Proceedings

of the Second International Conference

on

Intelligent Processing and Manufacturing of Materials

IPMMf99

Volume 1

Editors:John A. Meech, Marcello M. Veiga,

Michael H. Smith, Steven R. LeClair

TECHNISCHE

UNIVER5!TAT53!BL:OT! ;:£KHANNOVER

Hilton Hawaiian Village HotelHonolulu, Hawaii

July 10-15,1999

TOCUB/TIB Hannover SQ118 932 594 8 9mama

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IPMM'99The Second International Conference on

Intelligent Processing and Manufacturing of Materials

Volume 1

Contents

Plenary Presentations 1

From Computing with Numbers to Computing with Words: 3From Manipulation of Measurements to Manipulation of PerceptionsLot fi A. ZadehBerkeley Initiative in Soft Computing (BISC)Computer Science Division and the Electronics Research Laboratory,Department of Electrical Engineering and Computer Science,The University of California, Berkeley, California, USA

Hybrid Modeling for Testing Intelligent Software for Lunar-Mars 5Closed Life SupportJane T. MalinIntelligent Systems Branch, Automation, Robotics and Simulation DivisionNASA Johnson Space Center, Houston, Texas, USA

Image Analysis and Vision Systems for Processing Plants 11Antti J. Niemi*, Heikki Hyotyniemi*, and Raimo Ylinen** Helsinki University of Technology, Control Engineering LaboratoryM P . O . Box 5400, FIN-02015 HUT, Finland** University of Oulu, Systems Engineering Laboratory,

P.O. Box 4300, FIN-90401 Oulu, Finland

Progress in Japan's Intelligent Manufacturing Systems Research Program 21Yuji FurukawaTokyo Metropolitan University, Minami-Osawa, Hachioji, Tokyo, Japan

Analysis of Processes and Large Data Sets by a Self-Organizing Method 27Teuvo KohonenHelsinki University of Technology, Neural Networks Research Centre,P.O. Box 2200, FIN-02015 HUT, Finland

Rough Set Theory for Intelligent Industrial Applications 37Zdzislaw PawlakInstitute of Theoretical and Applied Informatics,Polish Academy of Sciences, Poland

IX

From Fuzzy Set Theory to Computational Intelligence - 45Special European ExperiencesHans-Juergen ZimmermannAachen University of Technology,RWTH, Institute of Operations Research, Aachen, Germany

Teleminingtm Systems Applied to Underground Hard Rock 53Metal Mining at Inco LimitedGregory R. BaidenINCO Mines Research, Sudbury, Ontario, Canada

Soft Sensors for Processing Plants 59Guillermo D. GonzalezDepartment of Electrical Engineering, University of Chile, Santiago, Chile

J. Keith Brimacombe Memorial Symposium:Intelligence in Materials Engineering 7!

In Memory of J. Keith Brimacombe: 73The Pursuit of Quality in the Casting of MaterialsIndira V. SamarasekeraThe Centre for Metallurgical Process Engineering, The J.K. Brimacombe AdvancedMaterials and Process Engineering Laboratory (AMPEL),The University of British Columbia, Vancouver, Canada

Towards Intelligent Steel Processing 75Rian J. DippenaarBHP Institute for Steel Processing and Products,The University of Wollongong, Wollongong, New South Wales, Australia

Computer Simulation and Information Management Systems 85for Material ProcessingYoshiyuki NagasakaDepartment of Distribution Science, Osaka Sangyo University, Osaka, Japan

Simulation of Springback with the Draw/Bend Test 91Kaiping Li, Lumin Geng, Robert H. WagonerDep't. Materials Science and Engineering, Ohio State University, Columbus, Ohio

Development of an Integrated System for Designing 105Steelmaking Aim CompositionsP.A. Manohar*, S.S. Shivathaya**, M. Ferry*, T. Chandra** Dep't. of Materials Engineering., University of Wollongong, NSW, Australia** Hawker de Havilland Ltd., Bankstown, Australia

A SCADA-based Expert System to Provide Delay Strategies for a 111Steel Billet Reheat FurnaceClifford Mui*, John A. Meech**, Peter Barr*** Dynapro Systems Inc., Vancouver, B.C., Canada** The Centre for Metallurgical Process Engineering,

