entities created during that 
process are called the length compensation pieces. The default distribution of 
the length compensation pieces is 50% to the outer leg and 50% to the inner leg. 
The inner leg is the leg, which is closer to the section forming point. The length of 
the length compensation pieces depends on the calculated neutral line. Depend-
ing on the bending angle, material strain has to be considered. Therefore the 
theoretical strip width, which equals the length of the neutral line, is smaller than 
the actual centre line of the final section. The length compensation pieces may 
also be positioned in the middle of a bend; this possibility is, however, very rarely 
made use of. 
Pros and Cons of this Calibrating Method: 
Pro: 
 
low spring back rate 
Con:  
bending areas tend to be cornered 
Restrictions: a bend cannot be folded with this method if the neighbour entities are 
also bends 
Characteristics of the Constant Radius Method: 
Inner radius: constant 
Bend angle: variable 
Length of neutral line: 
variable 
Length compensation: 
yes 
 
2.10.2. Constant Length of Neutral Line Method 
If used, the calculated length of the neutral line remains constant throughout all 
passes; the inner radius is automatically being calculated depending on the un-
folding angle of the bend. Material strain is considered during all forming steps. No 
length compensation pieces are created during the unfolding process. Optionally, 
straight entities may be folded by using that calibrating method. 
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Pros and Cons of this Calibrating Method: 
Pro: 
 
bending areas are not cornered 
Cons:  
higher spring back rate 
Characteristics of the Constant Length of Neutral Line Method: 
Inner radius:  
 
variable 
Bend angle:  
 
variable 
Length of neutral line: 
constant 
Length compensation: 
no 
2.10.3. Track-holding Method 
This method is a variant of the constant radius method. Just as with the constant 
radius method, the radius remains constant during all forming steps. The only dif-
ference is that the length compensation pieces are not defined by the user but 
calculated by COPRA®. Calculation results in a constant intersection point of the 
inner line of inner and outer leg. This calculation method is only valid for bending 
angles between 1° and 90°. 
Pros and Cons of this Calibrating Method: 
Pro: 
 
high accuracy of dimensions 
Con:  
difficult machine set-up 
Characteristics of the Constant Length of the Track-holding Method: 
Inner radius:  
 
constant 
Bend angle:  
 
variable 
Length of neutral line: 
variable 
Length compensation: 
yes 
2.10.4. Angle/Radius Method 
It may be necessary to not only modify the angle of a bend, but also the inner ra-
dius. Examples are Dutch bends with a bend angle of 180° and an inner radius of 
0mm. For a proper layout of this area it is necessary to find the correct pre-shape. 
For example, it would not be possible to start forming from flat with an inner radius 
of 0 mm. When modifying the angle as well as the inner radius the length of neu-
tral line has to be recalculated. When working with version 12c4 of COPRA® or 
higher, the applied strip width calculation method is added as an attribute to the 
bend. Thus, it is possible to recalculate the length of the neutral line for the bend 
with the same conditions. When working with a database created with version 
12c3 or lower, the strip width calculation method is not an attribute added to the 
bend. In this case the user has to take care of using the correct strip width calcula-
tion method. 
The length compensation pieces can be taken from the inner or the outer leg. The 
length compensation pieces may be positive or negative depending on the modifi-
cation. If, e.g., the angle is not modified and the radius increases, they will be 
negative. If the radius decreases, they will be positive.  
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The adjacent entities increase or decrease respectively. The default distribution of 
the length compensation pieces is 50% to the outer leg and 50% to the inner leg. 
The inner leg is the leg, which is closer to the section forming point. The length 
compensation pieces can also be positioned in the middle of a bend. 
Pros and Cons of this Calibrating Method: 
Pro: 
 
less restrictions than the above described methods: angle as well as 
radius can be varied  
Con:  
the length of the neutral line has to be recalculated. This may cause 
minor deviations within the flower. Prerequisite is that the calculated 
strip width remains constant. 
Restrictions: length compensation pieces cannot be taken from adjacent entities, 
if these are bends 
Characteristics of the Angle/Radius Method: 
Inner radius:  
 
