ITCP

VOLUME 2


VOLUME 1 VOLUME 3



Plenary Session I
Keynote Paper
Metal Forming - a Key Technology for Automobile Production

K.-D. V”hringer
3
Keynote Paper
25 Years German Metal Forming Association - Driving Force of Research and Development

K. Lange
13

Plenary Session II
Keynote Paper
Simulation of Metal Forming Processes - Applications and Future Trends

T. Altan, W. Thomas, V. Vazquez, M. Koc
23
Keynote Paper
Improvement of Product Accuracy in Cold Die Forging

K. Kondo
41
Keynote Paper
Examples on European Industrial Research on Bulk Metal Forming

N. Bay, T. Wanheim, B.G. Ravn, M. Arentoft
49
Keynote Paper
Innovative Metal Forming Processes to Manufacture Future Sheet Metal Products

R. Kopp, O. Drr
69

Quality & Economy
Invited Paper
Economical Significance of Metal Forming Processes

M. Hirschvogel
83
Invited Paper
Technology Fusion in Metal Forming Field

M. Kiuchi
85
Invited Paper
Business Unit as General Contractor

A. Stalmann
95
Standardised Product Data Representation for the Metal Forming Industries
D.J. Mynors, N. Swindells, A.N. Bramley
105
Application of Control Figure on Quality Management System
F. Pan, Y. He, J. Han
111

Knowledge Engineering
Invited Paper
Integration of Numerical Modelling and Knowledge Based Systems in Metal Forming

M. Tisza
117
Invited Paper
Process State Monitoring Based on Data Mining in Hot Rolling

L. Cser, A.S. Korhonen, O. Simula, P. Ruha
129
Computer-Aided Process Planning for Non-axisymmetric Hot Forging Products Using a Constraint Blackboard
T. Ohashi, M. Motomura
137
Optimal Blank Design Through an Inverse Identification Approach
N. Alberti, R. Di Lorenzo, L. Fratini
143
Development of Computer Integrated System Supporting Design of Process and Dies of Multiple Stage Forging Processes
D.Y. Yang, Y.T. Im, Y.K. Lee, C.H. Lee, C.H. Park, J.H. Song, Y.S. Lee, E.G. Yoh, J.H. Kim, K.K. Hong, J.H. Kim, S.R. Suh, J.H. Khang
149
The Prediction of Geometrical Configuration and Ductile Fracture Using the Artificial Neural Network for a Cold Forged Product
D.J. Kim, B.M. Kim
155

Machine Tools I
Invited Paper
Economic Manufacturing of Large Body Parts with New Press Technology

E. Harsch, B. Viehweger
163
Recent Process Developments and Press Type Criteria
A. Strauch, E. K”rner
171
Pliable Blank Holder Systems for the Optimisation of Process Conditions in Deep Drawing
E. Doege, L.-E. Elend, C. Ropers
177
Development of Set-up System for 12-High Cluster Type Rolling Mill
N. Nishiura, F. Fujita, R. Yagi, N. Suzuki, S. Murata
183
Research on Multi-Point Forming of Three-Dimensional Sheet Metal Parts
M. Li, C. Liu, Q.Chen
189
CNC Strategy in Technology of Plasticity
Yu. Bocharov
195

Machine Tools II
Invited Paper
Press Concept for the Future in Precision Forging

E. Doege, R. Bohnsack
203
Integration of Advanced Engineering with New Production Machinery for Net Shape Cold Forming
K.-H. Weiá, R.J. Schilling, J.W. Carper
211
State of the Art and Survey of Large Automatic Forging Presses in Japan
A. Baba, J. Nishikawa, Y. Kawashima
221
Implementation of Metal Forming Analysis in the Design of Forging Machines
F.H. Osman, J. Ferreira
227
Strike Characteristics of Double-strike Screw Presses
P. Li, S. Li, G. Hu, Y. Liu, Z. Yang
231
An Integrated Tool Design System in Collaboration with the Displacement Adjustment of Forging Machine
J.-J. Sheu
235

Tools I
Invited Paper
Optimisation of Life Performance and Net-Shape Capability of Cold-Forging Tools through Minimisation of Micro-Plastic Phenomena

