ITCP

VOLUME 1


VOLUME 2 VOLUME 3



Precision Forging I
Invited Paper
New Methods for Precision Forging

K. Osakada
735
Invited Paper
QS-9000 - A Challenge with New Opportunities for Net Shape Cold Forging Technology

M. Hänsel, M. Meidert, R. Geiger
741
Newer Process Developments in Cold- and Semi-Hot- Metal Flow Forming
C. Sekreter, E. K”rner, A. Meyer
749
A Study of Ironing as a Cold Post-Process to Achieve Net-shape
J. Cai, Z.M. Hu, T. A. Dean
753
Analysis of an Industrial Net-shape Forming Application through Numerical and Experimental Approach
L. Tricarico, M. De Cosmo
759

Precision Forging II
Invited Paper
Warm Forging of Straight Tooth Bevels for the Utility Vehicles' Production

Th. Herlan
767
Invited Paper
Near Net Shape Forging of Helical Gears - Economical and Technical Aspects

F. Dohmann, P. Wiebe
779
Precision Forging of Helical Gear with Axially Driven Die
K. Osakada, X. Wang, S. Hanami
787
Net-shape Forging of Gear Toothed Parts Utilizing Divided Flow Method
K. Ohga, F. Murakoshi, H. Ando, K. Miyoshi, K. Kondo
793
Investigation of Plastic Forming Process for Spur Gear
Z.M. Zhang, B.H. Zhang, L. Liang
799

Cold Forging
Invited Paper
Stability Control of Cold Forming Processes

K. Kuzman
805
Evaluation of Strain Distribution in Cold Extruded Workpiece by Means of Various Methods
A. Kocanda, S. Swillo
813
Practical Approach of Using FE Simulations for Eliminating Crack Defects of Cold Forged Parts
H. Kim, T. Yagi, M. Yamanaka
819
Hardness Measurements on Cold Formed Workpieces
A. E. Tekkaya
825
Process Design in Cold Forged Inner Pulley for Automobile Air-conditioner
D.J. Jeong, D.J. Kim, B.M. Kim
831
Numerical Simulation of Extrusion-upsetting Forming of Automotive Tyre Nut
X.L. Hu, Z.J. Wang, Z.R. Wang
837

Cold & Warm Forging
Invited Paper
FE-Simulation as an Instrument of Quality Prediction for 2D and 3D Cold and Semi-hot Forged Parts

A. Behrens
847
Warm Forging of 17-4PH Stainless Steel through Ausforming Process
S. Isogawa, H. Yoshida, Y. Tozawa
853
An Upper Bound Analysis for Torsional Upset Forging of Cylindrical Billets
Y.H. Kim, J.H. Park, Y.E. Jin
859
Working Load Reduction in Cold Forging with Cyclic Loading
M. Kakiuchi, T. Kawabe, K.Shiraishi, T. Wada
865
Die Forging Utilizing Thickening of Drawn Cup Wall
K. Katoh, K. Kondo
869
Evaluation of Galling Prevention Property of Cold Forging Oils for Stainless Steel
K. Kitamura, T. Ohmori
875

Forming of Microparts I
Foundations of Micro-Forming
J. Leopold
883
Forming of Microparts - Effects of Miniaturization on Friction
N. Tiesler, U. Engel, M. Geiger
889
Effects of Size and Texture on the Constitutive Behaviour for Very Small Components in Sheet Metal Forming
P. Picart, J.F. Michel
895
FEM Analysis and Experiment on Multistage Forging for Wrist Watch Parts
K. Yoshida, M. Fukazawa, B. Kuboki
901
Controlling Metal Flow of Surface Microgeometry in Coining Process
H. Ike, M. Plancak
907
Micro-parts Fabrication Technique by Shearing of Thin Wire
I. Aoki, T. Takahashi
913

Forming of Microparts II
High Precision Embossing of Microparts
R. Neugebauer, A. Schubert, J. Kadner, T. Burkhardt
921
Spread Rolling of Copper Alloy for Leadframes
Y. Saito, H. Utsunomiya, S. Kaneko, T. Sakai, T. Kanzaki
927
Dynamic Tool Behaviour in Microstamping Processes
E. Doege, T. Liesener, D. Straßer
933
Grain and Specimen Size Effects in Processing Metal Sheets
L.V. Raulea, L.E. Govaert, F.P.T. Baaijens
939
Analysis of Metal Injection Molding as a Near Net Shape Forming Process for Microparts
T. Barriere, M. Dutilly, J.C. Gelin
945

Ring & Shape Rolling
Invited Paper
Precision Forming of Rings for Bearing Manufacturing