The University of British Columbia, Vancouver, B.C., Canada

Simulation and Analysis of Thin Strip Casting Processes 119Yogeshwar Sahai, Manish GuptaDep't. Materials Science and Engineering, Ohio State University, Columbus, Ohio

Intelligent Manufacturing I 129

Agent-Based Control of Manufacturing Systems 131Laszlo Monostori, B. KadarComputer Automation Institute, Hungarian Academy of Sciences,Budapest, Hungary

Intelligent Database Support for Manufacturing and Processing of 139Industrial MaterialsSylvanus A. Ehikioya, E.G. Truelove, Thomas T. TranBrandon University, Brandon, Manitoba, Canada

Intelligent Production Management in Mining Systems 145Sean Dessureault, Malcolm Scoble, Scott DunbarDep't. of Mining and Mineral Process Engineering,University of British Columbia, Vancouver, B.C., Canada

Intelligent Quality Control for the Food Industry 151using a Fuzzy-Fractal ApproachOscar Castillo, Patricia MelinTijuana Institute of Technology, Chula Vista, California

Design Tool for Assessing Manufacturing Environments 157Daniel A. Holder*, Raymond D. Harrell*, Daniel Rochoviak**,Phillip Farrington**, Dawn Russell**, John Rogers**, Sherri Messimer*** US Army AMCOM, Redstone Arsenal, Alabama, USA** University of Alabama in Huntsville, Alabama, USA

Models, Algorithms and Decision Support Systems for Letter Mail Logistics 163Hans-Jiirgen SebastianRWTH Aachen , Operations Research Group, Aachen, Germany

Intelligent Processes for Production Control 165Edson Pacheco PaladiniUniversidade Federal de Santa Catarina, Florianopolis, SC, Brasil

XI

Fuzzy Systems I 171

Industrial Applications of Fuzzy System Modeling 173I. Burhan TurksenUniversity of Toronto, Canada

From Intelligent Models to Smart Ones 179Heikki HyotyniemiHelsinki University of Technology^spoo, Finland

A Fuzzy Design Evaluation Based on a Taguchi Quality Approach 185A. Donnarumma*, N. Cappetti*, M. Pappalardo*, Esamuele Santoro *** Universitadi Salerno, Italy.** Universitadi Napoli, Italy

Non-Traditional Performance Analysis 191J. Arlen CooperSandia National Laboratories, Albuquerque, New Mexico, USA

Methods of Creating Membership Functions for Fuzzy Rules 195in Knowledge BasesCezary OrlowskiTechnical University ofGdansk, Gdansk, Poland

An Efficient Method for Constructing Fuzzy Rules 201Bojan NovakUniversity ofMaribor, Stajerska, Slovenia

Fuzzy Clustering Model Based on Changes in Vagueness 207Mika Sato-IlicUniversity of Tsukuba, Ibaraki, Japan

Thin Films and Surface Processing 213

Modeling and Control of Optical Interference Filters Using Plasma 215Assisted Chemical Vapor DepositionDerek A. Linkens*, M.F. Abbod*, J. Metcalfe**, B. Nichols *** University of Sheffield, Sheffield, U.K.** GEC-Marconi Limited, Caswell, UK.

A Study of Mechanical Properties of Multi-Layered Thin Films 221T. Hirasawa, H. Kotera, T. Yamamoto, Y. Sakamoto, S. ShimaKyoto University, Sakyo4iu, Kyoto, Japan

Foundations of Micro-Machining 227Juergen LeopoldInstitute of Tool Engineering and Quality Management,Chemnitz, Germany

Xll

Design of Novel Smoothing by Atomic Layer Epitaxy for 233Microstructure FabricationS. Hirose*, A. Yoshida**, M. Yamaura**, H. Munekata ***Mechanical Engineering, AIST, MITI, Tsukuba, Ibaraki, Japan**Tokyo Institute of Technology, Midori-ku, Yokohama, Japan

Study of the Relationship Between Groove Cross Sectional Area 239per Pulse of Q-Switched Yag Laser and Strength of Processing SoundT. Kurita, T. OnoTokyo Metropolitan Institute of Technology, Tokyo, Japan

Optimization of Thickness Distribution of Micro-Membrane 245by Genetic AlgorithmHidetoshi Kotera, Y. Sakamoto, T. Hirasawa and S. ShimaKyoto University, Sakyo-ku, Kyoto, Japan

