HOME PRESS STRAIN ANALYSIS REPORT

BMW
Gestamp SC
F15

BODY SIDE OUTER LH

7287477
Evaluation Date: Nov 12, 2013
Part (Status/SF):

Safe / 11%
Report No: 7287477HP1
by
Mark Hammerl 248 320-1811

Contents
Strain Analysis Summary
Trial Information
Material Characterization - Blank #1
Forming Limit Diagram - Blank #1
Thickness Strain Chart - Blank #1
Part Figures
Attachments

Page Number
2
3
4
5
6
7
9

DISTRIBUTION
CUSTOMER
BMW

Company
AK Steel
Gestamp SC
Gestamp SC

AQP-Parts v 7.0 AK
Form No: AE #006, Rev: 4, 03/2003

Report No: 7287477HP1

AK Steel - BMW Confidential

GENERAL
Name
Daryl Underwood
Cameron Duncan
Chester Strecker

Evaluation Date : Nov 12, 2013

Page 1 of 12

Home Press Strain Analysis Summary

PART INFORMATION
BMW
Customer:
Body Side Outer LH
Part Name:
7287477
Part Number:

Production Location:
Program Name:
Vehicle Line:

Gestamp SC
F15

PURPOSE
To conduct strain analysis on LH Body Side Outer at Gestamp Union

STRAIN ANALYSIS RESULTS AND COMMENTS

Points
Part
Addendum
16
0
Analyzed:
16
0
Safe:
0
0
Marginal:
0
0
Failure:
0
0
Potential Wrinkling:
Safe / 11%
N/A
Status/SF:

N/A

OBSERVATIONS
Sixteen locations were reviewed using cirlce grid and thinning analysis.
AK Steel was not present during the forming of the panel.

RECOMMENDATIONS
There were no areas in the marginal zone.

AQP-Parts v 7.0 AK
Form No: AE #007, Rev: 5, 05/2006

Report No: 7287477HP1

AK Steel - BMW Confidential

Evaluation Date : Nov 12, 2013

Page 2 of 12

Trial Setup/Tonnage
PART INFORMATION
BMW
Customer:
Body Side Outer LH
Part Name:
7287477
Part Number:

Production Location:
Program Name:
Vehicle Line:

GENERAL INFORMATION
Home Press
Trial Type:
Gestamp Union
Trial Facility:
Cameron Duncan
Facility Contact:
Contact Phone No: 803 669-4455

Nov 12, 2013

Trial Date:
Press/Process Changes:
Panel Status:
Eng/Dev Change Level: N/A

Gestamp SC
F15

PRESS INFORMATION
N/A
Line:
N/A
Identification:
Line Conditions: N/A

Press Speed (SPM):

Bolster:
Nitrogen Pressure - Inner (psi):
Nitrogen Pressure - Outer (psi):
Cushion Stroke (in):
Cushion Pressure (psi):
Number of Cylinders:
Cylinder Size Diameter (in):
Calculated Tonnage (tons):

N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A

Shut Height - Inner (in):

Shut Height - Outer (in):
Counter Balance - Inner (psi):
Counter Balance - Outer (psi):
Binder Travel (in):
On Bottom?:
Load Monitor?:
Last Press Parallelism Date:

DIE INFORMATION
N/A
Die Number:
Draw
Die Type/Process:
Type of Operation: N/A
Surface Treatment - Upper Die: N/A
Surface Treatment - Lower Die: N/A
Comments: N/A

N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A

Tool Build Source:

N/A
Die Engineer:
N/A
Die Material:
Surface Treatment - Upper Binder: N/A
Surface Treatment - Lower Binder: N/A

LUBRICATION INFORMATION
Type:
Application:
Relative Amount:
Distribution:
BW Concentration:
Comments: N/A
TONNAGE INFORMATION
BINDER FORCE (tons)
N/A
N/A
LR:
RR:
N/A
N/A
LF:
RF:
Blankholder Force Window - Buckling (tons):
Comments:

MILL
EGL1
Electrostatic
Medium
Entire Blank

Total
N/A
N/A

BLANKER
N/A
N/A
N/A
N/A
N/A

PRESS
N/A
N/A
N/A
N/A
N/A

RAM FORCE (tons)

N/A
N/A
LR:
RR:
N/A
N/A
LF:
RF:
Blankholder Force Window - Splitting (tons):

Total
N/A
N/A

N/A

AQP-Parts v 7.0 AK
Form No: AE #025, Rev: 2, 03/2003

Report No: 7287477HP1

AK Steel - BMW Confidential

Evaluation Date : Nov 12, 2013

Page 3 of 12

Material Characterization - Blank #1

PART INFORMATION
BMW
Customer:
Body Side Outer LH
Part Name:
7287477
Part Number:
MATERIAL
Material Supplier:
Supplier Contact:
Contact Phone No:
Heat Number:
Coil Identification:
Lift Number:
P.O. Number:
Material Source:
Reference Number:
Specified Thickness (mm):
Measured Thickness (mm):

F15
Program Name:
Blanking Location: N/A
0.75 mm ; GS93032-2 CR4 EG 50/50 E
Material:

AK Steel
Mark Hammerl
248 320-1811
N/A
934601-01A
N/A
N/A
Middletown Works
N/A
0.75 min
0.760

MECHANICAL PROPERTIES
Property

Longitudinal

140.0

Tensile Strength
(MPa)

270.0

% Elongation
(Total - machine)

40.0

Work Hardening Exp.

n Value

0.20

50G/50G
EGL-1
1825
x
N/A
x
Configured
N/A

Transverse

3756
N/A

Diagonal

N/A

170.0

Yield Strength
(MPa)

GS93032-2 CR4 EG 50/50 E

EG
EDDS

Customer Specification:
AK Product:
AK Quality:
Quality Grade:
Coating Weight:
Surface Treatment:
Specified Blank Size (mm):
Measured Blank Size (in):
Specified Blank Shape:
Measured Blank Shape:

180.0

N/A

330.0

N/A

48.0

N/A

0.25

N/A

310.0

N/A
N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

44.0

N/A
N/A

N/A

0.226

N/A
N/A

N/A

N/A
N/A

Non-Directional
1.98
1.9

Plastic Strain Ratio

r Value (modul-r)
Note:

2.3

1. Production ranges represent data for the N/A calendar year for a thickness range of: N/A .

CHEMICAL COMPOSITION (%)

C
Mn
P
S
Si
N/A
N/A
N/A
N/A
N/A
SURFACE PROPERTIES
Ra
Pc
Location
(in)
(ppi)
N/A
N/A
Top
N/A
N/A
Bottom

AQP-Parts v 7.0 AK
Form No: AE #012, Rev: 5, 10/2008

Cu
N/A

Al
N/A

Coating Weight
(gm/m)
61.0
52.0

N
N/A

Cb
N/A

Ti
N/A

Mo
N/A

Organic Coating Weight

(gm/m)
N/A
N/A

Report No: 7287477HP1

AK Steel - BMW Confidential

Cr
N/A

V
N/A

B
N/A

Ni
N/A

Powdering

% Iron

N/A
N/A

N/A

Evaluation Date : Nov 12, 2013

Page 4 of 12

Forming Limit Diagram - Blank #1

PART INFORMATION
Customer:
Production Location:
Program Name:
Vehicle Line:
Part Name:
Part Number:

BMW
Gestamp SC
F15

110

DRAW

Body Side Outer LH

7287477

100

STRETCH

90
FLD PARAMETERS
FLDo Thickness (mm):
FLDo n Value:
Blank Thickness (mm):

0.760
0.20
0.760

32.4
24.5
S / 11%

FLDo:
% Thinning @ FLDo:
FLD Status/SF (% Maj):

DATA
Pt % Major % Minor
Thickness Strain
Strain
Strain Thickness % Thinning
(mm)

Point
Status

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25

S/22%
S/11%
S/19%
S/22%
S/21%
S/11%
S/21%
S/21%
S/23%
S/17%
S/15%
S/20%
S/21%
S/16%
S/16%
S/17%

29
27
22
15
15
36
14
11
27
30
28
12
11
28
16
36

-15
-5
-8
-5
-4
-11
-3
0
-14
-12
-9
0
0
-9
0
-15

0.693
0.631
0.675
0.693
0.687
0.63
0.687
0.687
0.698
0.663
0.651
0.677
0.685
0.655
0.657
0.659

8.8
17.0
11.2
8.8
9.6
17.1
9.6
9.6
8.2
12.8
14.3
10.9
9.9
13.8
13.6
13.3

CV
Status
[0%]

Label

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16

FAILURE

M
a
j
o
r

70

S
t
r
a
i
n

50

60
50%

MARGINAL

40
16 6

WRINKLING

30
1 1014
9 11 2
3
30%
20
SAFE
15
457
20%
12
8
13
10
10%

40%

0
-40

-30

-20

-10

10

20

30

40

% Minor Strain

Note: 1. Circle Grid Diameter (in) = 0.1

2. Measured Strain and Thickness values are shown when entered. Calculated values of % Major
Strain and Thickness are italicized.
3. Status, % Thinning and italicized values are calculated from the Thickness and % Minor Strain.
4. S = Safe, M = Marginal, F = Failure, W = Potential Wrinkling/Thickening
5. t @ FLDo = 0.574 mm ; t @ FLDo-MZ = 0.621 mm
AQP-Parts v 7.0 AK
Form No: AE #008, Rev: 5, 10/2008

80

Note: 1. Marginal Zone (% Major Strain) = 10

2. Potential Wrinkling/Thickening Strains are plotted as squares.
3. Points 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16 are plotted using calculated %
Major Strains of 29, 27, 22, 15, 15, 36, 14, 11, 27, 30, 28, 12, 11, 28, 16, 36 .