J. Groenbaek, T. Birker, T.O. Pedersen
243
Optimal Prestressing of Cold Forging Dies
T. Rodic, I. Gresovnik, M. H„nsel, M. Meidert
253
Damage and Fracture Analysis of Extrusion Dies by Local Approach with Continuum Damage Mechanics
K. Hayakawa, T. Nakamura, S. Tanaka
259
Controlled Wear as Mechanism for the Design of Geometrically Defined Nanometric Surface Structures on Forming Tools
K. Steinhoff, A. Kapoor, N. Guillon
265
Improved Fatigue Strength of Cold Forging Tools by Surface and Coating Technologies
Ch. Hinsel, M. Celeghini, U. Engel, M. Geiger
271

Tools II
Invited Paper
On Performance and Strength of Metal Forming Tools Subjected to Local Plastic Strains under Loading

A. Kocanda
281
The Feasibility of Using Approximate Tooling Profiles in the Simulation of Cold Forging
D.J. Mynors, J.M. Crookes, D. Garner, J. Hankers, A.N. Bramley
291
Computer Aided Preforming Tool Shape Design in Hot Forging
L. Fourment, D. Vieilledent
297
A Progressive Dies' Structure CAD System Based on the Function-Oriented Assembly Design Environment
Z.Q. Sheng, X.Z. Xiao, J.Y. Wen, J.J. Li
303
The Development of a Die Design Support System for Aluminum Extrusion
K.E. Nilsen, H.J.J. Kals, F.J.A.M. van Houten, T.H.J. Vaneker
309

Tribology Modelling
Tool/Workpiece Interface Interaction and Its Influence on Metal Forming Processes
Z.M. Hu, V. Pornbenjapakkul, T. A. Dean
317
FE-Process-Simulation of Cold Forging Processes with Adaptive Friction Factors
A. Behrens, H. Schafstall
323
Mechanical Modelling of Friction and Wear
H. Gläser, H. Wulf
329
Examination of Tribological Tool Load in Cold Forging and Fine Blanking with the Finite Element Analysis
F. Klocke, H.-W. Raedt
335
Application of Computer Technology to Select and Create Lubricants for Plastic Deformation Processes
N.P. Barykin, V.I. Semenov, A.Kh. Kildibaeva
341
Identification of Tribological Parameters during Upsetting Tests Using Inverse Analysis with a 2D Finite Element Code
B. Boyer, E. Massoni
347

Tribology Testing
Invited Paper
Frictional Study of Uncoated Steel Sheets

A. Wihlborg, R. Crafoord
355
A New Friction Test Using Simple Upsetting and Flow Analysis
X. Tan, W. Zhang, N. Bay
365
Measurement of 3D Oil Film Thickness at the Interface between Die and Workpiece in Lubricated Upsetting by means of Newly Developed Fluorescence Technique
A. Azushima, J. Miyamoto
371
Evaluation of Cold Forging Lubricants under Realistic Forging Temperature Conditions
H. Saiki, G. Ngaile, L. Ruan, Y. Marumo
377
Development of Environmentally Friendly Lubricant with High Performance and Simple Treatment for Cold Forging
M. Takeuchi, F. Ikesue, N. Kashimura
383
Three-Dimension Analysis of Contact Stress Measurements in Forming Processes
F.H. Osman, F. Potel, M.S. Loveday
391

Materials
Invited Paper
Development of a Low Carbon Hardened Steel for Hot, Cold andWarm Forging Applications

V. Ollilainen, E. Hocksell
399
Invited Paper
Innovation Potential of Materials and Their Impacts on Processing in Forming Technology

J. Reissner
409
Invited Paper
Bulk Mechanical Alloying for Processing of Functional Materials

T. Aizawa
419
Research on Recrystallization of SWRH-82B High during High Strain Rate
P. Yumei, C. Qingwu, T. Di, Z. Yuzhou, M. Zhenli
429
Analysis of the Impact Behavior of Interstitial Free (IF) Steels with Special Emphasis on Cold Work Embrittlement
A. Spalek, G. Reisner, E.A. Werner
435