Manufacturing of Metallic Prototypes and Tools by 251Laser Cutting and Diffusion BondingS. Sandig, P. WiesnerDep't. of Mechanical Engineering, Technical University ofllmenau, Germany

Evolutionary Systems and Machine Learning 255

Artificial Immune Systems: a New Frontier in Artificial Intelligence 257Dipankar Dasgupta*, Stephanie Forrest *** University of Memphis, Tennessee, USA** University of New Mexico, Albuquerque, NM, USA

Inductive Learning for Optimization of Simulation Model Output 269Rainer Barton*, Helena Szczerbicka *** German Aerospace Center (DLR), Institute for Flight Mechanics,

Braunschweig, Germany** University of Bremen, Bremen, Germany

A Genetically Optimised Fuzzy Parser of Natural Language 277Olgierd UnoldWroclaw University of Technology, Wroclaw, Poland

A Genetic Algorithm-based Approach to Solve Process Plan Selection 281ProblemsK.M. Tiwari*, S.K. Tiwari*, Debjit Roy*, N.K. Vidyarthi **.* Manufacturing Engineering, National Institute of Foundry and Forge

Technology, Hatia, Ranchi, India** Mechanical Engineering, NERIST, Nirjuli, Itanagar, India*** SriVenkateshNagar, Chennai-600092, India

Xlll

Breeding Policies in Evolutional Approximation of Optimal Subspace 285H.M. Huang and P.L. LeungCity University of Hong Kong, Kowloon, Hong Kong

Prediction of Cement Paste Mechanical Behaviour from Chemical 291Composition using Genetic Algorithms and Artificial Neural NetworksJose C. Cassa, Giovanni Floridia, Andre R. Souza, Rodrigo T. OliveiraUniversidade Federal da Bahia, Salvador, Bahia, Brazil

Rough Sets-based Machine Learning Using a Binary Discernability Matrix 299Reynaldo Felix, Toshimitsu UshioSystems and Human Science, Osaka University, Toyonaka, Japan

Intelligence in the Design of Materials and Processes I 307

INTELLIGOLD - An Expert System For Gold Plant Process Design 309Vanessa Torres*, Arthur Torres**, John A. Meech ****Companhia Vale do Rio Doce, Belo Horizonte, Brazil"""University of Sao Paulo, SP, Brazil***University of British Columbia, Vancouver, Canada

A Hardware Design for Real-Time Multiple Target Tracking 317Frederick Ferguson, Chandra CurtisNorth Carolina A&T State University, Greensboro, NC, USA

Low-Cost Supersonic Missile Inlet Fabrication Technique 325C.S. Cornelius, D.A. GibsonUS Army Aviation and Missile Command, Redstone Arsenal, AL

Design of High Performance Missile Structures Utilizing 331Advanced Composite Material TechnologiesJ.R. Esslinger, R.N. Evans, G.W. SnyderUS Army Aviation and Missile Command, Redstone Arsenal, AL

Modelling the Mechanical Stability of Metal Catalyst Carriers 339C. Guist, H. BodeBergische Universitat-Gesamthochschule Wuppertal, Germany

Integration of Newly Developed AI Assembly, Production, 347and Material Flow Virtual ToolsDaniel A. Holder*, Raymond D. Harrell*, Terri L. Calton**,John F. Atkinson*, Brandy M. Brasfield** US Army AMCOM, Redstone Arsenal, Alabama** Sandia National Laboratories, Albuquerque, NM

XIV

Prediction of Materials Properties 353

How ab-initio Computer Simulation Can Predict 355Materials Properties Before ExperimentYoshiyuki KawazoeTohoku University, Sendai, Japan

Data Driven Knowledge Extraction of Materials Properties 361J.S. Kandola*, S.R. Gunn*, I. Sinclair**, P.A.S. Reed **University of Southampton, U.K.