G.D. Lahoti
953
Simplified Three-dimensional Finite Element Simulation of Ring Rolling
K. Mori, O. Ebihara
959
Simulation of Material Flow at the Ring Rolling Process
E. Doege, H. Mathieu, S. Puller
965
Three-dimensional Finite Element Simulations of Shape Rolling
S.-Y. Kim, Y.-T. Im
971
Adaptive Mesh Generation Scheme for the Three-dimensional Deformation Analysis of Shape Rolling
J. Yanagimoto, H. Kubota
977
Finite Element Simulation of Shape Rolling of Complex Shaped Parts - A Steady State Approach
H.J. Kim, T.H. Kim, S.M. Hwang
983

Rapid Tooling
Invited Paper
New Developments in the Technology of Selective Laser Sintering

F. Klocke, C. Wagner
991
Rapid Sheet Metal Development Chain Supported by Laser Sintered Active Tool Parts
K. Kuzman, M. Geiger, A. Coremans, L. Cser, J.-P. Kruth
999
Direct Manufacturing of Metallic Tools by Laser Rapid Prototyping
F. Abe, K. Osakada, K. Uematsu, M. Shiomi
1005
Microstructuring of Metallic Powder / Hard Materials by Selective Laser Sintering Process
Y.P. Kathuria
1011

Laser Assisted Metal Forming
Closed Control Loop System for Laser Bending of Extrusion
A. Otto, V. Brandt
1019
Three-Dimensional Laser Bending of Sheet Metal
M. Otsu, M. Fujii, K. Osakada
1025
Forming in Combination with Lasers: Laser Assisted Flow Forming
F. Klocke, A. Demmer
1031
Sub-micron Accuracy of Assembled Systems by Laser Adjustment
B. Müller, A. Huber, M. Geiger
1037
Deep Drawing of Locally Optimized Aluminum Blanks
A. Hofmann, Th. Pohl, M. Geiger
1043

Bending of Sheets
Numerical Prediction of Residual Stresses in Sheet Bending and Experimental Measurement
L. Filice, F. Micari, L. Pagnotta, A. Poggialini
1053
Small Radius Bending of Sheet Metal by Indentation with V-shape Punch
H. Ogawa, A. Makinouchi
1059
High Longitudinal Accuracy V-Bending by Controlling Longitudinal Bending Force Distribution
J. Endou, T. Anzai, K. Koyama, T. Mizuno, H. Yamada
1065
A Rigorous Numerical Analysis of Residual Curvature of Sheet Metals Subjected to Bending-Unbending under Tension
T. Kuwabara, N. Seki, S. Takahashi
1071
Springback of Sheet Metal Laminates Subjected to Stretch Bending and the Subsequent Unbending
R. Hino, Y. Goto, M. Shiraishi
1077
Simulation of Compound Bending Forming of Sheet Metal by FEM
G. Yanjin, S. Sheng, W. Zuocheng, L. Yiguo, J. Zhong
1083

Bending & Spinning of Sheets
Dieless Shear Spinning of Truncated Conical Shells
K. Kawai, L.-N. Yang, H. Kudo
1089
A General Upper Bound Method for Forces Calculation in Tube Spinning Process
V. Paunoiu, D. Nicoara, M. Teodorescu
1095
Numerical Simulation of Sheet Spinning Process
K. Dai, X.C. Gao, D.C. Kang, Z.R. Wang
1101
FE Simulation of Tension Levelling Process for Clad Sheet Metals
F. Yoshida, M. Urabe
1107
Simulation of Binder Wrap Stage by Dynamic Explicit FEM
X. Dong, Y. Zhen, Z. Zhen, S. Li, Z. Li
1133

Forming of Lightweight Materials
Invited Paper
Lightweight Construction by Innovative Forming Technologies

R. Neugebauer, H. Bräunlich
1119
Invited Paper
Strategies and Future Developments in the Manufacturing Process of Light-Weight Car Bodies

H. Hoffmann, A. Toussaint
1129
Mechanical Properties of Magnesium Metal Matrix Composite Reinforced by SIC Particles
M. Takahashi, E. Masamura, K. Matsuzaki, H. Takeishi, T. Sano
1141
Study on Composite Forming Conditions of Stretch Draw and Ironing for Laminated Steel
I. Komatsu, K. Takao, K. Imazu
1147
Conical Cup and Erichsen Testing of Light Metal Sheets at Elevated Temperatures
M. Sugamata, J. Kaneko, M. Numa
1153

Hydroforming
Invited Paper
Product Innovation with Internal High Pressure Forming

D. Bobbert
1161
Invited Paper
Innovative Forming Technologies for Space Frames

W. Leitermann, K.-H. von Zengen, P. Dick
1165
Invited Paper
State of the Actual and Prospective Development of Hydroforming

D. Schmoeckel
1171
Product Development of Complex Hydroformed Parts and Requirements Regarding Tool Manufacture
C. Hartl, T. Abbey
1183
Tee Fitting Hydraulic Formability of Aluminium Alloy Tubes
H. Mizukoshi, H. Okada, H. Wakabayashi
1189

