GeStamp Union, South Carolina

Strain analysis service provided to AK Steel by Phoenix Services LLC

STATUS PANEL REPORT

Report No. :
N/A
F25 Sideframe LH
2122
PL-2
05/07/14
07/15/14
Annual Formability Analysis

Part Name :
Part Number :
Line No. :
Forming Date :
Report Date :
Reason for Report:
Formability Status : SAFE 13%

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

Part Name: F25 Sideframe LH

Die Number: NA

Part Number:
2122
Date of Forming: 05/07/14
Material
Steel Supplier: AK Steel
Coil ID: NA
GeStamp Union, South Carolina CR5
Coil Width: NA
Coating: EG50G/50G E
Blank Size: 1800
X
3506
Specified Gage: .80 mm
Blank Shape: Developed
Blank Loc. Analysis: NA
Blanked At: Gonvauto
Mechanical Properties
Yield
Tensile
Elongation
N- Value
R- Value
Strength
Strength
in 2 inches
Mpa
Mpa
%
(-3 sigma)
N/A
N/A
N/A
N/A
N/A
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: N/A
X
N/A
Shut Height Inner: 1300 mm
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:
600
Right Rear Inner:
600
Left Front Inner:
650
Right Front Inner:
650
Inner Ram Total:
2500
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:
N/A
Current Strain Status
Safe: 0.13
Marginal: N/A
Failure: N/A
Circle Grid Analysis
FLDo:
36.3
Marginal Zone:
26.3
Pt. 1:
18
4
Pt. 9:
21
6
Pt. 17: N/A
N/A
Pt. 25: N/A
N/A
Pt. 2:
20
3
Pt. 10:
12
2
Pt. 18: N/A
N/A
Pt. 26: N/A
N/A
Pt. 3:
10
6
Pt. 11:
13
7
Pt. 19: N/A
N/A
Pt. 27: N/A
N/A
Pt. 4:
11
4
Pt. 12:
14
6
Pt. 20: N/A
N/A
Pt. 28: N/A
N/A
Pt. 5:
26
4
Pt. 13:
25
-6
Pt. 21: N/A
N/A
Pt. 29: N/A
N/A
Pt. 6:
22
3
Pt. 14:
17
2
Pt. 22: N/A
N/A
Pt. 30: N/A
N/A
Pt. 7:
16
-1
Pt. 15:
15
5
Pt. 23: N/A
N/A
Pt. 31: N/A
N/A
Pt. 8:
16
4
Pt. 16:
14
3
Pt. 24: N/A
N/A
Pt. 32: N/A
N/A
Ultrasound Thickness
Critical Thickness:
0.590
Marginal Thickness:
0.637
Pt. 1:
0.6540
Pt. 9:
0.6250
Pt. 17:
N/A
Pt. 25:
N/A
Pt. 2:
0.6480
Pt. 10:
0.6870
Pt. 18:
N/A
Pt. 26:
N/A
Pt. 3:
0.6900
Pt. 11:
0.6560
Pt. 19:
N/A
Pt. 27:
N/A
Pt. 4:
0.6830
Pt. 12:
0.6690
Pt. 20:
N/A
Pt. 28:
N/A
Pt. 5:
0.6220
Pt. 13:
0.6630
Pt. 21:
N/A
Pt. 29:
N/A
Pt. 6:
0.6260
Pt. 14:
0.6820
Pt. 22:
N/A
Pt. 30:
N/A
Pt. 7:
0.6930
Pt. 15:
0.6730
Pt. 23:
N/A
Pt. 31:
N/A
Pt. 8:
0.6690
Pt. 16:
0.6880
Pt. 24:
N/A
Pt. 32:
N/A
*** WHEN PRINTED THIS BECOMES AN UNCONTROLLED COPY ***