A Quantum Neural Net: with Applications to Materials Science 367B. Igelnik*, M. Tabib-Azar*, Y.-H. Pao*, and S. R. LeCIair ***Case Western Reserve University, Cleveland, OH, USA**Material Directorate, Wright Laboratory, Fairborn, OH, USA

Ontology for Phase Diagram Databases 373N. Ono, R. Kainuma, H. Ohtani, K. Ishida, M. KatoTohoku University, Sendai, Japan

Prediction of Concrete Mechanical Behaviour from Data 381at Lower Ages using Artificial Neural NetworksJose C. Cassa, Giovanni Floridia, Andre R. Souza, Rodrigo T. OliveiraUniversidade Federal da Bahia, Salvador, Bahia, Brazil

Improving the Prediction Accuracy of a Constitutive Model 389with ANN ModelsL.X. Kong and P.D. HodgsonDeakin University, Geelong, Victoria, Australia.

Hybrid Fuzzy Modelling Using Simulated Annealing: 395Application to Materials Property PredictionMin-You Chen, Derek A. LinkensThe University of Sheffield, Sheffield, UK

Intelligence in Materials Science I 401

Inorganic Glasses: Old and New Structures on the Eve of the 21st Century 403J. Sestak *, B. Hlavacek +, N. Koga **** Czech Academy of Sciences, Prague, Czech Republic** University of Pardubice, Pardubice, Czech Republic*** Hiroshima University, Higashi-Hiroshima, Japan

Oxygen Solubility Modeling in Aqueous Solutions 411Desmond TromansUniversity British Columbia, Vancouver, B.C., Canada

XV

On the Oxidation of Steel in CO2 and Air 417Gity Samadi Hosseinali, Ainul AkhtarPowertech Labs Inc., Surrey, British Columbia, Canada

Retardation of Hydrogen Embrittlement by Electrolytic ZrO2 423Coating of AISI 430 Stainless SteelI.B. Huang, S.K. YenNational Huwei Institute of Technology, Huwei, Taiwan

The Effect of Ca Addition on Viscosity and Electrochemical 429Properties of Mg-Alloys Produced by CastingH.S. Kim*, Shuji Hanada*, Ha-Guk Jeong*, Dong-Wha Kum *** Tohoku University, Sendai, Japan** Korea Institute of Science and Technology, Seoul, Korea

Bio-Compatible Ceramics as Mimetic Material for Bone Tissue Substitution 431Zdenek Strnad*, Jaroslav Sestak ***Lab. for Glass and Ceramics (LASAK), Prague, Czech Republic**Czech Academy of Sciences, Prague, Czech Republic

Intelligent Design of GaSb doped Single Crystals 437B. Stepanek, J.Sestak, J.J.Mares J.Kristofik, V.Sestakova, P.HubikAcademy of Sciences of the Czech Republic, Semiconductor Department, Prague,Czech Republic,

Intelligent Image Analysis Applications 443

Astronomical Image Processing - Applications To 445Ultra-Faint Imaging of Small, Moving, Solar System Bodies:Comets and Near-Earth ObjectsKaren J. MeechUniversity of Hawaii, Institute for Astronomy, Honolulu, HI, USA

A High Performance Computing Algorithm for Improving 447In-Line HolographyHesham EldeibElectronic Research Inst., National Research Center, Giza, Egypt

Human Face Detection System by KenzanNET with 453Preprocess Analyzing of Hyperspectral ImageTakakazu Chashikawa*, Keizo Fujii**, Yoshiyasu Takefuji ** Keio University, Kanagawa, Japan.**NITTAN Co., Ltd., Japan

XVI

Using Image Analysis and Partial Least Squares Method to 459Estimate Mineral Concentrations in Mineral FlotationJari Hatonen*, Heikki Hyotyniemi*, J. Miettunen**, L.-E. Carlsson ***Helsinki University of Technology, Espoo, Finland

**Outokumpu Mining Oy, Pyhasalmi Mine, Pyhasalmi, Finland***Boliden Mineral AB, Mineral Processing, Boliden, Sweden

A Combined Morphological and Color-Based Approach to 465Characterize Flotation Froth BubblesGiuseppe Bonifazi, Silvia Serranti, F. Volpe, R. ZucoUniversita degli Studi di Roma, "La Sapienza", Italia

Robust Bubble Delineation Algorithm for Froth Images 471Weixing X. Wang, O. StephanssonDepartment of Civil and Environmental Engineering,Royal Institute of Technology, Stockholm, Sweden

The Characterization of Flotation by Colour Information and 477Selecting the Proper EquipmentA.K. SirenVTT Information Technology, Espoo, Otaniemi, Finland