Hydroforming of Tubes
Invited Paper
Hydroforming: Needs, Developments and Perspectives

F. Vollertsen, T. Prange, M. Sander
1197
3D Numerical Simulation of Tube Hydroforming
O. Ghouati, M. Baida, H. Lenoir, J.C. Gelin
1211
Evaluation of Material Characteristics in Tube Hydroforming: Hydraulic Bulge Testing of Tubes
T. Sokolowski, K. Gerke, M. Ahmetoglu, T. Altan
1217
Experimental Investigation into a Tube Forming Method for Providing Tubes with Thickness Distribution in Axial Direction
A. Shirayori, S. Fuchizawa, M. Narazaki
1223
FE Analysis on Local Thinning and Fracture Phenomenon in Hydroforming of Tubular Components
K. Manabe, M. Amino, S. Nakamura
1229
Technological Analysis and Engineering Calculation on Hydraulic Extrusion-Bulging Forming of Multi-Way Tube Joint
H. Shen-zhang, Z. Zhen-peng
1235

Hydroforming of Sheets
Invited Paper
Processes and Control of Sheet Metal Hydroforming

M. Kleiner, W. Homberg, A. Brosius
1243
Invited Paper
Numerical Simulation of Some New Integrated Hydroforming Processes

Z.R. Wang
1253
Process Limits for the Hydroforming of Sheet Metal Pairs
S. Bobbert
1261
Advanced Process Control Strategies for the Hydroforming of Sheet Metal Pairs
P. Hein, M. Geiger
1267
Numerical Simulation of the Hydromechanical Deep Drawing Process
S.H. Zhang, L.H. Lang, D.C. Kang, J. Danckert, K.B. Nielsen, Z.R. Wang
1273

Material Modelling
Predictions of Microstructure in Hot Forging of Microalloyed Steels
T. Ishikawa, N. Yukawa, Z. Wang, A. Kono, T.-Q. Li
1281
Determination of Constitutive Parameters of Anisotropic Plastic Materials Using a Finite-Element Polycrystalline Model
T. Sueyoshi, M. Goya, K. Miyagi, K. Ito
1287
A CAE Supported Ball Indentation Method for the Stress Strain Curves of Hard Materials, such as Hardened and High Speed Steels
K.-D. Bouzakis, N. Vidakis, A. Lontos
1293
Sintering Process Simulation by the Coupled Macro-micro Modeling
F. Tsumori, T. Aizawa
1301
Study of Strain Localization of Sheet Material by Using Elastic/Crystalline Viscoplastic Finite Element Method
E. Nakamachi, M. Harimoto, C.L. Xie
1309
The Numerical Simulation of Dynamic Recrystallization and Prediction of Grain Size Inhomogeneity
Q. Jin, F. Xu
1315

Powder Metallurgy
Thin Film Forming of Pure Aluminum Powders by Dynamic Compaction
N. Nakayama, K. Hanada, T. Sano, S. Horikoshi, H. Takeishi
1321
Dynamic Powder Compaction Method to Control Strain Distribution in Metallic Powder
N. Sukegawa, T. Sano, S. Horikoshi, H. Takeishi
1327
A Study of Fracture Behaviour of Powder Compacts
S. Shima, H. Kotera, K. Nishimura
1333
Fabrication of Ni-Ti Bimetallic Rods by Explosive Powder Compaction and Extrusion
A.G. Mamalis, A. Szalay, D.E. Manolakos, N.M. Vaxevanidis
1339
Magnetic Powder Characteristics Simulated by 3D Particle Dynamics Method
H. Kitahara, H. Kotera, S. Shima
1345
Magneto-Cosserat Continuum Theory for Simulating the Magnetic Powder Behavior during Compaction in Applied Magnetic Field
H. Kotera, S. Shima
1351

Sheet Metal Formability I
A Hybrid Quasi-static-dynamic Process for Increased Limiting Strains in the Forming of Large Sheet Metal Aluminum Parts
V.J. Vohnout, G. Daehn, R. Shivpuri
1359
Plasticity of Aluminum Alloy 1050 During Non-Proportional Loading
J.J. Gracio, F. Barlat, J. Ferreira Duarte
1365
Process Variables for Improving the Drawability of Aluminum Alloy Sheet in Fuzzy Adaptive Control-based Deep Drawing
S. Yoshihara, K. Manabe, M. Yang, H. Nishimura
1371
Warping of Pressings - Forming Limit Charts
R. Samek, A. Calkovský
1377
Formability of Stainless Steel and Commercially Pure Titanium Sheets in Plate Heat Exchanger Applications
P. Gabrielson, E. Schedin, G. Ekstrand
1383
Analysis of Planar Anisotropic Sheet Metal Stretching by the Finite Element Method
M. Farzin, M. Foroutan
1389