Metallurgy
Effect of Carbon Content on Deformation Behaviour of Carbon Steels in the Austenite Temperature Range
C. Nagasaki, J. Kihara
443
Optimization of the Hot Flat Rolling by its Modelling at the Laboratory Mill Tandem
I. Schindler, M. Radina, T. Kubina, F. Kure, A. Silbernagel, L. Cizek
449
Fabrication of Refractory Metal Silicides and Aluminides from Mechanical Alloyed Precursor
M. Suzuki, T. Aizawa
455
Precipitation, Strain Hardening and Softening during Hot and Warm Rolling of Microalloyed Steels
S. Ksters, H. Langner, W. Bleck
461
Deformation Behavior and Resulting Microstructure Development of Microalloyed Steels Deformed in the Two-phase Region
J. Majta, A.K. Zurek
467
Experimental Research of Tertiary Recrystallization in Grain Oriented Silicon Steel Produced by Cross Shear Rolling
K. Qi, X. Gao, T. Wang, H. He, R. Li
473

Modelling & Simulation I
Invited Paper
Future Perspectives and Limits for the Mathematical Modelling of Metal Forming Processes in Automotive Industry

H.-J. Haepp, K. Roll
481
Keynote Paper
Recent Progresses in Optimal Design of Metal Forming Processes through Numerical Simulation

J.C. Gelin, O. Ghouati
489
Invited Paper
Constitutive Modelling for Simulation in Forming Technology

K. Wegener
497
Process-oriented FEM Forming Simulation
J. Leihkauf, G. Obieglo
507
UBET Using the Stream Function and a New Element for This Technique
T. Shimizu, T. Sano
513

Modelling & Simulation II
Invited Paper
Automatic Mesh Generation and Remeshing for Finite Element Analyses of 3D Bulk Forming Processes

D.Y. Yang, Y.K. Lee
521
Invited Paper
Material Laws and Elements for Sheet Metal Forming Simulations

D. Besdo
533
Invited Paper
The Increasing Requirements on Empirical Data for Use in Metalforming Process Simulation Packages

T.A. Dean, Z.M. Hu
541
3D Finite Element Analysis of Radial Forging Using Process Frame Approach
T. Rodic, O. Wensel, A. Pristovsek
551
Simulation of Metal Deformation Induced by Differential Heating
F.H. Osman, M. Hua, J. Graeff, Y.F. Guo
557

Ecological Manufacturing
Special Seminar organized in cooperation with the ICEM International Committee on Environment and Manufacturing
Keynote Paper
Steps Towards Sustainable Manufacturing in Automotive Plants - State of the Art and Future Challenges with the View on Technology, Economy and Ecology

W. Pollmann
563
Keynote Paper
Metal Forming and Global Environment

T.Sano, A. de Winter
569
Research Trend of the Environmental Production Technology Innovation
K. Nakajima, Y. Tsuchida, T. Inoue
577
'Provens, Possibles and Probables' of Cascading in Metal Processing
A. de Winter, J. Quakernaat
583
Reduction of Environmental Impact Attained by Magnesium Alloys for Automotive Components
T. Sano, A. de Winter, T. Saiki, S. Horikoshi, S. Fuchizawa, S. Sado
589
Estimation of Energy Consumption in Steel Forging Process
K. Kubo, H. Sekiguchi, Y. Nakamaru, S. Kuromatsu
595
Environmental-Friendly PIM Technique Using Supercritical CO2
T. Shimizu, A. Kitazima, T. Sano
601
Manufacturing of Magnesium by Turning and Burnishing Operations
H.K. Tönshoff, B. Karpuschewski, J. Winkler, C. Podolsky
607
Local Collar Developed by Metal Plastic Deformation
T. Iura, K. Mori, K. Yamamoto, Y. Aono, K. Kurita, O. Nakamura, T. Sano
613
Towards Optimized Lubrication by Micro Texturing of Tool Surfaces
Th. Neudecker, U. Popp, T. Schraml, U. Engel, M. Geiger
619
Lubricant Reduction in Aluminium Deep Drawing by Means of Tool Coatings or Lubricating Primers
P.J. Bolt, R.P. Schaake
627
Deep Drawing of Sheet Metal with Hydraulic Counter Pressure and Vibration Using Volatile Lubricant
S. Kataoka, M. Murata
633
Application of Thermo-Mechanical Control Process (TMCP) to Ecological Issues
Y. Tsuchida, T. Inoue, K. Nakajima, Y. Hosoi
637
Papers accompanying poster presentations