variable 
Bend angle:  
 
variable 
Length of neutral line: 
variable 
Length compensation: 
yes 
 
2.10.5. Power Bending Method 
This option is known as “tube profiling“ from earlier versions of COPRA®. Actually, 
it can not only be used for tubes. It is an advanced Angle/Radius calibrating 
method without the restrictions described above. The length compensation piece 
can not only be selected via a percentage of the neighbour entities but also by 
picking the entity the material should be taken from or distributed to. Selection is 
by using the crosshairs. 
Pros and Cons of this Calibrating Method: 
Pro: none of the restrictions of the above described methods: angle as well as 
radius can be varied; folding is possible even if adjacent entities are bends 
Con: the length of the neutral line has to be recalculated. This may give rise to 
little deviations within the flower. Pre-requisite is that the calculated strip 
width remains constant.  
Characteristics of the Power Bending Method: 
Inner radius:  
 
variable 
Bend angle:  
 
variable 
Length of neutral line: 
variable 
Length compensation: 
yes 
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© Copyright by data M Software GmbH  
2.11. Reference Point 
 
Function: 
Modify the vertical position of a flower 
In COPRA® the vertical position of the section forming point is constant by default. 
In most cases this is also the way a section is actually manufactured. But some-
times it is necessary to change the vertical positions of individual sections within a 
flower. A typical example is a section with a dovetail.  
The vertical position can now be changed with the Move option from the 
FLOWER screen menu or with the RefPoint function. Selecting the RefPoint 
function will open a new dialogue box. 
 
 
Fig. 5   Unfolding Reference Point 
 
Fig. 6   Modified Reference Point 
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2.12. The Profile Utilities toolbar 
 
 
 
2.12.1. Edit Profile Section 
 
Function:  
Modify dimensions and geometries of the section 
Normally, it is not necessary to modify a section within a flower. This can be done 
with the standard COPRA® options. This function is only required for a handful of 
cases. 
 
This function allows you to modify the calculated length of the neutral 
line. Use carefully as improper use may cause problems. 
Pass Data: 
Supplies information about the current flower 
• 
Number of passes saved in the data base 
• 
Current pass number to be modified 
• 
Number of entities in the current section 
• Material thickness 
Flower Data: 
Provides a list of data for all sections within a flower. 
Strip Width: 
Supplies information about changes of the originally calculated strip width 
• Original (old) strip width left of the section forming point 
• Original (old) strip width right of the section forming point 
• 
Current strip width left of the section forming point 
• 
Current strip width right of the section forming point 
• 
Difference between original and current strip width left of the section form-
ing point 
• 
Difference between original and current strip width right of the section form-
ing point 
• 
The differences between the strip widths are provided for verification of the 
changes. 
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Listbox: 
If an entity is highlighted by selecting it with the crosshairs, its geometry data are 
transferred to the edit boxes at the bottom of the window. The values can be 
modified. Selecting the OK will make the changes permanent. The entities at the 
section forming point FP are marked with an asterisk. 
Radio Button S: 
Activated by COPRA®, if only a straight entity in the list is highlighted. A straight 
entity can be changed into an arc entity by selecting B. The previous data of the 
straight are saved. If the arc entity is converted back to a straight, the previous 
data will be restored. 
Radio Button B: 
Activated by COPRA®, if only an arc entity in the list is highlighted. An arc entity 
can be changed into a straight entity by selecting S. The previous data of the arc 
are saved. If the straight entity is converted back to an arc, the previous data will 
be restored. 
Bend Angle: 
The angle of all entities selected in the list is set to the pre-set value. Depending 
on the selected procedure, the radii and lengths of the entities will be adjusted or 
a length compensation is applied. This function is especially helpful if, for exam-
ple, not the inner radius but the outer radius is used as a basis. 
Inside Radius: 
The inner radius of all entities selected in the list is set to the pre-set value. De-
pending on the selected procedure, the angles and length of the entities are ad-
justed or a length compensation is applied. 
Contour Radius: 
The contour radius of all entities selected in the list is set to the pre-set value. De-
pending on the selected method the angles and lengths of the entities are ad-
justed or a length compensation is applied.  
Length: 
The length of the neutral line of all entities selected in the list is set to the pre-set 
value. Depending on the selected procedure the angles and radii of the entities 
are adjusted or a length compensation is applied. 
Profile Entity: 
Here the number of entities in a section can be changed. In combination with the 
function distribute the length difference to selection it is also possible to separate 
entities. 
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% New: 
The percentage of the neutral line with regard to the entire original strip width of all 
entities selected in the list is set to the pre-set value. The lengths of the neutral 
line are recalculated. Depending on the selected procedure, the angles and radii 
of the entities are adjusted or a length compensation is applied. 
 For a description of how to select entities refer to, General Information. 
Add: 
If only one entity is highlighted in the list, it can be copied by using the Add !, op-
tion. The new entity will be inserted after the selected entity. If the copied entity is 
a straight it can be converted to an arc if A is selected. If the copied entity is an 
arc it may be converted to a straight. 
 The data of the new entity are similar to those of the copied entity. Strip 
width differs by the length of the copied entity. 
Remove: 
All highlighted entities will be removed from the list.  
Modification Procedures: 
The different procedures have different effects on the section when changing an-
gle, radius or length of an entity. Several types of length compensations can be 
applied.  
Free: 
This procedure is equal to the COPRA® calibration method Angle/Radii. 
 
