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Gestamp Union, South Carolina

Strain analysis service provided to AK Steel by Phoenix Services LLC

STATUS PANEL REPORT


Report No. :
1
Front Door Inner Left Hand ("A"Blank)
7288855
NA
NA
12/11/13
Supplier evaluation

Part Name :
Part Number :
Line No. :
Forming Date :
Report Date :
Reason for Report:
Formability Status : Safe 17%

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

Part Name: Front Door Inner Left Hand ("A"Blank)


Part Number:
7288855
Die Number: NA
Date of Forming: NA
Material
Steel Supplier: AK Steel
Coil ID: NA
Grade: CR-4
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:
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:
AN
Right Front Outer:
NA
Outer Ram Total:
NA
Current Strain Status
Safe: N/A
Marginal: N/A
Failure: N/A
Circle Grid Analysis
FLDo:
46.1
Marginal Zone:
36.1
Pt. 1:
25
-4
Pt. 9: N/A
N/A
Pt. 17: N/A
N/A
Pt. 25: N/A
N/A
Pt. 2:
26
4
Pt. 10: N/A
N/A
Pt. 18: N/A
N/A
Pt. 26: N/A
N/A
Pt. 3:
22
3
Pt. 11: N/A
N/A
Pt. 19: N/A
N/A
Pt. 27: N/A
N/A
Pt. 4:
27
3
Pt. 12: N/A
N/A
Pt. 20: N/A
N/A
Pt. 28: N/A
N/A
Pt. 5:
20
5
Pt. 13: N/A
N/A
Pt. 21: N/A
N/A
Pt. 29: N/A
N/A
Pt. 6:
21
5
Pt. 14: N/A
N/A
Pt. 22: N/A
N/A
Pt. 30: N/A
N/A
Pt. 7:
28
0
Pt. 15: N/A
N/A
Pt. 23: N/A
N/A
Pt. 31: N/A
N/A
Pt. 8: N/A
N/A
Pt. 16: N/A
N/A
Pt. 24: N/A
N/A
Pt. 32: N/A
N/A
Ultrasound Thickness
Critical Thickness:
1.214
Marginal Thickness:
1.303
Pt. 1:
1.4780
Pt. 9:
N/A
Pt. 17:
N/A
Pt. 25:
N/A
Pt. 2:
1.3720
Pt. 10:
N/A
Pt. 18:
N/A
Pt. 26:
N/A
Pt. 3:
1.3900
Pt. 11:
N/A
Pt. 19:
N/A
Pt. 27:
N/A
Pt. 4:
1.3440
Pt. 12:
N/A
Pt. 20:
N/A
Pt. 28:
N/A
Pt. 5:
1.4110
Pt. 13:
N/A
Pt. 21:
N/A
Pt. 29:
N/A
Pt. 6:
1.3820
Pt. 14:
N/A
Pt. 22:
N/A
Pt. 30:
N/A
Pt. 7:
N/A
Pt. 15:
N/A
Pt. 23:
N/A
Pt. 31:
N/A
Pt. 8:
N/A
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 ("A"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
"A" blank portion of door panel is safe 17%, in strain analysis.
Binder pinching was noted at weld seam at the A pillar of the panel.

Recommendations
Binder area at weld seam needs to be spotted to proper thickness and location of the "A"
blank.
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 ("A"Blank) Part Number:
Die Number: NA
Date of Forming: NA

7288855

Forming Limit Diagram


90

80

70
Critical

% Major Strain

60
Marginal
50

40
Safe
30
7
1

20

42
3 6
5

10

0
-30

-20

-10

10

20

% Minor Strain

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

30

Part Name: Front Door Inner Left Hand ("A"Blank) Part Number:
Die Number: NA
Date of Forming: NA

7288855

Final Thickness

Thickness Strain Analysis


0.000

Data Points

0.200

Critical Thickness

0.400

Marginal Thickness

0.600

Original Thickness

0.800
1.000
1.200
1.400
1.600

Safe

1.800
2.000

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

1.214
1.303
1.773
0.200
46.0
36.0

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31

Part Name: Front Door Inner Left Hand ("A"Blank) Part Number:
Die Number: NA
Date of Forming: NA

7288855

1
2

4
5

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

Part Name: Front Door Inner Left Hand ("A"Blank) Part Number:
Die Number: NA
Date of Forming: NA

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

7288855