PRODUCTION STRAIN ANALYSIS REPORT

BMW
Gestamp SC
F15

BODY SIDE OUTER RH

7287478
Evaluation Date: Nov 21, 2013
Part (Status/SF):

Marginal / 5%
Report No: F15 7478 BSO RH
by
Mark Hammerl 513-425-2071
Earl Donges 615-478-8279

Contents
Strain Analysis Summary
Trial Information
Material Characterization - Blank #1
Forming Limit Diagram - Blank #1
Thickness Strain Chart - Blank #1
Part Figures
Attachments

Page Number
2
3
4
5
6
7
9

DISTRIBUTION
CUSTOMER
BMW

Company
AK Steel
AK Steel
Gestamp SC

AQP-Parts v 7.0 AK
Form No: AE #006, Rev: 4, 03/2003

Report No: F15 7478 BSO RH

AK Steel - BMW Confidential

GENERAL
Name
Donges, Earl
Myers, Patrick
Cameron Duncan

Evaluation Date : Nov 21, 2013

Page 1 of 10

Production Strain Analysis Summary

PART INFORMATION
BMW
Customer:
Body Side Outer RH
Part Name:
7287478
Part Number:

Production Location:
Program Name:
Vehicle Line:

Gestamp SC
F15

PURPOSE
To complete strain analysis on draw panel after die improvements.

STRAIN ANALYSIS RESULTS AND COMMENTS

Points
Part
Addendum
25
0
Analyzed:
23
0
Safe:
2
0
Marginal:
0
0
Failure:
0
0
Potential Wrinkling:
Marginal / 5%
N/A
Status/SF:

FLDo was calculated using the actual blank thickness and

minimum n-value.
The panel was analyzed and twenty-five (25) locations
were recorded in this report.
Critical area #25 was thinning only no circle gidding had
been applied in this area.

OBSERVATIONS
AK Steel was not present when panel was formed due to scheduling conflicts.
25 locations were recorded on the draw panel and of these 25 locations all were in the safe formability zone, except
for location #15 (0.599) and #21 (0.616) both of these areas were in the marginal zone.
Critical Thickness 0.573
Marginal Thickness 0.620

RECOMMENDATIONS
The part exhibits marginal formability with 2 areas recorded in the marginal zone.
These areas may need to be re-evaluated after additional forming is done in other operations in these areas to
complete the forming of the finished part.

AQP-Parts v 7.0 AK
Form No: AE #007, Rev: 5, 05/2006

Report No: F15 7478 BSO RH

AK Steel - BMW Confidential

Evaluation Date : Nov 21, 2013

Page 2 of 10

Trial Setup/Tonnage
PART INFORMATION
BMW
Customer:
Body Side Outer RH
Part Name:
7287478
Part Number:

Production Location:
Program Name:
Vehicle Line:

GENERAL INFORMATION
Production
Trial Type:
Gestamp
Trial Facility:
N/A
Facility Contact:
Contact Phone No: N/A

Nov 21, 2013

Trial Date:
Press/Process Changes:
Panel Status:
Eng/Dev Change Level: N/A

Gestamp SC
F15

PRESS INFORMATION
PL2
Line:
N/A
Identification:
Line Conditions: N/A

Press Speed (SPM):

Bolster:
Nitrogen Pressure - Inner (psi):
Nitrogen Pressure - Outer (psi):
Cushion Stroke (in):
Cushion Pressure (psi):
Number of Cylinders:
Cylinder Size Diameter (in):
Calculated Tonnage (tons):

N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A

Shut Height - Inner (in):

Shut Height - Outer (in):
Counter Balance - Inner (psi):
Counter Balance - Outer (psi):
Binder Travel (in):
On Bottom?:
Load Monitor?:
Last Press Parallelism Date:

DIE INFORMATION
N/A
Die Number:
Draw
Die Type/Process:
Type of Operation: N/A
Surface Treatment - Upper Die: N/A
Surface Treatment - Lower Die: N/A
Comments: N/A

N/A
N/A
N/A
N/A
N/A
Yes
N/A
N/A

Tool Build Source:

N/A
Die Engineer:
N/A
Die Material:
Surface Treatment - Upper Binder: N/A
Surface Treatment - Lower Binder: N/A