Change 
Angle 
Radius 
Length 
Length compensation 
Angle 
 
Unchanged 
Is adjusted None 
Radius 
unchanged 
 
Is adjusted None 
Length 
Option: Adjust Option: Adjust 
 
None 
 
Constant Length/Adjust: 
This procedure is equal to the COPRA® calibration method Angle/Radii. 
 
Change 
Angle 
Radius 
Length 
Length compensation 
Angle 
 
Unchanged 
Is adjusted None 
Radius 
unchanged 
 
Is adjusted None 
Length 
Option: Adjust Option: Adjust 
 
None 
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Compensation with Straights only: 
This procedure is equal to the COPRA® calibration method Constant Radius.  
Length compensation is done with straight entities only. If an adjacent entity of the 
modified entity is not a straight entity, a new straight entity will be created auto-
matically. 
 
Change 
Angle 
Radius 
Length 
Length compensation 
Angle 
 
Unchanged 
Is adjusted With straights only 
Radius 
Unchanged 
 
Is adjusted With straights only 
Length 
Option: Adjust  Option: Adjust 
 
With straights only 
 
Compensation in adjacent Entities: 
This procedure is equal to the COPRA® calibration method Tube Profiling. 
Length compensation is done with the adjacent entities of the modified entity, no 
matter whether the adjacent entities are straight or arc entities. 
 
Change 
Angle 
Radius 
Length 
Length compensation 
Angle 
 
Unchanged 
Is adjusted 
Adjacent entities 
Radius 
Unchanged 
 
Is adjusted 
Adjacent entities 
Length 
Option: Adjust Option: Adjust 
 
Adjacent entities 
 
Length Compensation: 
If the selected procedure is based on direct length compensation, it can be de-
fined, in which way the lengths are to be distributed right and left of the modified 
entity. 
Outside: 
Outside is the entity next to the modified entity, which is further away from the 
point of unfolding and closer to the end of the section or, in case of closed sec-
tions, closer to the welding point. 
Inside: 
Inside is the entity next to the modified entity, which is closer to the point of unfold-
ing and further away from the end of the profile, or, in case of closed sections, 
further away from the welding point.  
Adjust: 
If changing the length of an arc or if an arc is used as a length compensation en-
tity either the radius or the angle can be adjusted to the new length. 
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Angle: 
If required, the angle of an arc entity can be adjusted to the new length. 
Radius: 
If required, the radius of an arc entity can be adjusted to the new length. 
Length Difference: 
After the user-defined editing of the section data a difference between the original 
strip width and the new strip width may occur. This difference can be distributed to 
the entities selected in the list. 
Even: 
The difference, is divided by the number of selected entities. The resulting value is 
added to each entity.  
Percentage: 
The difference is distributed as a percentage of the length of the entity. A longer 
entity gets a higher percentage of the total difference and vice versa. 
 
