Journal of Materials i): Processing a Technology ELSEVIER Volume 113, Issues 1-3, 15 June 2001 www.elsevier.com/locate/jmatprotec Contents Preface Obituary: Prof. Kobayashi S. Inaba Development of a drilling burr control chart for low alloy steel, AISI 4118 S. Min, J. Kim, D.A. Dornfeld Problems of accuracy control in cold forming K. Kuzman Bulk forming Tool lubricating systems in warm forging ......... S. Sheljaskow Effect of the surface structure on the resistance to plastic deformation of a hot forging tool H. Saiki, Y. Marumo, A. Minami, T. Sonoi A flexible shear spinning of truncated conical shells with a general-purpose mandrel K. Kawai, L.-N. Yang, H. Kudo Cost effective implementation of forging simulation N. Biba, S. Stebounov, A. Lishiny Recent development and applications of three-dimensional finite element modeling in bulk forming processes G. Li, J.T. Jinn, W.T. Wu, S.I. Oh Analyses of plane-strain upsetting by the rigid—plastic domain-boundary element method Y.-M. Guo, K. Nakanishi FEM simulation of the flat-die preform forging of steel shaft-disc type components by thermal differential heating. .. . M. Hua, S.Q. Lu Process modification of bevel gear forging using three-dimensional finite element analysis YK Lees SiR. Lee; CHS Lee; DIY: Yang The micro-formability of Zr-based amorphous alloys in the supercooled liquid state and their application to micro-dies Y. Saotome, S. Miwa, T. Zhang, A. Inoue Analysis of the milli-forming of single-crystal and poly-crystal bar .. . Y.I. Kim, K.S. Sim, E.G. Yoh, Y.S. Lee, H.J. Park, K.H. Na Processing of single crystals for high temperature applications R.H. Zee, Z. Xiao, B.A. Chin, J. Liu The utility of radially and ultrasonically vibrated dies in the wire drawing process M. Murakawa, M. Jin The publisher encourages the submission of articles in electronic form thus saving time and avoiding rekeying errors. A leaflet describing our requirements is available from the publisher upon request. CONTE NTS This journal is part of ContentsDirect, the free alerting service which sends tables of contents by e-mail for Elsevier Science books and journals. You can register for ContentsDirect online at: ® www.-.elsevier.nl/locate/contentsdirect Elsevier Science B.V. Vili Contents The process sequence Gesign ol a power-assipion StecnBP PAN coo. 5 se eS ie eee ssa oe aes Sele telele omer s D.-H. Jang, T.-K. Ryou, D.-Y. Yoon, B.-B. Hwang 3D flow analysis inside shear and streamlined extrusion dies for feeder plate design .......0.0..... c.ee .ee .ee .ee e 93 B.V. Mehta, I. Al-Zkeri, J.S. Gunasekera, A. Buijk The lateral extrusion of copper pipes with a lost core of low temperature melting alloy .......................00000. 98 T. Ohashi, K. Matsui, Y. Saotome A UBET analysis of non-axisymmetric forward and backward extrusion. ......0.0.2 ..ee.e e.et. e.en s H.I. Lee, B.C. Hwang, W.B. Bae The intivence Of die ceomeny On ihe TAGIAlIeKIUSION PIGCESSES« «5. 5... os os sic i es ce ee a es Fe ow Sale wos 109 B.D. Ko, D.J. Kim, S.H. Lee, B.B. Hwang Phe Tittite ercmnent amin yeIs one tary AONINE BMOCESS 200055: ér55 2S 2.55 ae Ses Seen HS ae ew Se eos nes wrS cene wes eee 115 C.-K. Shih, C. Hung, R.-Q. Hsu Approximate analysis of roll force in a round—oval—round pass rolling sequence ........0..0.0. e.e ee. .ee.e e.e e 124 Yee; YS Kam Optimization of the irregular shape rolling process with an artificial neural network.....0..0.0..00. 0.0 .ee.ee. e.ee D.J. Kim, Y.C. Kim, B.M. Kim ane sommiie Chamctensncs On madial—forward GxusiON: 6. oc). css ee 2 a4 ees le thea Cae eds Dales sea we dasa Y.S. Lee, S.K. Hwang, Y.S. Chang, B.B. Hwang The fonmoip e Cn aCensucs OldaGial— pack Wane CKITUSION 6565. 