LUBRICATION INFORMATION
MILL
N/A
Type:
N/A
Application:
N/A
Relative Amount:
N/A
Distribution:
BW Concentration:
Comments: Blank was relubed following circle gridding.
TONNAGE INFORMATION
BINDER FORCE (tons)
N/A
N/A
LR:
RR:
N/A
N/A
LF:
RF:
Blankholder Force Window - Buckling (tons):
Comments:

Total
N/A
N/A

BLANKER
N/A
N/A
N/A
N/A
N/A

PRESS
N/A
N/A
N/A
N/A
N/A

RAM FORCE (tons)

N/A
N/A
LR:
RR:
N/A
N/A
LF:
RF:
Blankholder Force Window - Splitting (tons):

Total
N/A
N/A

N/A

AQP-Parts v 7.0 AK
Form No: AE #025, Rev: 2, 03/2003

Report No: F15 7478 BSO RH

AK Steel - BMW Confidential

Evaluation Date : Nov 21, 2013

Page 3 of 10

Material Characterization - Blank #1

PART INFORMATION
BMW
Customer:
Body Side Outer RH
Part Name:
7287478
Part Number:
MATERIAL
Material Supplier:
Supplier Contact:
Contact Phone No:
Heat Number:
Coil Identification:
Lift Number:
P.O. Number:
Material Source:
Reference Number:
Specified Thickness (mm):
Measured Thickness (mm):

F15
Program Name:
Blanking Location: N/A
0.75 mm ; GS93032-2 CR4 EG 50/50
Material:

AK Steel
Patrick Myers
937-545-5763
N/A
934601-01A
N/A
N/A
Middletown Works
N/A
0.75 min
0.759

MECHANICAL PROPERTIES
Property

Customer Specification:
AK Product:
AK Quality:
Quality Grade:
Coating Weight:
Surface Treatment:
Specified Blank Size (mm):
Measured Blank Size (mm):
Specified Blank Shape:
Measured Blank Shape:

Longitudinal

140.0

Tensile Strength
(ksi)

270.0

% Elongation
(Total - machine)

40.0

Work Hardening Exp.

n Value

0.20

50G/50G
1825
x
N/A
x
Configured
Configured

Transverse

170.0

Yield Strength
(ksi)

GS93032-2 CR4 EG 50/50

EG
EDDS

3756
N/A

Diagonal

N/A
180.0

N/A

330.0

N/A

48.0

N/A

0.25

N/A

310.0

N/A
N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

44.0

N/A
N/A

N/A

0.226

N/A
N/A

N/A

N/A
N/A

Non-Directional
1.98
1.9

Plastic Strain Ratio

r Value
Note:

2.3

1. Production ranges represent data for the N/A calendar year for a thickness range of: N/A .

CHEMICAL COMPOSITION (%)

C
Mn
P
S
Si
0.002 0.086 0.006 0.011 0.005
SURFACE PROPERTIES
Ra
Pc
Location
(in)
(ppi)
N/A
N/A
Top
N/A
N/A
Bottom

AQP-Parts v 7.0 AK
Form No: AE #012, Rev: 5, 10/2008

Cu
0.072

Al
0.041

Coating Weight
(gm/m)
61.0
52.0

N
Cb
Ti
Mo
0.0027 0.0010 0.0500 0.0080
Organic Coating Weight
(gm/m)
N/A
N/A

Report No: F15 7478 BSO RH

AK Steel - BMW Confidential

Cr
0.045

V
B
Ni
0.0030 0.0000 0.0027

Powdering

% Iron

N/A
N/A

N/A

Evaluation Date : Nov 21, 2013

Page 4 of 10

Forming Limit Diagram - Blank #1

PART INFORMATION
Customer:
Production Location:
Program Name:
Vehicle Line:
Part Name:
Part Number:

BMW
Gestamp SC
F15

110

DRAW

Body Side Outer RH

7287478

100

STRETCH

90
FLD PARAMETERS
FLDo Thickness (mm):
FLDo n Value:
Blank Thickness (mm):

0.759
0.20
0.759

32.4
24.5
M / 5%

FLDo:
% Thinning @ FLDo:
FLD Status/SF (% Maj):