2.12.2. Move Profile 
 
Function: 
Move section 
This function allows you to move a selection of sections by defining reference and 
target points. The sections to be moved are displayed in the same colour. Option-
ally, additional sections can be displayed which will be listed in a different colour. 
The changes will be automatically saved to the database. If only one section was 
moved, it can be saved optionally. 
2.12.3. Rotate Profile 
 
Function: 
Rotate section 
This function allows rotation of a section as desired by selecting reference points. 
The sections to be rotated are displayed in the same colour. Optionally, additional 
sections can be displayed which are listed in a different colour. The changes are 
automatically saved to the database. If only one section was moved, it can be 
saved optionally. 
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2.12.4. Split Entity 
 
Function: 
Split one entity into two parts 
Sometimes it may be necessary to insert an entity in the same position already 
occupied by another entity. In this case the Split entity function can be used to 
break an entity in two. The entity to be split has to be selected with the crosshairs. 
The entity data will be displayed and the entity selection has to be confirmed. In 
case of a straight the length to the break point has to be entered, in case of an arc 
the including angle has to be entered. If the break position is valid, the entity will 
be split in the position defined and the new section will be displayed. 
2.12.5. Join Entities 
 
Function: 
Join split entities 
If selected, two adjacent equal entities can be joined.  
To do so, pick the entities with the crosshairs. All entities between, which have the 
same geometrical values, will be automatically joined. In case of arcs, the inner 
radii have to be equal.  
2.12.6. Join All Entities 
 
Function: 
Join separate entities 
If selected, all adjacent equal entities are joined within the section. In case of arcs, 
the inner radii have to be equal. 
2.12.7. Same Number of Entities for 2 Profiles 
 
Function: 
Adjust number of entities of two sections  
The number of entities of the current pass and a second pass is adjusted. In the 
occurring dialogue box the second pass has to be selected. 
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2.13. The Profil Utils toolbar 
 
 
2.13.1. Write Part of Profile to File 
 
Function: 
Writes a part of a profile for copying purposes to harddisk 
In some types of sections there are repeated shapes. To avoid a new design of 
these shapes they can be written to file with the, Write PP function and copied 
with the Read PP function.  
A typical example would be stiffing ribs in a trapezoidal section. 
Simply pick the first and last entity of the entities to be copied and enter a filename 
describing that part. The entity data are written to file and are ready for copy. 
2.13.2. Read Part of a Profile from File 
 
Function: 
Reads a part of a profile from harddisk and inserts it in the current section 
Each part of a profile written to harddisk can be inserted into the current section 
with various options. After entering the filename these options are listed in the 
status line: 
Option 1: A - insert Part of Profile at the Beginning of the Section 
Entering the A option causes the profile part to be added to the beginning of the 
section. The beginning of the section is at entity no. 1. The entity picked first when 
writing the part of profile will be added to entity no. 1 as the first one. 
Option 2: E - insert Part of Profile at the End of the Section 
Entering the E option causes the part of profile to be added to the end of the sec-
tion. The end of the section is at the entity with the highest number. The entity 
picked first when writing the part of profile will be added to that entity as the first 
one. 
Option 3: G - insert Part of Profile at a Location picked by Crosshairs 
Entering the G option causes the part of profile to be added at a position picked by 
crosshairs. The part of profile will be added before the entity picked by the cross-
hairs. The entity picked first when writing the part of profile will be added to that 
entity as the first one. 
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Option 4: N - insert Part of Profile at a Location defined by an Entity Number 
Entering the N option causes the part of profile to be added at a position defined 
by an entity number. The part of profile will be added before the entity number 
entered. The entity picked first when writing the part of profile will be added to that 
entity as the first one. 
 
