Gestamp Union, South Carolina

Strain analysis service provided to AK Steel by Phoenix Services LLC

STATUS PANEL REPORT

Report No. :
1
Rear Door Inner Left Hand "A"Blank
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NA
NA
12/17/13
Supplier Evaluation

Part Name :
Part Number :
Line No. :
Forming Date :
Report Date :
Reason for Report:
Formability Status : Safe 30%

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Part Name: Rear Door Inner Left Hand "A"BlankPart Number:

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Die Number: NA
Date of Forming: NA
Material
Steel Supplier: AK Stel
Coil ID: NA
Grade: CR-4
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:
N/A
Outer Ram Total:
NA
Current Strain Status
Safe: N/A
Marginal: N/A
Failure: N/A
Circle Grid Analysis
FLDo:
45.7
Marginal Zone:
35.7
Pt. 1:
18
5
Pt. 9: N/A
N/A
Pt. 17: N/A
N/A
Pt. 25: N/A
N/A
Pt. 2:
14
2
Pt. 10: N/A
N/A
Pt. 18: N/A
N/A
Pt. 26: N/A
N/A
Pt. 3:
18
3
Pt. 11: N/A
N/A
Pt. 19: N/A
N/A
Pt. 27: N/A
N/A
Pt. 4:
16
6
Pt. 12: N/A
N/A
Pt. 20: N/A
N/A
Pt. 28: N/A
N/A
Pt. 5:
15
2
Pt. 13: N/A
N/A
Pt. 21: N/A
N/A
Pt. 29: N/A
N/A
Pt. 6: N/A
N/A
Pt. 14: N/A
N/A
Pt. 22: N/A
N/A
Pt. 30: N/A
N/A
Pt. 7: N/A
N/A
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:
1.198
Marginal Thickness:
1.286
Pt. 1:
1.4300
Pt. 9:
N/A
Pt. 17:
N/A
Pt. 25:
N/A
Pt. 2:
1.5100
Pt. 10:
N/A
Pt. 18:
N/A
Pt. 26:
N/A
Pt. 3:
1.4470
Pt. 11:
N/A
Pt. 19:
N/A
Pt. 27:
N/A
Pt. 4:
1.4230
Pt. 12:
N/A
Pt. 20:
N/A
Pt. 28:
N/A
Pt. 5:
1.5130
Pt. 13:
N/A
Pt. 21:
N/A
Pt. 29:
N/A
Pt. 6:
N/A
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
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Part Name: Rear Door Inner Left Hand "A"Blank Part Number:
Die Number: NA
Date of Forming: NA

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Observations
"A" blank portion of door inner is 30% 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 few wrinkles and only minor burnishing on the binder surface.

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.
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.

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Part Name: Rear Door Inner Left Hand "A"Blank

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

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Forming Limit Diagram

90

80

70
Critical

% Major Strain

60
Marginal

50

40
Safe
30

20
3 1
5
2

10

0
-30

-20

-10

10

20

% Minor Strain

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30

Part Name: Rear Door Inner Left Hand "A"Blank

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

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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

1.198
1.286
1.745
0.200
45.7
35.7

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

31

Part Name: Rear Door Inner Left Hand "A"Blank

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

7288875

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

Part Name: Rear Door Inner Left Hand "A"Blank

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

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

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