DATA
Pt % Major % Minor
Thickness Strain
Strain
Strain Thickness % Thinning
(mm)

Point
Status

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25

S/20%
S/21%
S/23%
S/21%
S/20%
S/22%
S/14%
S/22%
S/20%
S/24%
S/13%
S/18%
S/26%
S/14%
M/5%
S/12%
S/14%
S/29%
S/26%
S/27%
M/9%
S/21%
S/12%
S/21%
S/12%

16
14
11
16
16
15
27
18
15
9
25
20
8
19
35
20
18
6
9
7
37
14
26
14
20

-3
-3
-2
-4
-4
-4
-7
-7
-2
-1
-5
-5
-2
-1
-6
0
0
-3
-3
-2
-10
-3
-5
-3
0

0.676
0.684
0.699
0.684
0.68
0.688
0.645
0.689
0.676
0.703
0.637
0.665
0.72
0.645
0.599
0.633
0.644
0.74
0.716
0.721
0.616
0.685
0.632
0.686
0.633

10.9
9.9
7.9
9.9
10.4
9.4
15.0
9.2
10.9
7.4
16.1
12.4
5.1
15.0
21.1
16.6
15.2
2.5
5.7
5.0
18.8
9.7
16.7
9.6
16.6

CV
Status
[0%]

Label

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25

Note: 1. Circle Grid Diameter (in) = 0.1

2. Measured Strain and Thickness values are shown when entered. Calculated values of % Major
Strain and Thickness are italicized.
3. Status, % Thinning and italicized values are calculated from the Thickness and % Minor Strain.
4. S = Safe, M = Marginal, F = Failure, W = Potential Wrinkling/Thickening
5. t @ FLDo = 0.573 mm ; t @ FLDo-MZ = 0.620 mm
AQP-Parts v 7.0 AK
Form No: AE #008, Rev: 5, 10/2008

80

FAILURE

M
a
j
o
r

70

S
t
r
a
i
n

50

60
50%

MARGINAL

40
21
15

30
7 23
11
30%
25
16
20 12 14
8
17 SAFE
5
4
1
624
29
22
20%
3
10 19
10
13
20
18
10%

WRINKLING

40%

0
-40

-30

-20

-10

10

20

30

40

% Minor Strain
Note: 1. Marginal Zone (% Major Strain) = 10
2. Potential Wrinkling/Thickening Strains are plotted as squares.
3. Points 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25
are plotted using calculated % Major Strains of 16, 14, 11, 16, 16, 15, 27, 18, 15, 9, 25, 20,
8, 19, 35, 20, 18, 6, 9, 7, 37, 14, 26, 14, 20 .

Report No: F15 7478 BSO RH

AK Steel - BMW Confidential

Evaluation Date : Nov 21, 2013

Page 5 of 10

Thickness Strain Chart - Blank #1

PART INFORMATION
Customer:
Production Location:
Program Name:
Vehicle Line:
Part Name:
Part Number:

BMW
Gestamp SC
F15

Actual % Thinning, when Minor Strain <= 0

Adjusted % Thinning, when Minor Strain > 0

Body Side Outer RH

7287478

% Thinning @ FLDo

FLD PARAMETERS
FLDo Thickness (mm):
FLDo n Value:
Blank Thickness (mm):

0.759
0.20
0.759

32.4
24.5
M / 5%

FLDo:
% Thinning @ FLDo:
TSC Status/SF (% Maj):

% Thinning @ FLDo less Marginal Zone

50

DATA
Pt % Major % Minor
Thickness Strain
Strain
Strain Thickness % Thinning
(mm)
Act
Adj

Point
Status

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25

S/20%
S/21%
S/23%
S/21%
S/20%
S/22%
S/14%
S/22%
S/20%
S/24%
S/13%
S/18%
S/26%
S/14%
M/5%
S/12%
S/14%
S/29%
S/26%
S/27%
M/9%
S/21%
S/12%
S/21%
S/12%