2.13.3. Write a Sequence of Passes to File 
 
Function: 
Write flower to file 
This function allows saving a flower or part of a flower to a file.  
2.13.4. Read a Sequence of Passes into Flower 
 
Function: 
Read flower from file 
This function allows you to read a flower or part of a flower from a file. 
 
2.13.5. Material Thickness 
 
Function: 
Change material thickness subsequently 
This function allows you to subsequently change the sheet thickness for a com-
plete flower. In the occurring dialogue box you can choose between several meth-
ods. After having selected a method, a slide provides a preview of how sheet 
thickness will change. 
Select: 
Select the passes the material thickness of which is to be changed. 
Plate Thickness old: 
Information on the old material thickness. 
Plate Thickness new: 
Dialogue field for the new sheet thickness value. 
Datum Line: 
Defines the reference line for the modification of sheet thickness. 
Internal Radius constantly: 
The inner radius of the section remains constant. 
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Tubemill map Selection 
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Outer Radius constantly: 
The outer radius of the section remains constant. 
Outer Contour constantly: 
The outer contour of the section remains constant. 
Centre Line constantly: 
The centre line of the section remains constant. 
Internal Contour constantly: 
The inner contour of the section remains constant. 
 
 
3. Tubemill map Selection 
 
Function: 
To manage all created Machines and Machine Data 
The Tubemill map Selection dialogue box is divided into the areas Machine, se-
lected Tubemill map, current Machine and a few other options. 
Tube Ø: 
Shows the finish Tube diameter entered in the Flower. 
Stations: 
Shows the number of Stations entered in the machine layout. 
Comment: 
A comment is especially allocated to the selected Tubemill map in order to have 
another information possibility. 
  The Machine definition consists of the name of the machine and an identifi-
cation for the profile. 
Machines: 
Shows the current and all other available machines. The highlighted Machine is 
the one used last.  
Profiles: 
Shows the current profile and all other available profiles. The highlighted profile is 
the one used last, assigned to the selected machine. 
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3.1. Selected Tubemill map 
Copy: 
To use a machine for another profile, it should be copied and renamed. 
  The same machine should not be used for different profiles. The original ma-
chine should always be copied and renamed according to the profile. The 
reason for this is that if some data in the machine are changed, they will also 
be changed in all the profiles for which this machine is used.  
Delete: 
The DELETE function is used for the deletion of machines. 
 
3.2. Import/Export 
Tubemill map: 
If selected, the database can be imported. This function is needed e.g. if the 
spring-back was calculated in the flower. After selecting this function the Im-
port/Export dialogue box appears: 
The dialogue box is divided into the areas Import/Export, import flower database 
and further options. 
Current Tubemill map: 
Shows the current machine name, the final diameter and the pass number. 
Import/Export of Tubemill map Data: 
Shows the final diameter and the pass number of the machine to which the data 
shall be imported or exported. 
Import: 
If selected, Machine information can be chosen and imported into that being cur-
rently used. 
Export: 
If selected, Machine information can be chosen and exported into that being cur-
rently used. 
Machines: 
Shows the current and all other available machines. The highlighted machine is 
the one used last. 
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Profiles: 
Shows the current profile and all other available profiles. The highlighted profile is 
the one used last and is assigned to the highlighted machine. 
The Block Import/Export: 
Layout: 
The layout is imported or exported into or from the selected machine according to 
the chosen option. 
Flower: 
The flower data will be imported into or exported from the selected machine ac-
cording to the chosen option. 
Machine: 
The machine data will be imported into or exported from the selected machine 
according to the chosen option. 
Rolls: 
The roll data will be imported into or exported from the selected machine accord-
ing to the chosen option. 
The Block Import Data Base: 
Use Tubemill map Settings: 
The settings of the Tubemill map will be used. 
Join Entities before Import: 
All entities will be joined before the import of the database. 
Import Flower from Database: 
The database of the modified flower, spring-back, will be imported into the Tube-
mill map. 
Import of Data Base in Machine... is allowed : 
Shows whether the modified database can be imported into the Tubemill map. 
Import of Data Base... finished: 
Shows whether the modified database was imported into the Tubemill map. 
Old Version: 
This is only used for the import of data from the old COPRA® Modules. 
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4. The Tubemill map Layout 
 
