Gestamp Union, South Carolina

Strain analysis service provided to AK Steel by Phoenix Services LLC

STATUS PANEL REPORT

Report No. :
2
Front Door Inner Left Hand "B" blank
7288855
NA
NA
12/11/13
Supplier Evaluation

Part Name :
Part Number :
Line No. :
Forming Date :
Report Date :
Reason for Report:
Formability Status : Marginal 9%

*** WHEN PRINTED THIS BECOMES AN UNCONTROLLED COPY ***

Part Name: Front Door Inner Left Hand "B" blank

Part Number:
7288855
Die Number: NA
Date of Forming: NA
Material
Steel Supplier: AK Steel
Coil ID: NA
Grade: CR-5
Coil Width: NA
Coating: Hot Dipped
Blank Size:
NA
X
NA
Specified Gage: NA
Blank Shape: Developed laser welded
Blank Loc. Analysis: NA
Blanked At: NA
Mechanical Properties
Yield
Tensile
Elongation
N- Value
R- Value
Strength
Strength
in 2 inches
Mpa
Mpa
%
(-3 sigma)
NA
NA
NA
NA
NA
Lubricant
Mill
Press Line
Type: NA
Type: NA
Application Method: NA
Application Method: NA
Amount: NA
Amount: NA
Location: NA
Location: NA
Press/Die
Press Number: NA
Cushion Pressure: NA
Die Material: NA
Bolster:
NA
X
NA
Shut Height Inner: NA
Press Speed: NA
Shut Height Outer: NA
Type of Form: NA
Counterbalance Inner: NA
Surface Treatment: NA
Counterbalance Outer: NA
Blocks and Shims: See Setup Recipe
Press Loads
Inner Ram (Kn)
Left Rear Inner:
N/A
Right Rear Inner:
N/A
Left Front Inner:
N/A
Right Front Inner:
N/A
Inner Ram Total:
NA
Outer Ram (Kn)
Left Rear Outer:
N/A
Right Rear Outer:
N/A
Left Front Outer:
N/A
Right Front Outer:
N/A
Outer Ram Total:
NA
Current Strain Status
Safe: N/A
Marginal: N/A
Failure: N/A
Circle Grid Analysis
FLDo:
35.7
Marginal Zone:
25.7
Pt. 1:
16
-2
Pt. 9:
32
-4
Pt. 17: N/A
N/A
Pt. 25: N/A
N/A
Pt. 2:
10
0
Pt. 10:
24
3
Pt. 18: N/A
N/A
Pt. 26: N/A
N/A
Pt. 3:
17
1
Pt. 11:
20
4
Pt. 19: N/A
N/A
Pt. 27: N/A
N/A
Pt. 4:
15
3
Pt. 12: N/A
N/A
Pt. 20: N/A
N/A
Pt. 28: N/A
N/A
Pt. 5:
15
4
Pt. 13: N/A
N/A
Pt. 21: N/A
N/A
Pt. 29: N/A
N/A
Pt. 6:
22
0
Pt. 14: N/A
N/A
Pt. 22: N/A
N/A
Pt. 30: N/A
N/A
Pt. 7:
24
0
Pt. 15: N/A
N/A
Pt. 23: N/A
N/A
Pt. 31: N/A
N/A
Pt. 8:
17
0
Pt. 16: N/A
N/A
Pt. 24: N/A
N/A
Pt. 32: N/A
N/A
Ultrasound Thickness
Critical Thickness:
0.562
Marginal Thickness:
0.606
Pt. 1:
0.6800
Pt. 9:
0.6030
Pt. 17:
N/A
Pt. 25:
N/A
Pt. 2:
0.6900
Pt. 10:
0.6040
Pt. 18:
N/A
Pt. 26:
N/A
Pt. 3:
0.6370
Pt. 11:
0.6180
Pt. 19:
N/A
Pt. 27:
N/A
Pt. 4:
0.6450
Pt. 12:
N/A
Pt. 20:
N/A
Pt. 28:
N/A
Pt. 5:
0.6300
Pt. 13:
N/A
Pt. 21:
N/A
Pt. 29:
N/A
Pt. 6:
0.6230
Pt. 14:
N/A
Pt. 22:
N/A
Pt. 30:
N/A
Pt. 7:
0.6120
Pt. 15:
N/A
Pt. 23:
N/A
Pt. 31:
N/A
Pt. 8:
0.6500
Pt. 16:
N/A
Pt. 24:
N/A
Pt. 32:
N/A
*** WHEN PRINTED THIS BECOMES AN UNCONTROLLED COPY ***

Part Name: Front Door Inner Left Hand "B" blank Part Number:
Die Number: NA
Date of Forming: NA

7288855

Observations
Analysts was not present when part was formed.
No press settings from time of part formation were available
Coil number was not available, analysis preformed using actual measured thickness of blank
and minimum specified "N" value
"B" blank portion of door panel is marginal 9%, in strain analysis.
Areas at points 6,7,8, & 10 were not etched. Surface strain, for these areas, is based on
Thinning analysis and plane strain mode of deformation.
Wrinkles along A pillar and header area of window.
Severe hard mark on binder, outside of bead, adjacent to points 3 & 10.

Recommendations
Spotting binder at weld line for proper clearance of "A" will reduce wrinkles above A pillar
portion of blank.
Spotting binder surface to remove hard mark in latch area will reduce major strains at points
three, four, and ten.
At evaluation point 9, optimize radii and wall angles of to print design to reduce major strain
recorded in this area.
Second die forms hinge and latch areas deeper and these areas should have additional strain
analysis preformed.

*** WHEN PRINTED THIS BECOMES AN UNCONTROLLED COPY ***

Part Name: Front Door Inner Left Hand "B" blank

Part Number:
Die Number: NA
Date of Forming: NA

7288855

Forming Limit Diagram

90

80

70
Critical

% Major Strain

60

50
Marginal
40
Safe
30

7 10
6
11
8
3
1
45

20

10
2

0
-30

-20

-10

10

20

% Minor Strain

*** WHEN PRINTED THIS BECOMES AN UNCONTROLLED COPY ***

30

Part Name: Front Door Inner Left Hand "B" blank

Part Number:
Die Number: NA
Date of Forming: NA

7288855

Final Thickness

Thickness Strain Analysis

0.000

Data Points

0.100

Critical Thickness

0.200

Marginal Thickness

Original Thickness

0.300
0.400
0.500
0.600
0.700

Safe

0.800
0.900

11 13 15 17

19 21 23

25 27 29

Measurement Point
Critical Thickness
Marginal Thickness
Original Thickness - Inches
Minimum n - VALUE
FLDo
FLD Marginal

0.562
0.606
0.762
0.220
35.7
25.7

*** WHEN PRINTED THIS BECOMES AN UNCONTROLLED COPY ***

31

Part Name: Front Door Inner Left Hand "B" blank

Part Number:
Die Number: NA
Date of Forming: NA

11

10

*** WHEN PRINTED THIS BECOMES AN UNCONTROLLED COPY ***

7288855

Part Name: Front Door Inner Left Hand "B" blank

Part Number:
Die Number: NA
Date of Forming: NA

*** WHEN PRINTED THIS BECOMES AN UNCONTROLLED COPY ***

7288855

Part Name: Front Door Inner Left Hand "B" blank

Part Number:
Die Number: NA
Date of Forming: NA

*** WHEN PRINTED THIS BECOMES AN UNCONTROLLED COPY ***

7288855