Report No: 7287477HP1

AK Steel - BMW Confidential

Evaluation Date : Nov 12, 2013

Page 5 of 12

Thickness Strain Chart - Blank #1

PART INFORMATION
Customer:
Production Location:
Program Name:
Vehicle Line:
Part Name:
Part Number:

BMW
Gestamp SC
F15

Actual % Thinning, when Minor Strain <= 0

Adjusted % Thinning, when Minor Strain > 0

Body Side Outer LH

7287477

% Thinning @ FLDo

FLD PARAMETERS
FLDo Thickness (mm):
FLDo n Value:
Blank Thickness (mm):

0.760
0.20
0.760

32.4
24.5
S / 11%

FLDo:
% Thinning @ FLDo:
TSC Status/SF (% Maj):

% Thinning @ FLDo less Marginal Zone

50

DATA
Pt % Major % Minor
Thickness Strain
Strain
Strain Thickness % Thinning
(mm)
Act
Adj

Point
Status

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25

S/22%
S/11%
S/19%
S/22%
S/21%
S/11%
S/21%
S/21%
S/23%
S/17%
S/15%
S/20%
S/21%
S/16%
S/16%
S/17%

29
27
22
15
15
36
14
11
27
30
28
12
11
28
16
36

-15
-5
-8
-5
-4
-11
-3
0
-14
-12
-9
0
0
-9
0
-15

0.693
0.631
0.675
0.693
0.687
0.63
0.687
0.687
0.698
0.663
0.651
0.677
0.685
0.655
0.657
0.659

8.8
17.0
11.2
8.8
9.6
17.1
9.6
9.6
8.2
12.8
14.3
10.9
9.9
13.8
13.6
13.3

CV
Status
[0%]

Label

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16

40
% 35
T
h
i
n
n
i
n
g

30
25
20
15
10
5
0
1

10 11 12 13 14 15 16

Point

Note: 1. Circle Grid Diameter (in) = 0.1

2. Measured Strain and Thickness values are shown when entered. Calculated values of % Major
Strain and Thickness are italicized.
3. Status, % Thinning and italicized values are calculated from the Thickness and % Minor Strain.
4. S = Safe, M = Marginal, F = Failure, W = Potential Wrinkling/Thickening
5. t @ FLDo = 0.574 mm ; t @ FLDo-MZ = 0.621 mm
AQP-Parts v 7.0 AK
Form No: AE #010, Rev: 5, 10/2008

45

Note: 1. Marginal Zone (% Thinning) = 6.17

2. Potential Wrinkling/Thickening Strains are plotted as squares at 0 % Thinning.

Report No: 7287477HP1

AK Steel - BMW Confidential

Evaluation Date : Nov 12, 2013

Page 6 of 12

Part Figures A, B
PART INFORMATION
BMW
Customer:
Body Side Outer LH
Part Name:
7287477
Part Number:

Program Name:
Vehicle Line:

F15

FIGURE A:
Location 2 was 11% safe

FIGURE B:
Location 6 was 11% safe

AQP-Parts v 7.0 AK
Form No: AE #013, Rev: 4, 03/2003

Report No: 7287477HP1

AK Steel - BMW Confidential

Evaluation Date : Nov 12, 2013

Page 7 of 12

Part Figures C, D
PART INFORMATION
BMW
Customer:
Body Side Outer LH
Part Name:
7287477
Part Number:

Program Name:
Vehicle Line:

F15

FIGURE C:
Location 11 is 15% safe

FIGURE D:

AQP-Parts v 7.0 AK
Form No: AE #014, Rev: 4, 03/2003

Report No: 7287477HP1

AK Steel - BMW Confidential

Evaluation Date : Nov 12, 2013

Page 8 of 12

Attachment 1
PART INFORMATION
BMW
Customer:
Body Side Outer LH
Part Name:
7287477
Part Number:

Program Name:
Vehicle Line:

F15

Attachment 1:

AQP-Parts v 7.0 AK
Form No: AE #017, Rev: 2, 03/2003

Report No: 7287477HP1

AK Steel - BMW Confidential

Evaluation Date : Nov 12, 2013

Page 9 of 12

Attachment 2
PART INFORMATION
BMW
Customer:
Body Side Outer LH
Part Name:
7287477
Part Number:

Program Name:
Vehicle Line:

F15

Attachment 2:

AQP-Parts v 7.0 AK
Form No: AE #018, Rev: 2, 03/2003

Report No: 7287477HP1

AK Steel - BMW Confidential

Evaluation Date : Nov 12, 2013

Page 10 of 12

Attachment 3
PART INFORMATION
BMW
Customer:
Body Side Outer LH
Part Name:
7287477
Part Number:

Program Name:
Vehicle Line:

F15

Attachment 3:

AQP-Parts v 7.0 AK
Form No: AE #019, Rev: 2, 03/2003

Report No: 7287477HP1

AK Steel - BMW Confidential

Evaluation Date : Nov 12, 2013

Page 11 of 12

Attachment 4
PART INFORMATION
BMW
Customer:
Body Side Outer LH
Part Name:
7287477
Part Number:

Program Name:
Vehicle Line:

F15

Attachment 4:

AQP-Parts v 7.0 AK
Form No: AE #020, Rev: 2, 03/2003

Report No: 7287477HP1

AK Steel - BMW Confidential

Evaluation Date : Nov 12, 2013

Page 12 of 12