Gestamp Union, South Carolina

Strain analysis service provided to AK Steel by Phoenix Services LLC

STATUS PANEL REPORT

Report No. :
NA
Rear Door Inner LH "B" Blank
7288875
NA
NA
12/17/13
N/A

Part Name :
Part Number :
Line No. :
Forming Date :
Report Date :
Reason for Report:
Formability Status : SAFE 16%

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

Part Name: Rear Door Inner LH "B" Blank

Die Number: NA

Part Number:
7288875
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: NA
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:
NA
Right Rear Inner:
NA
Left Front Inner:
NA
Right Front Inner:
NA
Inner Ram Total:
NA
Outer Ram (Kn)
Left Rear Outer:
NA
Right Rear Outer:
NA
Left Front Outer:
NA
Right Front Outer:
NA
Outer Ram Total:
NA
Current Strain Status
Safe: N/A
Marginal: N/A
Failure: N/A
Circle Grid Analysis
FLDo:
36.2
Marginal Zone:
26.2
Pt. 1:
16
7
Pt. 9:
10
6
Pt. 17: N/A
N/A
Pt. 25: N/A
N/A
Pt. 2:
15
5
Pt. 10:
21
3
Pt. 18: N/A
N/A
Pt. 26: N/A
N/A
Pt. 3:
14
4
Pt. 11:
15
8
Pt. 19: N/A
N/A
Pt. 27: N/A
N/A
Pt. 4:
12
4
Pt. 12:
22
-2
Pt. 20: N/A
N/A
Pt. 28: N/A
N/A
Pt. 5:
8
0
Pt. 13:
18
3
Pt. 21: N/A
N/A
Pt. 29: N/A
N/A
Pt. 6:
14
5
Pt. 14: N/A
N/A
Pt. 22: N/A
N/A
Pt. 30: N/A
N/A
Pt. 7:
11
3
Pt. 15: N/A
N/A
Pt. 23: N/A
N/A
Pt. 31: N/A
N/A
Pt. 8:
14
1
Pt. 16: N/A
N/A
Pt. 24: N/A
N/A
Pt. 32: N/A
N/A
Ultrasound Thickness
Critical Thickness:
0.584
Marginal Thickness:
0.630
Pt. 1:
0.6540
Pt. 9:
0.6940
Pt. 17:
N/A
Pt. 25:
N/A
Pt. 2:
0.6500
Pt. 10:
0.6440
Pt. 18:
N/A
Pt. 26:
N/A
Pt. 3:
0.6730
Pt. 11:
0.6380
Pt. 19:
N/A
Pt. 27:
N/A
Pt. 4:
0.6800
Pt. 12:
0.6620
Pt. 20:
N/A
Pt. 28:
N/A
Pt. 5:
0.7300
Pt. 13:
0.6470
Pt. 21:
N/A
Pt. 29:
N/A
Pt. 6:
0.6710
Pt. 14:
N/A
Pt. 22:
N/A
Pt. 30:
N/A
Pt. 7:
0.6850
Pt. 15:
N/A
Pt. 23:
N/A
Pt. 31:
N/A
Pt. 8:
0.6830
Pt. 16:
N/A
Pt. 24:
N/A
Pt. 32:
N/A
*** WHEN PRINTED THIS BECOMES AN UNCONTROLLED COPY ***

Part Name: Rear Door Inner LH "B" Blank

Die Number: NA

Part Number:
Date of Forming: NA

7288875

Observations
"B" blank portion of door inner is 14% safe strain state as evaluated using Circle Grid analysis
supported with ultrasonic thickness readings.,
Analyst was not present when Panel was gridded or formed.
No press settings or die recipe were recorded at time of forming.
Coil number was not available, analysis based on actual thickness measured on formed part
and minimum specified "N" value.
Binder surface show wrinkles at bottom of door then opposite hand panel.
Blank material remains on binder surface outside bead, above window header area after
forming.
Material left on binder at front and rear of window opening is well balanced with no excess
blank on binder after forming (no opportunity from blank reduction).

Recommendations
Second die redraws hinge area of panel deeper. A circle grid evaluation of that forming
operation should be conducted prior to chroming the draw die.
Review weld line location on punch and binder surfaces to document location of blank. Use
this panel as guide in reviewing potential relocation (regauging) of Right hand Rear door blank.
A review of press log for potential set-up changes on this die should be reviewed. If no
changes are documented, a current production draw panel should be obtained, with press and
die recipe recorded.
A thinning analysis and panel comparison should be conducted to verify that Circle Grid panel
matches current production conditions.
If thickness and quality checks confirm part duplication, press and die settings should be
established as production recipe.

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

Part Name: Rear Door Inner LH "B" Blank

Die Number: NA

Part Number:
Date of Forming: NA

7288875

Forming Limit Diagram

90

80

70
Critical

% Major Strain

60

50
Marginal

40

30
Safe
20

12

10
13

10

1
32
6 11
74 9

0
-30

-20

-10

10

20

% Minor Strain

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30

Part Name: Rear Door Inner LH "B" Blank

Die Number: NA

Part Number:
Date of Forming: NA

7288875

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

0.584
0.630
0.795
0.220
36.2
26.2

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31

Part Name: Rear Door Inner LH "B" Blank

Die Number: NA

Part Number:
Date of Forming: NA

7288875

4
2
5
6

12

13

8
10

11

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

Part Name: Rear Door Inner LH "B" Blank

Die Number: NA

Part Number:
Date of Forming: NA

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

7288875