Intelligence in Environmental Applications 479

Robust Engineering Approaches to Maximize Results in Business, 481Cost, Engineering, Human, Quality and System TechnologiesRoberto C. Villas Boas** CYTED - Science and Technology for Development in Iberoamerica, MineralTechnology Sub-Program, Madrid, Spain

Imaging Techniques for Process Optimization and Control 485in Glass RecyclingGiuseppe Bonifazi, Paolo MassacciIngegneria Chimica, dei Materiali, Materie Prime e Metallurgia,Universita degli Studi di Roma "La Sapienza", Roma, Italia

Application of Heuristic Modeling in Natural Resource Sciences 491Steven MackinsonFisheries Centre, University of British Columbia,Vancouver, B.C., Canada

ARDEX - A Fuzzy Expert System for ARD Site Remediation 499Judita Balcita, John A. MeechUniversity of British Columbia, Vancouver, B.C., Canada

XV11

Modeling of Gold Heap Leaching for Criteria of Sustainability Targets 505Luiz R. P. De Andrade Lima*, Roberto C. Villas-Boas*** Federal University ofBahia, Salvador, BA, Brazil** Center for Mineral Technology, Rio de Janeiro, RJ, Brazil

Design Optimisation of Aluminium Recycling Using the Taguchi Approach 513A.R. Khoei, D.T. Gethin, I. MastersMechanical Engineering, University of Wales Swansea, UK

Towards a Better Understanding of Environmental Science through 519Application of Fuzzy SetsMory M. Ghomshei, John A. MeechUniversity of British Columbia, Vancouver3-C, Canada

Intelligence in Rolling Processes 527

Data Mining and State Monitoring in Hot Rolling 529jLCser* **, A.S. Korhonen**, P.Mantyla***, O. Simula**, J.Ahola *** Bay Zoltan Institute for Logistics and Production Technology,

Miskolc-Tapolca, Hungary** Helsinki University of Technology,Espoo, Finland*** Rautaruukki Steel, Raahe, Finland

Determination of Thickness Control Parameters of Rolling 537Processes by the Sensitivity Method, using Neural NetworksLuis E. Zarate*, Horacio Helman *** Departamento de Cienciada Computacao, Pontificia Universidade

Catolica de Minas Gerais, Belo Horizonte, Brazil** Departamento de Engenharia Metaliirgica e de Materiais,

Universidade Federal de Minas Gerais, Belo Horizonte, Brazil

AI Approach to Modeling Rolling Loads in Design of 543Cold Rolling ProcessesJ. Kusiak*, J.G. Lenard**, K. Dudek** AkademiaGorniczo-Hutnicza, Krakow, Poland** University of Waterloo, Waterloo, Ontario, Canada

Direct Determination of Sequences of Passes for Strip Rolling 549Process by Means of Fuzzy Logic RulesC.D.M.Pataro, H. HelmanUniversidade Federal deMinas Gerais, Belo Horizonte, Brazil

Elongation-Controlled Rolling of H-Shaped Wire 555H. Utsunomiya, M. Shinkawa, F. Shimaya, Y. SaitoMaterials Science and Engineering, Osaka University, Japan.

XV111

Application of a Neural Network to Speed Up a Mathematical 561Model for Calculation of Strip Profiles in Flat RollingYukio Shigaki, Horacio HelmanUniversidade Federal de Minas Gerais, Belo Horizonte, Brazil

Intelligent Methods in Metal Forming Processes 563

A Fundamental Study of the Incremental Deep Drawing Process 565S. Shima, H. Kotera, K. Kamitani, S. NagatomoMechanical Engineering, Kyoto University, Kyoto, Japan

Intelligent Design Architecture for Process Control of Deep-Drawing 571K. Manabe*, H.Koyama*, K.Katoh**, S. Yoshihara **** Mechanical Engineering, Tokyo Metropolitan University, Japan** Integrated Systems Japan,Ltd., Tokyo, Japan*** Tokyo National College of Technology, Tokyo, Japan

An Iterative Approach to Determine Heat-Treatment and 577Composition from the Mechanical Yield Strength of an Al-Li AlloyJames M. Fragomeni,Ohio University, Mechanical Engineering, Athens, Ohio, USA