Part Name: F25 Sideframe LH

Die Number: NA

Part Number:
Date of Forming: 05/07/14

2122

GeStamp Union, South Carolina

Phoenix personnel were not present when part was formed.
Die and press settings were documented by GeStamp personnel at time part was formed.
Blank size information was not measured manually. This information was taken from material
card.
Coil identity was not recorded at time part was formed, so actual mechanical properties were
unavailable.
Panel Strain state is SAFE 13% using minimum N and specified thickness values.
Point 1: Wrinkles on binder & addendum below rear wheel well
Point 2: Wrinkles on addendum below rear wheel well
Points 3: & 4 Pinch point along blank edge below rear wheel well
Point 5: Wrinkles on addendum in tail light area
Point 6: Pinch point along blank edge above tail light
Point 7: Wrinkles on binder above rear window
Point 8: Pinch points along blank edge along "A" pillar
Point 9: Wrinkles on binder and addendum along "A" pillar
Point 10: Wrinkles on binder on front end

Recommendations
Save circle gridded panel as a future reference tool.
Continue running to press library settings for this part.
Measure and document equalizer blocks and shims for reference.
Points 1, 2, 5, 7, 9, & 10: Re-spot the binder to minimize wrinkles.
Points 3, 4, 6, & 8: Grind and polish binder.

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

Part Name: F25 Sideframe LH

Die Number: NA

Part Number:
Date of Forming: 05/07/14

GeStamp Union, South Carolina

9
10
8

7
1
3

5
6

4
2

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

Observation Photos 1

2122

Part Name: F25 Sideframe LH

Die Number: NA

Part Number:
Date of Forming: 05/07/14

2122

GeStamp Union, South Carolina

7
9
10
8

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

Observation Photos 2

Part Name: F25 Sideframe LH

Die Number: NA
GeStamp Union, South Carolina

Part Number:
Date of Forming: 05/07/14

2122

Forming Limit Diagram

90

80

70

% Major Strain

60
Critical
50
Marginal
40
Safe
30
5

13

20

6 9
2
1
14
7
8
16 1512
10 4 11
3

10

Actual FLDo

0
-30

-20

-10

10

20

% Minor Strain

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

30

Part Name: F25 Sideframe LH

Die Number: NA

Part Number:
Date of Forming: 05/07/14

2122

GeStamp Union, South Carolina

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
1

11 13 15 17

19 21 23 25 27 29 31

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

0.590
0.637
0.805
0.220
36.3
26.3

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

Part Name: F25 Sideframe LH

Die Number: NA

Part Number:
Date of Forming: 05/07/14

GeStamp Union, South Carolina

1
2

16

5
6
7
15
8

14

9
10
11

12

13

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

Photos 1

2122

Part Name: F25 Sideframe LH

Die Number: NA

Part Number:
Date of Forming: 05/07/14

GeStamp Union, South Carolina

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

Photos 2

2122

Process Recipe
Revision Date: No Date Entered

Part Identification
Line: PL-2
Part Number:
GeStamp Union,
F25
South
Sideframe
Carolina
LH

2122
Die #: Die # Unavailable

Material
Steel Vendor:
AK Steel
Coating: EG50G/50G E
Blanker #:
No Data Available

Grade: CR5
Spec. Thickness Range:
Blank Size:
1800
W:

.80 mm
3506
x P:

Longitudinal Mechanical Properties Acceptable Range

YS (ksi)
TS (ksi)
EL (%)
n-Value
N/A
N/A
N/A
N/A
Shut Height Inner:
1300 mm in.
Counterbalance Inner:
N/A psi
Nitro Upper:
psi
Inner Ram Kn Total:
2500
LR:
600
RR:
600
LF:
650
RF:
650

in.
in.

r-Value
N/A

Press / Die
Shut Height Outer:
N/A
in.
Counterbalance Outer:
N/A psi
Nitro Lower:
psi
Outer Ram Kn Total:
N/A
LR:
N/A
RR:
N/A
LF:
N/A
RF:
N/A
Comments

1 Die and press settings were documented by GeStamp personnel at time part was formed.
2
3
4
5
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