%0 Conference Paper %1 Briesenick.2023b %A Briesenick, David %A Beck, Maxim %A Riedmueller, Kim Rouven %A Liewald, Mathias %D 2023 %J 14th European LS-DYNA Conference, Baden-Baden, Germany %K imported KR DB MBE ML %T Numerical study on a new forming method for manufacturing large metallic bipolar plates %X Fuel cell technology offers a sustainable power supply solution for heavy-duty vehicles, aviation and shipping as well as stationary application. Manufacturing of metallic bipolar plates (MBPP) as a key component of fuel cells is nowadays one of the main topics in production-based research and processing industry. One reason for this is that although stamping of thin stainless-steel foils enables an economic large-scale production of metallic bipolar plates, tooling and press technologies required for embossing and shear cut operations are highly demanding and thus continuously being developed. Particular challenges are posed by the embossing of the complex flow field structure, which can cause forming defects and pronounced springback phenomena. Moreover, multiple embossing operations and high press forces are needed to plastify the metal foils as homogeneously as possible and thus form the desired channel geometry. Accordingly, future demand for large metallic bipolar plates is likely to exceed the limits of current press technologies in terms of force capacity and stiffness. Similarly, rolling is also not suitable for forming such large plates due to severe wrinkling and springback. Therefore, this paper proposes the so-called TIP-Form as a new forming process with a tilting forming kinematic of one or both tool halves as well as a crowning of the active surface. In this regard, a numerical study is presented, in which the new forming approach to decrease the force demand and improve the formability when embossing bipolar plates was investigated. Explicit forming simulations of a flow field section were performed using LS-DYNA and forming forces as well as formability were evaluated. Compared to conventional embossing, the controlled tipping and crowning of the punch could reduce the simultaneous acting contact zone between tool and foil and therefore maximum forming forces have been reduced. In addition, thinning of formed channels decreased, as the tipping forming kinematics enabled a beneficial material flow. The promising numerical results motivate for further research work and emphasis the development of a new press technology with tipping ram or table for the manufacturing of large metallic bipolar plates.

@inproceedings{Briesenick.2023b, abstract = {Fuel cell technology offers a sustainable power supply solution for heavy-duty vehicles, aviation and shipping as well as stationary application. Manufacturing of metallic bipolar plates (MBPP) as a key component of fuel cells is nowadays one of the main topics in production-based research and processing industry. One reason for this is that although stamping of thin stainless-steel foils enables an economic large-scale production of metallic bipolar plates, tooling and press technologies required for embossing and shear cut operations are highly demanding and thus continuously being developed. Particular challenges are posed by the embossing of the complex flow field structure, which can cause forming defects and pronounced springback phenomena. Moreover, multiple embossing operations and high press forces are needed to plastify the metal foils as homogeneously as possible and thus form the desired channel geometry. Accordingly, future demand for large metallic bipolar plates is likely to exceed the limits of current press technologies in terms of force capacity and stiffness. Similarly, rolling is also not suitable for forming such large plates due to severe wrinkling and springback. Therefore, this paper proposes the so-called TIP-Form as a new forming process with a tilting forming kinematic of one or both tool halves as well as a crowning of the active surface. In this regard, a numerical study is presented, in which the new forming approach to decrease the force demand and improve the formability when embossing bipolar plates was investigated. Explicit forming simulations of a flow field section were performed using LS-DYNA and forming forces as well as formability were evaluated. Compared to conventional embossing, the controlled tipping and crowning of the punch could reduce the simultaneous acting contact zone between tool and foil and therefore maximum forming forces have been reduced. In addition, thinning of formed channels decreased, as the tipping forming kinematics enabled a beneficial material flow. The promising numerical results motivate for further research work and emphasis the development of a new press technology with tipping ram or table for the manufacturing of large metallic bipolar plates.}, added-at = {2024-07-29T11:44:39.000+0200}, author = {Briesenick, David and Beck, Maxim and Riedmueller, Kim Rouven and Liewald, Mathias}, biburl = {https://puma.ub.uni-stuttgart.de/bibtex/24cf1257938538dbee87846944cac86eb/ifu}, file = {Tip-Form{\_}LS-DYNA{\_}Conference:Attachments/Tip-Form{\_}LS-DYNA{\_}Conference.pdf:application/pdf}, interhash = {e17b9f26fc3a055c0428ced6e1b797de}, intrahash = {4cf1257938538dbee87846944cac86eb}, journal = {14th European LS-DYNA Conference, Baden-Baden, Germany}, keywords = {imported KR DB MBE ML}, month = oct, timestamp = {2024-07-29T11:44:39.000+0200}, title = {Numerical study on a new forming method for manufacturing large metallic bipolar plates}, year = 2023 }