Evaluation of Forming Quality and Spring-back of Fuel Cell Metallic Bipolar Plate during Stamping via Simulations

摘要

This research studies the effects of mold design parameters on stampingrnof fuel cell metallic bipolar plate (MBP). The Taguchi method is used as therntheoretical basis of the mold design optimization, and a simulation is carriedrnout using the Deform 3D software. The optimal mold design parameters inrncritical locations where defects might occur are derived for micro-levelrnsimulations. The thinning ratio and damage are compared with differentrncombinations of several parameters, such as fillet radius, channel depth,rnround corner radius, channel width, rib width, draft angle, frictionalrncoefficient and punch velocity. The first three parameters are morernsignificant in affecting the micro-level quality of MBP than the others, withrnthe fillet radius of being the most important. Dynaform is also used tornsimulate the forming properties of macro-level mold design, while a formingrnlimit diagram is used to analyze the forming quality of the design pattern,rnand spring-back is simulated to predict the warpage of the sheet. The MBP isrnstamped using the optimal parameters, and the forming results are comparedrnto those from the simulations. The use of two simulation methods with thernTaguchi method is proved produce results that are very similar to thernexperimental ones.