5.5 @ 5-5. Sc. os fs ooo ne Sai o dis alee wa Biaiard SW did. 3,b lew lee elere wala eles 14] H.-J. Choi, J.-H. Choi, B.-B. Hwang Application of nimonic BOA to the hot foreine of an exhaust valve head. «0. ...0.22 6S. be Fede oN s ean k eee eee 148 D.K. Kim, D.Y. Kim, S.H. Ryu, D.J. Kim Finite element modeling of the deformation behavior of semi-solid materials... ......... 00000000 e eee eee eee 155 J.-H. Yoon, Y.-T. Im, N.-S. Kim Composites An investigation into the performance of solar cured adhesive bonded joints... .. 1.2... 0.0.0.0... eee eee ee eee 160 P.K.D.V. Yarlagadda, L.A. Stoynov, I.-S. Kim Effect of extrusion compounding on the mechanical properties of rubber-toughened polymers containing short glass fibers ... . 167 G. Sui, S.-C. Wong, C.-Y. Yue A composite cantilever arm for guiding a moving wire in an electrical discharge wire cutting machine .................. 172 C.S. Lee, J.H. Oh, D.G. Lee, J.H. Choi Damping characteristics of composite hybrid spindle covers for high speed machine tools ..............0..000 e0e0e J.D. Suh, S.H. Chang, D.G. Lee, J.K. Choi, B.S. Park Applications of fixed and variable frequency microwave (VFM) facilities in polymeric materials processing and joining ...... 184 H.S. Ku, F. Siu, E. Siores, J-.A.R. Ball, A.S. Blicblau A statistical expenmental) study of the injection molding of optical lenses... . 0.05.6. ck eh wee ee ee eee see as X. Lu, L.S. Khim Manufacture of composite screw rotors for air compressors by RTM process... .....00:. ce .ee ee.e e.ee 0ee e.ee eee J.D. Suh, D.G. Lee The fabrication process and mechanical properties of SiC,/Al—Si metal matrix composites for automobile IR CONIC ER CLINEST O P D110 \S awn aie Sen Aaa go Sanne a A SgR O BE Ue ra ee ame, aa to ee OE ae a a 202 H.S. Lee, J.S. Yeo, S.-H. Hong, D.J. Yoon, K.H. Na Measurement of the degree of cure of glass fiber-epoxy composites using dielectrometry........0.0.0.00.0. ..e.e e 209 K.G. Bang, J.W. Kwon, D.G. Lee, J.W. Lee Casting, welding, brazing and rapid prototyping WiIGE Pap Saving Ol Siaimiess Stee) 10 MNCKCI-DAseG SUPETALIOY 54065026 6 4 516 65 oa sw oh Gwe s leh ee a ow Eglo ede Oe 215 X.W. Wu, R.S. Chandel, H.P. Seow, H. Li | Joining OL ausicnine stainless stec!zand fermilac stainless Stee) 4o'sialon | ..2.06 0 es Se eb Ee a ee ee ee 222 | P. Hussain, A. Isnin Infrared sensing techniques for penetration depth control of the submerged arc welding process .................000005 228 H.C. Wikle III, S. Kottilingam, R.H. Zee, B.A. Chin Welding characteristics of the Inconel plate using a pulsed Nd:YAG laser beam. .........00.00. ce0ce. ee0e .ee.e e.e e 234 W.J. Han, J.G. Byeon, K.S. Park Contents The flowability of bentonite bonded green molding sand Y. Chang, H. Hocheng Modeling of the thermal history of the sand casting process S. Sulaiman, A.M.S. Hamouda Experimental investigation of semi-solid casting and die design by thermal fluid-solidification analysis . C.G. Kang, Y.I. Son, S.W. Youn Numerical analysis of secondary cooling and bulging in the continuous casting of slabs J.S. Ha, J.R. Cho, B.Y. Lee, M.Y. Ha On the improvement of the stereolithography (SL) process A.Y.C. Nee, J.Y.H. Fuh, T. Miyazawa Direct metal laser sintering for rapid tooling: processing and characterisation of EOS parts. . M.W. Khaing, J.Y.H. Fuh, L. Lu Development of a direct metal freeform fabrication technique using CO, laser welding and milling technology D.