A Design of Experiments Statistical Approach to Determine 585the Effect of Extrusion Process Variables on the MechanicalProperties of a Heat-Treated Al-Li AlloyJames M. FragomeniOhio University, Mechanical Engineering, Athens, Ohio, USA

Control of Liquid Segregation of Semi-Solid Al-Alloys during 593Intelligent Compression TestingC.G. Kang, K.D. Jung, H.K. JungPusan National University, Mechanical Engineering, Korea

Adaptability to Frictional Change of Fuzzy Adaptive Blank 601Holder Control for Deep DrawingS. Yoshihara*, K. Manabe**, H. Nishimura *** Tokyo National College of Technology, Mechanical Eng., Japan** Tokyo Metropolitan University, Tokyo, Japan

An AI Process Control System with Simulation Database and 607Adaptive Filter for V-BendingM. Yang*, A. Katayama*, K. Manabe*, N. Aikawa *** Dep't. of Mechanical Engineering, Tokyo Metropolitan University, Japan** Tokyo Engineering University, Japan

XIX

Intelligent Manufacturing II 613

The Distributed Intelligent Control of Complex Systems 615Wayne J. DavisUniversity of Illinois at Urbana-Champaign,Department of General Engineering, Urbana, IL, USA

PDM-based Virtual Enterprises - Bridging the Semantic Gap 623A. Karcher, J. WirtzDep't. of Mechanical Engineering, Technical University of Munich,Garching, Germany

A Methodology to Diagnose the Target Cost in a Manufacturing Process 629A. Arioti, C. Fantozzi, M.Granchi, E. VettoriMechanical, Nuclear and Manufacturing Engineering,University of Pisa, Italy

Resource Allocation for a Fast-Tracked Project 635Yassiah Bissiri, Scott DunbarDepartment of Mining and Mineral Process Engineering,University of British Columbia, Vancouver, B.C., Canada

Hybrid Simulation Objects using Fuzzy Set Theory for 641Simulation of Innovative Process ChainsT. Menzel, M. GeigerDep't. of Manufacturing Technology,University Erlangen-Nuremberg, Erlangen, Germany

Manufacturing Management Improvement through 649Rapid Production of BudgetsE.J. ColvilleSchool of Engineering, University of Tasmania,Hobart, Tasmania, Australia

A Connectionist Method to Solve Job Shop Problems 655Marko Fabiunke, Gerd KockGMD Research IT Center,(FIRST) Berlin, Germany

Fuzzy Systems II 661

Designing in Many-Valued Logic 663A. Donnarumma and Michele PappalardoUniversity of Salerno, Mechanical Engineering, Fisciano, Italy

XX

Modulus Genetic Algorithm and its Application to 669Fuzzy System OptimizationSinn-Cheng LinDep't. of Educational Media and Library Sciences,Tamkang University, Tamsui, Taipei Hsien Taiwan, PRC

Fuzzy Evolutionary Programming for Portfolio Selection 675in Investment DecisionsT. Van LeFaculty of Information Sciences and Engineering,University of Canberra, Belconnen, Australia.

Design of a Region-Wise Fuzzy Sliding Mode Controller with Fuzzy Tuner 681C.C. Kung, W.C. LaiDep't. of Electrical Engineering,Tatung Institute of Technology, Taipei, Taiwan

A Multi-Input Current-Mode Fuzzy Integrated Circuit 687for Pattern RecognitionGu Lin, Bingxue ShiInstitute of Microelectronics, Tsinghua University, Beijing, PRC

A Framework for Intelligent Systems based on 695Vector-Annotated Logic ProgramsKazumi Nakamatsu*, Yumi Hasegawa*, Jair Minoro Abe**,Atsuyuki Suzuki ***.*Himeji Institute of Technology, School of Humanity,Environment Policy and Technology, Himeji, Hyogo, Japan

**Paulista University, Sao Paulo, Brazil.***Shizuoka University, Japan

A Fuzzy Logic Assisted Electrodynamic Balance for Unit 703Operations on Single Levitated ParticlesM. Pappalardo*, A. Pellegrino*, M. d'Amore**,P. Giordano**, P. Russo *** Dep't. of Mechanical Engineering, University of Salerno,

Fisciano, Italy** Dep't. of Chemical and Food Engineering., University of Salerno,

Fisciano, Italy

Author's Index 1-1