Sheet Metal Formability II
A Relation Between the Limit-Drawing Ratio LDR and the Material Properties Strain-Hardening Exponent n and Anisotropy Factor R
J.A.H. Ramaekers
1397
Anisotropic Fractal of Surface Irregularities of Aluminum Sheets Subjected to Uniaxial Tension
Y. Kurosaki, M. Matsui, K. Kuroki, K. Ishikawa
1405
Analytical and Experimental Investigation on Anisotropic Yield Criteria
D. Banabic, T. Balan, K. Pöhlandt
1411
Advanced Deformation Measurement in Sheet Metal Forming
B. Alpers, D. Bergmann, K. Galanulis, D. Winter
1417
New Method for Evaluating Superplastic Tensile Properties by R-type Specimen
S. Mizunuma, H. Takahashi, Y. Takayama, N. Furushiro, T. Mimaki
1423
Tensile Properties and Press Formability of a Mg-Li Alloy Sheet
H. Takuda, S. Kikuchi, K. Kubota, N. Hatta
1429

Joining by Forming
Invited Paper
Multiple Press Joining of Coated Sheet Metal Parts as an Example of Integrated Manufacturing of Household Appliances

H.-P. Liebig, M. Pander, J. Bober
1437
Fabrication of Near-net Shape Functional Components by Mashy-State Joining
M. Kiuchi, J. Yanagimoto, S. Sugiyama
1443
High Precision Joining of Metal Sheet and Spindle by Using Plastic Deformation
K. Kato, T. Yasuhara, M. Adachi, M. Ban
1449
Theoretical and Experimental Studies on the Compound Forming Process of a Tube Junction
T. Wang, X. Zhao, G. Zhao
1455
Research on Numerical Simulation for Combinative Process of Superplastic Forming/Diffusion Bonding
L. Jingyi, W. Weiying, Z. Zhongyuan
1461
Fatigue Strength of Pressure Welded Joint of Aluminum Alloys
S. Maki, N. Tsuji, Y. Harada, M. Nakamura
1469

Incremental Forming
Incremental Sheet Metal Forming Using Elastic Tool
S. Tanaka, T. Nakamura, K. Hayakawa
1477
A Simple Deformation Analysis for Incremental Bulging of Sheet Metal Using High Speed Water Jet
H. Iseki
1483
Improvement of Mechanical Properties of Spring Steel Using Warm Shot-peening
Y. Harada, K. Mori, Y. Fukuoka, S. Maki
1489
Cylindrical Incremental Drawing of Sheet Metals by CNC Incremental Forming Process
K. Kitazawa, A. Nakajima
1495
Deformation Analysis for Stretch Forming of Sheet Metal with CNC Machine Tools
T. Sawada, S. Matsubara, M. Sakamoto, G. Fukuhara
1501

Rolling of Sections I
A Methodology to Attain Higher Straightening and Lower Residual Stress in Bar Products by a Two-roll Straightening Technique
M. Asakawa, Y. Nishikori, T. Yanagihashi, H. Okada
1507
Improvement of Seizure Defect on Rolling of Stainless H-Beams
Y. Kusaba, M. Izawa, T. Hibi, J. Ikeda
1513
Application of Three Dimensional Thermal-mechanical Coupled FE Analysis to Bar Rolling Process
Y. Wang, Y. Kang, D. Yuan, W.Wen, Z. Yu
1517
Experimental and Finite-Element Analysis of Axial Feed Bar Rolling (AVQ)
M. Houska, M.-I. Rotarescu
1523
Analysis of Interacting Influencing Parameters on the Tolerances of Wire Rod and Bars in the Rolling Process
P.J. Mauk
1529
Elongation-Control Rolling of Square Wire
H. Utsunomiya, Y. Saito, M. Shinkawa, F. Shimaya
1537

Rolling of Sections II
Characterization of Wire Rolling and Wire Roll Drawing Using 2-roll, 3-roll and 4-roll Mills
K. Ono, J. Yanagimoto
1545
Finite Element Analysis and Experiments on Helical Rolling of Tube
H. Takizawa, T. Kimura
1551
An Integrated Approach for Robust Roll Pass Design and Evaluation
S. Kini, R. Shivpuri
1557
Development of Flexible-size Technology for Sections with a Skewed Roll Mill, a Pre-forming Rolling Mill
K. Hiroguchi, K. Fujita, M. Kodama, N. Onodera
1563
New Development on Cross Wedge Rolling Technology in China
G.S. Ren, C.G. Xu, J.L. Wang
1569
Measurement of Pressure and Frictional Stress on the Roll Surface during Mandrel Mill Rolling
T. Yoneyama, M. Yamada, T. Yamada
1575