Function: 
Defines the machine layout 
The layout of an almost arbitrary tube-welding street can be defined quite simply. 
The complete machine can be defined by simply selecting the different passes. 
  To get the dialogue box for designing a flower for a rectangular the last pass 
in the machine layout must be a Turk head rectangular or a round rectangu-
lar pass. 
Tubemill map: 
Shows the selected Tubemill map. The name consists of the chosen machine and 
the tube to be manufactured. 
Sequence of Stations: 
Shows the selected sequence of stations from the first to the last pass. 
Modify: 
To change the pass type, a dialogue box opens, when selected, with all available 
passes. The current pass type is highlighted. 
Pass Selection: 
All available pass types are shown in slides. 
Zoom in by Mouse click: 
Clicking on the slide with the right mouse button can enlarge it. 
Previous: 
The previous macro with pass types will be shown. 
Next: 
The next macro with pass types will be shown. 
 Another possibility to select a pass type is to make a double click on the 
slide. In this case the Toggle "Zoom in by Mouse click" must not be set. 
Add: 
This must be selected to add another pass. The added pass is added behind the 
highlighted pass. 
Remove: 
The highlighted pass will be removed from the Tubemill map layout.  
COPRA® Round & Rectangular Tubes 
 
Flower (round Tube) 
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Split all Top/Bottom Rolls: 
When activated, all top and bottom rolls will be split. If it is not set, the bottom rolls 
are only split where the vertical adjustment of the shafts is not sufficient for the 
assembly of the rolls. In this case the top rolls remain undivided. If the bottom roll 
shall not be split, the vertical adjustment of the shafts must be defined bigger. 
 Tip for the pass types: breakdown pass type 2 should be used only as first 
breakdown, since it cannot be used over 90°. The same applies for idler 
pass type 3. It can also not be used for more than 90°. 
 
 
5. Flower (round Tube) 
 
Function: 
Calculate the flower automatically 
The Tube flower set-up dialogue box is divided into the areas Final section, 
Welding section, Wall thickness, Additions, Strip width, Formingsteps and further 
options. 
 To get this dialogue box, a Turkhead round tube must be the last pass in the 
Tubemill map layout. 
Tubemill map: 
Shows the selected Tubemill map. 
The Block Final Section:  
Tube Diameter: 
The final diameter of the round tube is entered here. 
Contour Line: 
Shows the calculated contour line of the round pipe. 
Centre Line: 
Shows the calculated centre line of the round tube. 
The Block Welding Section: 
Weld Diameter: 
Shows the welding diameter incl. the calibration addition. 
COPRA® Round & Rectangular Tubes 
 
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© Copyright by data M Software GmbH  
Contour Line: 
Shows the calculated contour line of the round tube including the calibration addi-
tion. 
Centre Line: 
Shows the calculated centre line of the round tube including the calibration addi-
tion. 
The Block Wall Thickness: 
Wall Thickness: 
The minimal wall thickness of the round tube to be manufactured is entered here. 
  Increasing the wall thickness can influence the radius of the top roll. 
Max. Wall Thickness: 
Entry for the maximum wall thickness of the round tube to be manufactured. 
 