-S. Choi, S.H. Lee, B.S. Shin, K.H. Whang, Y.A. Song, S.H. Park, H.S. Jee Development of a composite suitable for rapid prototype machining. .. . M.Y. Yang, S.G. Ryu A new rapid prototyping system using universal automated fixturing with feature-based CAD/CAM D.S. Choi, S.H. Lee, B.S. Shin, K.H. Whang, K.K. Yoon, S.E. Sarma A high speed twin roll caster for aluminum alloy strip T. Haga, S. Suzuki Deformation behaviour of aluminium single crystals in ultraprecision diamond turning. . . S. To, W.B. Lee Electrochemical micro-machining: new possibilities for micro-manufacturing B. Bhattacharyya, B. Doloi, P.S. Sridhar Development of an expert system for turning and rotating tool selection in a dynamic environment R. Mookherjee, B. Bhattacharyya Material removal and cutting Tool wear monitoring during the turning process J. Kopac, S. Sali Tool wear study in a lathe made of cementitious material M. Rahman, M.A. Mansur, S.H. Lau Selected examples of cutting process monitoring and diagnostics A. Sokotowski, J. Kosmol A monitoring technique using a multi-sensor in high speed machining .................22-000005 M.C. Kang, J.S. Kim, J.H. Kim Dynamic elastic-plastic analysis of 3D deformation in abrasive waterjet machining A.I. Hassan, J. Kosmol Development of a practical ultrasonic vibration cutting tool system M. Jin, M. Murakawa Ductile cutting of tungsten carbide Kobi XP. The application of micro-groove machining for the mold of PDP barrier ribs I.-H. Cho, S.-C. Jeong, J.-M. Park, H.-D. Jeong Investigation of chip formation in high speed end milling....................0-. Y. Ning, M. Rahman, Y.S. Wong An adaptive three-dimensional finite element algorithm for the orthogonal cutting of composite materials M. Mahdi, L. Zhang A finite element model for the orthogonal cutting of fiber-reinforced composite materials M. Mahdi, L. Zhang A new method for determining the undeformed chip thickness in milling .. 2.6... 6... ee ee ee FEZ. Lak Pus ACP kt New development of a grinding wheel with resin cured by ultraviolet light T. Tanaka, Y. Isono Contents Analysis of burr formation in drilling with a new-concept drill S.-L. Ko, J.-K. Lee Prediction of contour accuracy in the end milling of pockets........ K.M.Y. Law, A. Geddam Evaluation of the thermal characteristics an high-speed ball-end milling... . 2... ee eee ee ee ce cee S.W. Kim, C.M. Lee, D.W. Lee, J.S. Kim, Y.H. Jung Simulation of sutiace rousuness and profile in high-speed ‘end mulling... . 2... ei ee ae ew ete eee ees K.Y. Lee, M.C. Kang, Y.H. Jeong, D.W. Lee, J.S. Kim Computer aided techniques Apolicaions Gt Vaal manuiachmine ahimatenmals Processing <4... 6 oe ae ae So ela OGG Sue Se we es W.B. Lee, C.F. Cheung, J.G. Li Assessing the environmental impact of materials processing techniques using an analytical hierarchy process method S.K. Ong, T.H. Koh, A.Y.C. Nee Initial process-parameters setting of transfer moulding in microchip encapsulation: a case-based reasoning approach K.W. Tong, C.K. Kwong, C.Y. Chan Neural network analysis of experimental data for air/water spray cooling .....0.... e.ee. e.ee .ee .ee .ee e M.S.A. Oliveira, A.C.M. Sousa Powder forming and ceramics Processing and characterization of metal-ceramics functionally gradient materials ......0.00..000.0 .cec.e .ee.e e ee J. Ma, G.E.B. Tan Processing of thermally stable doped perovskite PZT ceramics G.H.L. Wong, B.W. Chua, L. Li, M.O. Lai REC VIASINAN AOCCASIE AOL MIA APC CIV ENORV ANIC GHOWGEIS «oc 65S ciaie aye aS acaod oS ip eters a beg Uwe Bim ee eels R. Kumar, P. Cheang, K.A. Khor The effect of Fe doping on the sintering behavior of commercial CeO. powder Z. Tianshu, P. Hing, H. Huang, J. Kilner