Bending, Spinning, Rolling & Roll Forming
Plate Bending of Spherical Tank
B. Grizelj
643
Effects of Compressive Forces on Axial Direction in Tube Spinning
R. Muta, M. Murata
645
Features and Peculiarities at Deformation in the Two-phase-region
L. Chabbi, W. Lehnert
651
Finite Element Analysis for Roll Forming of Tubes and Channels
N. Kim, J. Kim
653

Deep Drawing


Dimensional Inaccuracy in Drawing Process of Aluminium Alloy Sheets
S. Bac, F. Stachowicz
657
A Study of the Effects on the Dynamic Explicit Analysis of Autobody Panel Stamping Processes by using the Faster Punch Velocity and the Mass Scaling Scheme
D.W. Jung, D.Y. Yang
659
3D FE Simulation of Square Cup Deep Drawing
D. Malgyn, Gy. Krallics, K. Kardos
661
Simulation of Springback Effect during Stretching
Ö. SzabadĄts, Gy. Krallics, D. Malgyn
663
Experiences with Expert Systems for Process Planning of Deep Drawing
M. Tisza jr.
665
Effect of Hot-Rolling Processing Parameters on Deep-Drawing Properties of Hot-Rolled Interstitial-Free (IF) Steel
Z.C. Wang, X.J. Guan, X.J. Wang, Z.R. Wang
669

Extrusion & Drawing
Modelling of Extrusion Processes based on Asymptotic Velocity Fields
S. Alexandrov, G. Mishuris, W. Miszuris, R. Sliwa
673
Technological Lubricants for Wet Drawing of Brass-coated Wire
N.P. Barykin, V.I. Semenov, A.Kh. Kildibaeva, L.Sh. Shuster
675
Extrusion with Changing Cross Section Shape of Tube
K. Hasegawa, M. Murata
677
Contribution of Finite Element Analysis Approach to Backward Extrusion
M. Math, B. Jerbic, S. Mahovic
681

Forging
Analysis of Circumferential Forces Acting during Rotary Forging Process
T. Balawender, F. Stachowicz
685
Warm Compression of Aluminum Alloy Axisymmetric Rings
C. Borsellino, F. Micari, V.F. Ruisi
687
3D Forging Simulation of Components for Aircraft Applications
W. Horvath, G. Weber
689
Possibilities of FEM Simulation by Large Crankshaft Production
B. Masek, Z. Novy, D. Kesner
691

Materials
Combinatorial Method of Analysis of Non-linear Properties of Structural-Mechanical Models of Materials
N. Barykin, A. Galimov
695
Modern Method for Investigating Normalised Condition of Steel Wide Strips
Z. Csepeli, G. Kralik, J. Lorinczi
697
Development and Prospects on Crack Healing of Metal
J. Han, D. Wei, H. Hu, Y. He
699
Analysis of Plastic Deformation on the Basis the Grain Microdeformation
S. Randjelovic, V. Stoiljkovic
701
On Evolutional Constitutive Equations Construction for the Finite Deformations
A. Rogovoy, R. Novokshanov
703
Effect of Microstructure on the Mechanical Behavior of Aluminum Alloys
N. Solomon, I. Solomon
709
Serrated Behaviour of Al-Mg Sheet in In-plane Stressing
M. Yoshimizu, H. Ohsawa
711

Tools & Machine Tools
Experimental and Numerical Evaluation of Different Powder Metallurgical Steels for Cold Forging Tools
B. Falk, U. Engel, M. Geiger
715
Development of Control Systems for the Blank-holding Action in Sheet Metal Forming
C. Garcia, F. Le Maitre
717
A New Approach In Die Set's Design
A. Kocov, J. Lazarev
719
Some Issues in Design of Presses with Levers
Y. Sun, X. Zhu, P. Chen, X. Xiao, Z. Zhang
723

Other Processes
Examination of Working Limitation for Change of Sectional Shape in Dieless Shearing of Extruded Section
H. Kida, N. Takatsuji, M. Tokizawa, K. Murotani, K. Matsuki
727
Laser Machines for Contour Cutting and Their Influence on Working Quality
M. Radovanovic
729
The Possibility of Creation of Complex Coating Layers by Dual Beam Ibad Method
B. Rajchel, E. Wantuch
731