5.1. List of Additions 
Entry for the additions to the strip width calculation. The List of additions dia-
logue box is divided into the areas, reduction addition, welding addition, sizing ad-
dition, strip guide addition and further options. 
Reduction Addition RA: 
This value refers to the strip width and compensates for the material loss caused 
by the reduction in the fin passes. 
Parameter is Factor: 
If set, the factor for the reduction addition is used from parameter. 
Factor for Reduction Addition: 
The factor can only be entered manually if the additions are not used from the pa-
rameter file (option not set). 
Welding Addition WA: 
This value refers to the strip width and compensates for material loss cause by 
welding. In case there is no material loss in welding the value must be set at 0. 
WA (mm): 
The value can only be entered manually in millimetres if the additions are not used 
from the parameter file (option not set). 
COPRA® Round & Rectangular Tubes 
 
Flower (round Tube) 
© Copyright by data M Software GmbH  
 
53 
WA (%): 
The value can only be entered manually in percent if the additions are not used 
from the parameter file (option not set). 
Sizing Addition SA: 
This value refers to the tube diameter and compensates for material loss caused 
through sizing. 
SA (mm): 
The value can only be entered manually in millimetres if the additions are not used 
from the parameter file (option not set). 
Zk (%): 
The value can only be entered manually in percent if the additions are not used 
from the parameter file (option not set). 
Use Reduction in the driven Stations only: 
If set, the reduction is distributed only in the driven stations. The driven stations 
are not taken into account here. 
Strip Guide Addition GA: 
This value refers to the strip width and compensates for material loss caused by 
strip guiding into the first station. This value is only actual if a strip guide is used in 
the Tubemill map and if there is a reduction happening during this process. 
GA (mm): 
The value can only be entered manually in millimeters if the additions are not used 
from the parameter file (option not set). 
GA (%): 
The value can only be entered manually in percent if the additions are not used 
from the parameter file (option not set). 
Assignment: 
The appropriate passes are shown in the list-box by selecting the right addition. 
The values can be distributed to the passes in percent. 
Uniform: 
The addition value is distributed uniformly to all passes in which this value is taken 
into account.  
Use Parameter: 
If set, all additions are used from the parameter file. 
COPRA® Round & Rectangular Tubes 
 
Flower (round Tube) 
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© Copyright by data M Software GmbH  
5.2. Strip Width 
The Strip Width dialogue box shows the different methods available for calculata-
tion. 
  The method which is closer to the results of the strip width hitherto calcu-
lated according to company experience should not be used here. It is impor-
tant to check which factors or additions refer to which value of the profile. 
Calculation Method: 
The Calculation Method is to determine the strip width, which can be selected. 
Calculation Method 0: 
This option is for the Strip Width to be entered manually for each pass, and not to 
be calculated. 
Calculation Method: 1: 
In this method the sizing addition is used twice in the bracket and in this case re-
fers to the final radius of the round tube. All other additions are added up on the 
result. 
Calculation Method: 2: 
In this method the sizing addition is used once in the bracket and in this case re-
fers to the final diameter of the round tube. This means the diameter change cor-
responds to the sizing addition. All other additions are added up on the result. 
Calculation Method: 3: 
The reduction addition is used in the bracket. The sizing addition is added up only 
after the inquiry of the centre line of the final profile and therefore refers to the 
strip width. Then the welding addition (WA) and the wall thickness are added up 
on the result. 
Calculation Method: 4: 
The centre line is calculated in the bracket without additions. All additions are 
added up only after the calculation of the centre line of the final profile and there-
fore refer to the strip width. 
Round Strip Width with selected calculation Method: 
The calculated strip width can be rounded off. 
Round: 
The calculated strip width can be rounded up or down. Also the possibility to set a 
maximum tolerance for the entered values is given. 
COPRA® Round & Rectangular Tubes 
 