Synthesis of ternary intermetallics by exothermic reaction T. Sritharan, S. Murali Thermal diffusivity of pure and impurity-doped titanium dioxides ceramics0.00.000. c.c e.e .e.ee. .e.e.e F. Fang, P. Hing, J.T. Oh, H.S. Fong, X. Chen, M. Wu The influence of PMMA content on the properties of 316L stainless steel MIM compact M.A. Omar, H.A. Davies, P.F. Messer, B. Ellis pintenne <echuolopy Tesearcn Of tes AW/Al5O. ceramiG COMPOSIES «6. ag 4 se 5G) Se eh ee bee Oe eee ee ee eee bs K. Sun, A. Li, X. Cui, Y. Yin, P. Li An experimental study on the optimization of powder forging process parameters for an aluminum-alloy piston J.-O. Park, K.-J. Kim, D.-Y. Kang, Y.-S. Lee, Y.-H. Kim Metallurgy, thermo-mechanical treatments and coatings Effect of the deposition parameters on the properties of the two-layer surface coatings obtained using magnetron sputtering. . . . L.A. Dobrzanski, W. Kwasny, R. Shishkov, J. Madejski The shot-peening effect on the HCF behavior of high-strength martensitic steels A.M. Eleiche, M.M. Megahed, N.M. Abd-Allah Study of the surface layer formed by the laser processing of Ti-6AI-4V alloy in a dilute nitrogen environment M.S. Selamat, T.N. Baker, L.M. Watson Intermetallic coatings produced by TIG surface melting S. Mridha, H.S. Ong, L.S. Poh, P. Cheang Plasma surface hardening of ASSAB 760 steel specimens with Taguchi optimisation of the processing parameters L.J. Yang Comparison of the thermal fatigue resistance and structure of the 47CrMoWVTiCeZr16-26-8 hot-work tool steel with X40CrMoV5-1 type one L.A. Dobrzanski, J. Mazurkiewicz, E. Hajduczek, J. Madejski Fatigue life of cold-forging dies with various values of hardness Y.-C. Lee, F-K. Chen Contents Effects of surface treatments and lubricants for warm forging die life D.J. Jeong, D.J. Kim, J.H. Kim, B.M. Kim, T.A. Dean Deformation and annealing textures of drawn Al—Mg-Si alloy tubes. . . H. Park, D.N. Lee A new empirical formula for the calculation of Ms temperatures in pure iron and super-low carbon alloy steels C. Liu, Z. Zhao, D.O. Northwood, Y. Liu Effect of TiC in copper—-tungsten electrodes on EDM performance L. Li, Y.S. Wong, J.Y.H. Fuh, L. Lu Microstructural characteristics and mechanical properties of hypo-eutectic and hyper-eutectic Al—Si alloys in the H.K. Jung, P.K. Seo, C.G. Kang Viscoplastic behaviour of porous bronzes and irons B. Wang, J.R. Klepaczko, G. Lu, L.X. Kong Prediction of the flow stress and grain size of steel during thick-plate rolling J.-J. Park Retained austenite in dual-phase silicon steels and its effect on mechanical properties M.H. Saleh, R. Priestner The influence of hot forging conditions on the microstructure and mechanical properties of two microalloyed steels......... M. Jahazi, B. Eghbali Effects of particle shape and size on the homogeneity of dispersed U;3Si particles in high uranium density research reactor fuels W.H. Sohn, S.H. Hong, C.K. Kim Bundling and drawing processing of Cu-Nb microcomposites with various Nb contents........ J.H. Chung, J.S. Song, S.I. Hong Heavily drawn Cu-Fe—Ag and Cu—Fe—Cr microcomposites . J.S. Song, S.I. Hong, H.S. Kim Finite element analysis Of mighipresstike (OLSON |PLOCESSING 2s Loc c.3-6. Seis sedsioia alw eer ed we dye end Beare H.S. Kim Plastic deformation analysis of metals during equal channel angular pressing H.S. Kim, M.H. Seo, S.1. Hong Tube and sheet metal forming Effects of lap sheets on the improvement of the formability of metal foil Y. Marumo, H. Saiki, A. Onoue Development of high-speed superplastic Al alloy by the MA process using Al foil T. Ishikawa, N. Yukawa, Y. Yoshida, K. Murakami An in-situ incremental microforming system for three-dimensional shell structures of foil materials Y. Saotome, T. Okamoto Microdeep drawability of very thin sheet steels Y. Saotome, K. Yasuda, H. Kaga The effects of temperature and forming speed on the forming limit diagram for type 5083 aluminum—magnesium alloy sheet T. Naka, G. Torikai, R. Hino, F. Yoshida he ToRmabiley7ole aliginen SHeCoIMINCECINENtah LORMING cog ccc. a 2S o's boo bate Oe aed a ww eee alee gle Sl eters eat elele ee M.