September 13, 2005
Ubeco's Profil roll form design software automatically creates the flower pattern, which speeds up roll tool design for recurring profiles.
The required know-how is taken from the system's knowledge base that increases as the system is used. When a new profile is designed, usually a successfully produced similar profile from a previous project is utilized. The flower pattern and the roll tooling are modified in accordance with the new profile form.
The software automates the process by first creating a development table from the existing design project. This table represents the flower pattern scheme and contains the bending angles and methods. If necessary, the table can be edited and modified or can be created manually. To create the table for a new profile with different angles, the designer converts table angles to percentages related to the final angle. After adding any comments, the designer saves the development table, thus creating a company-specific knowledge base for different profiles.
To create a new profile, the designer simply opens the appropriate development table and applies it to the new profile, automatically creating the flower pattern for all passes without using a software-based algorithm.
Results can be verified and checked using the quality management tools: band edge stress calculation, profile stress analysis (PSA), and the Virtual Roll Forming Machine that simulates the roll forming process by finite element analysis (FEA).