Flower (round Tube) 
© Copyright by data M Software GmbH  
 
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Compensation in Addition: 
The rounded value can be distributed to the appropriate additions. 
RA/WA/SA/GA 
An addition can be defined by setting one of these options.  
Sequence of Stations: 
The calculated or entered value of the strip width is listed pass by pass. If the cal-
culation method 0 was selected, all values of the strip width can be modified. 
5.3. Forming Steps 
Here all data are entered to design a tube flower. The Forming Steps dialogue 
box is divided into the areas number of arcs, calculations, ovalism, angles, radii, 
fin widths, arc lengths, and profile data. 
 If a star (*) follows a calculated or entered value, it indicates that this entity is 
a straight element. The value is the length of the element. 
The Block Methods: 
The methods can be selected to design the tube flower. 
5.3.1. No. of Arcs 
Here the Number of Arcs to form the tube are defined. The Number of Arcs dia-
logue box is divided into the areas, sequence of stations, arc selection and num-
ber of arcs. 
Sequence of Stations/No. of Arcs: 
Shows the sequence of stations and the number of the arcs used in each pass. 
Arc Selection: 
The number of arcs can be selected by operating the slide. The number of arcs 
varies according to the forming strategy of the designer. Maximum 4 arcs can be 
used for each symmetrical side. 
Number of Arcs: 
Single pass types, which shall be formed double symmetrically, can be selected. 
The condition for this function is that a double symmetrical profile gets formed. 
Only a quarter of the profile will be defined. The values will be mirrored twice. 
 This method offers the possibility to design with a maximum of 8 arcs per 
symmetrical side. The condition is that the final profile is double symmetrical. 
COPRA® Round & Rectangular Tubes 
 
Flower (round Tube) 
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© Copyright by data M Software GmbH  
5.3.2. Calculations 
The calculation method of each pass can be defined. The Calculations dialogue 
box is divided into the areas sequence of stations, calculation method and factors. 
Sequence of Stations: 
Shows the sequence of stations and the currently selected pass. 
Possible Dependencies: 
A possible dependence of the previous or following pass can be defined. No val-
ues will be defined here. The actual settings are defined in the Calculation 
Method dialogue box. 
From previous Station: 
If set, the dependency from the previous station will be used. 
From next Station: 
If this toggle is set the dependency from the next station will be used. 
Current Station only: 
If set, no dependencies are used. 
 
5.3.2.1. Calculation Method  
Shows the used calculation method with the respective slide and formula. Differ-
ent pass types can have also different calculation methods. 
Modify: 
If selected, the Calculation Method can be changed. 
  At least one value must be calculated from the strip width and one value 
must be set on user-defined. 
Modify Station/Calculation Method: 
The dialogue box is split into the areas radius, angle and dependencies. 
Radius: 
Offers different possibilities to determine the radius of the selected arc. 
Angle: 
Offers different possibilities to determine the angle of the selected arc. 
COPRA® Round & Rectangular Tubes 
 
Flower (round Tube) 
© Copyright by data M Software GmbH  
 
57 
Dependencies: 
Depending on the selection which was made in the calculation/dependencies 
dialogue box, is it now possible to use factors and to enter a dependency on the 
previous, the next pass or any pass number. 
  A calculation of the fin width can be used in the fin passes. In the sizing 
passes, only the calculation formula is shown since the profile is already 
closed. 
  In case there are any problems with the inserted values and the calculation 
cannot be made an error message will appear. 
Factors: 
Here the factors will be defined for the dependence of passes for the respective 
radii and angles. The values can be adapted depending on the forming strategy. 
For example, the welding radius is bent in the first station and kept until the weld-
ing (Weld radius x Factor 1). 
 
5.3.3. Ovalism 
The Ovalism can be defined for the passes. The Ovalism dialogue box is split 
into the areas, station and form of profile.  
 An Ovalism can be defined only for a closed pass (fin pass or sizing pass). 
Station: 
Shows which pass is set on actual, and should be modified. 
Form:  
Shows which method is used for defining the profile form: calculation or oval 
Form of Profile:  
Here the form of the profile can be chosen from four different options 
Acc. to Calculation:  
If an oval form is not to be calculated, this option must be selected. 
High:  
When using the method high oval, the value for the Ovalism can be entered in 
percent. This means that the profile, according to the entered value, is higher than 
wider. To determine the oval there is also a possibility to change the angles. 
Round: 
When selecting this option, the profile is formed round.