-S. Shim, J.-J. Park A new technology to improve the 7-value of interstitial-free (IF) steel sheet Z. Wang, X. Wang A study on the improvement of formability for eliiptical deep drawing processes... . 2... 6.6... eeeeee eee D.H. Park, S.S. Kang, S.B. Park Design sensitivity analysis and optimization of the hydroforming process .... 6.6... cece ee eee ees J.-B. Yang, B.-H. Jeon, S.-I. Oh Prediction of the forming limit in hydroforming processes using the finite element method and a ductile fracture criterion L.P. Lei, B.S. Kang, S.J. Kang The application of AI techniques in the optimal design of multi-pass cold drawing processes G. Celano, S. Fichera, L. Fratini, F. Micari Contents The effect of the drawbead dimensions on the weld-line movements in the deep drawing of tailor-welded blanks Y.M. Heo, S.H. Wang, H.Y. Kim, D.G. Seo Evaluation of the mechanical properties of welded metal in tailored steel sheet welded by CO, laser B.Y. Ghoo, Y.T. Keum, Y.S. Kim A design method for rectangular hollow sections in bending F. Paulsen, T. Welo, O.P. Sdvik PEM simlahon Ol Gatance SinODININe In We BIOTINE PrOOESS «6 s..6) 5 5 ssc s Sees 2 De es ee ae eG ee SN ae as Z. Wang, K. Dohda, Y. Jeong 3D rigid—plastic FEM numerical simulation on tube spinning Y. Xu, S.H. Zhang, P. Li, K. Yang, D.B. Shan, Y. Lu The parametric process design of tension levelling with an elasto-plastic finite element method H. Huh, H.W. Lee, S.R. Park, G.Y. Kim, S.H. Nam Y.-M. Huang, K.-H. Chien A unified test for evaluating material parameters for use in the modelling of sheet metal forming K.P. Rao, E.V.R. Mohan Quantitative characterization of the surface topography of cold rolled sheets — new approaches and possibilities G.F. Batalha, M. Stipkovic Filho PUSHINY 000 se SLOW MAMTA MONO VANIRTECALMIIIOS 16.2555 2a ete wins eee. aR GR ale aie a elage sors Sue ohne See OEE K.S. Lee, L. Lu Plastic bending of adhesive-bonded sheet metals M. Takiguchi, F. Yoshida Milliccompinrnt somnlne wolaeCrane MAT CUD RAWADE 6.4655 5S. secs o ies is 3 dl a Bey sete Sec wc apleca ieee o/so )W eegeens Sheraneeae T.-W. Ku, S.-M. Hwang, B.-S. Kang Numerical simulation of the superplastic moving die forming process with a modified membrane finite element method K.S. Lee, H. Huh Analysis of the deformation of a perforated sheet under thermal and tension load using finite element method S.-K. Park, J. Kim, Y.-C. Chang, B.-S. Kang Design modification in a multi-stage rectangular cup drawing process with a large aspect ratio by an elasto-plastic Titi SLOT OTC ATAUS T ees aus hee a ae er et a a ea ee Ce eae ae Neen tre grt Eee ao S.-H. Kim, S.-H. Kim, H. Huh AUB ALAMCINIC BUY On ao MmAND MCTt EA GT OL MOTI 25 5 enc Sos ce 5s awe asi ED Sele kg Be) otal peo to wee ees S. Hong, S. Lee, N. Kim Finite element inverse analysis for the design of intermediate dies in multi-stage deep-drawing processes with large aspect ratio S.H. Kim, S.H. Kim, H. Huh The bending of an aluminum structural frame with a rubber pad H.C. Kwon, Y.T. Im, D.C. Ji, M.H. Rhee Author Index Subject Index