16
14
11
16
16
15
27
18
15
9
25
20
8
19
35
20
18
6
9
7
37
14
26
14
20

-3
-3
-2
-4
-4
-4
-7
-7
-2
-1
-5
-5
-2
-1
-6
0
0
-3
-3
-2
-10
-3
-5
-3
0

0.676
0.684
0.699
0.684
0.68
0.688
0.645
0.689
0.676
0.703
0.637
0.665
0.72
0.645
0.599
0.633
0.644
0.74
0.716
0.721
0.616
0.685
0.632
0.686
0.633

10.9
9.9
7.9
9.9
10.4
9.4
15.0
9.2
10.9
7.4
16.1
12.4
5.1
15.0
21.1
16.6
15.2
2.5
5.7
5.0
18.8
9.7
16.7
9.6
16.6

CV
Status
[0%]

Label

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25

Note: 1. Circle Grid Diameter (in) = 0.1

2. Measured Strain and Thickness values are shown when entered. Calculated values of % Major
Strain and Thickness are italicized.
3. Status, % Thinning and italicized values are calculated from the Thickness and % Minor Strain.
4. S = Safe, M = Marginal, F = Failure, W = Potential Wrinkling/Thickening
5. t @ FLDo = 0.573 mm ; t @ FLDo-MZ = 0.620 mm
AQP-Parts v 7.0 AK
Form No: AE #010, Rev: 5, 10/2008

45
40
% 35
T
h
i
n
n
i
n
g

30
25
20
15
10
5
0
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25

Point
Note: 1. Marginal Zone (% Thinning) = 6.17
2. Potential Wrinkling/Thickening Strains are plotted as squares at 0 % Thinning.

Report No: F15 7478 BSO RH

AK Steel - BMW Confidential

Evaluation Date : Nov 21, 2013

Page 6 of 10

Part Figures A, B
PART INFORMATION
BMW
Customer:
Body Side Outer RH
Part Name:
7287478
Part Number:

Program Name:
Vehicle Line:

F15

FIGURE A: Bottoming Mark

Bottoming mark was present on
circle grid panel.

FIGURE B: Scratches
Some scratches and pick-up was
noted on binder area, nothing
near finished part.

AQP-Parts v 7.0 AK
Form No: AE #013, Rev: 4, 03/2003

Report No: F15 7478 BSO RH

AK Steel - BMW Confidential

Evaluation Date : Nov 21, 2013

Page 7 of 10

Part Figures C, D
PART INFORMATION
BMW
Customer:
Body Side Outer RH
Part Name:
7287478
Part Number:

Program Name:
Vehicle Line:

F15

FIGURE C: Point #15

This location Point 15 was in the
marginal zone, thinning may
increase after additional forming
in this area.

FIGURE D: Point #21

This location Point 21 was in the
marginal zone and may be of
more concern after additional
forming in this area.

AQP-Parts v 7.0 AK
Form No: AE #014, Rev: 4, 03/2003

Report No: F15 7478 BSO RH

AK Steel - BMW Confidential

Evaluation Date : Nov 21, 2013

Page 8 of 10

Attachment 1
PART INFORMATION
BMW
Customer:
Body Side Outer RH
Part Name:
7287478
Part Number:

Program Name:
Vehicle Line:

F15

Attachment 1: Draw Panel

AK Steel was not present during
the forming of the panel and is
not aware if any changes were
made to the part or tooling after
the part was formed.

AQP-Parts v 7.0 AK
Form No: AE #017, Rev: 2, 03/2003

Report No: F15 7478 BSO RH

AK Steel - BMW Confidential

Evaluation Date : Nov 21, 2013

Page 9 of 10

Attachment 2
PART INFORMATION
BMW
Customer:
Body Side Outer RH
Part Name:
7287478
Part Number:

Program Name:
Vehicle Line:

F15

Attachment 2: Strain Locations

AK Steel was not present during
the forming of the panel.
AK Steel recorded 25
locations .using thinning and
circle grid analysis. Of the 25
areas recorded all were in the
safe formability zone, except for
areas #15 and #21, they were
both in the marginal zone.

AQP-Parts v 7.0 AK
Form No: AE #018, Rev: 2, 03/2003

Report No: F15 7478 BSO RH

AK Steel - BMW Confidential

Evaluation Date : Nov 21, 2013

Page 10 of 10