Investigating the effect of flexible forming process variables on the uniformity of thickness distribution in U-Shaped Micro-channels

Document Type : Original Article

Author

Faculty Member, Faculty of Mechanical Engineering, University of Kashan, Kashan, Iran

Abstract

In this research, the effect of rubber layer characteristics such as hardness and thickness of the rubber layer on the thinning of metallic bipolar plate channels at a constant depth was investigated experimentally and through simulation. The accuracy of the simulation results was evaluated using experimental data. For the experimental stages, a die with parallel grooves and a 60-ton press were used to apply force to the forming die. According to the results obtained, reducing the hardness of the rubber layer will lead to a more uniform thickness distribution at the same depth. The minimum thickness of the formed sample using a Shore A 55 rubber layer was 0.703 mm, which represents a 1.3% improvement in thinning compared to Shore A 90 hardness. Furthermore, increasing the thickness of the rubber layer improves the shaping process, and based on the results at the same depth, a thicker rubber layer will result in the formation of microchannels with a more uniform thickness distribution in critical areas.

Keywords

References

[1] Bar-On I, Kirchain R, Roth R. Technical cost analysis for PEM fuel cells. Journal of Power Sources. 2002;109(1):71-5. doi: 10.1016/S0378-7753(02)00062-9
[2] Hermann A, Chaudhuri T, Spagnol P. Bipolar plates for PEM fuel cells: A review. International journal of hydrogen Energy. 2005;30(12):1297-302. doi: 10.1016/j.ijhydene.2005.04.016
[3] Talebi-Ghadikolaee H, Barzegari MM, Seddighi S. Investigation of deformation mechanics and forming limit of thin-walled metallic bipolar plates. International Journal of Hydrogen Energy. 2023;48(11):4469-91. doi: 10.1016/j.ijhydene.2022.10.270
[4] Talebi-Ghadikolaee H, Ahmadi Khatir F, Seddighi S. Numerical-experimental study on the thickness distribution of metallic bipolar plates for PEM fuel cells. Hydrogen, Fuel Cell & Energy Storage. 2022;9(1):1-18. doi: 0.22104/IJHFC.2021.5217.1230
[5] Talebi-Ghadikolaee H, Elyasi M, Dadgar Asl Y, Zeinolabedin Beygi A, Davoudi M. Feasibility of Forming U-Shaped Microchannels by Flexible-Die Forming Process. Karafan Quarterly Scientific Journal. 2022;19(3):53-70. doi: 10.48301/KSSA.2022.336972.2063
[6] Talebi-Ghadikolaee H, Modanloo V, Elyasi M, Khatir FA. Multiple criteria decision support analysis for manufacturing process parameters selection of metallic bipolar plates for polymer electrolyte membrane fuel cells. Proceedings of the Institution of Mechanical Engineers, Part L: Journal of Materials: Design and Applications. 2023:14644207231203312. doi: 10.1177/1464420723120331
[7] Yuan XZ, Wang H, Zhang J, Wilkinson DP. Bipolar plates for PEM fuel cells-from materials to processing. Journal of New Materials for Electrochemical Systems. 2005;8(4):257.
[8] Modanloo V, Talebi-Ghadikolaee H, Alimirzaloo V, Elyasi M. Fracture prediction in the stamping of titanium bipolar plate for PEM fuel cells. International Journal of Hydrogen Energy. 2021;46(7):5729-39. doi: 10.1016/j.ijhydene.2020.11.088
[9] Lim S, Kim Y, Kang C. Fabrication of aluminum 1050 micro-channel proton exchange membrane fuel cell bipolar plate using rubber-pad-forming process. The International Journal of Advanced Manufacturing Technology. 2013;65:231-8. doi: 10.1007/s00170-012-4162-8
[10] Jeong M-G, Jin C-K, Hwang G-W, Kang C-G. Formability evaluation of stainless steel bipolar plate considering draft angle of die and process parameters by rubber forming. International journal of precision engineering and manufacturing. 2014;15:913-9. doi: 10.1007/s12541-014-0417-7
[11] Mohammadtabar N, Bakhshi-Jooybari M, Hosseinipour S, Gorji A. Feasibility study of a double-step hydroforming process for fabrication of fuel cell bipolar plates with slotted interdigitated serpentine flow field. The International Journal of Advanced Manufacturing Technology. 2016;85:765-77. doi: 10.1007/s00170-015-7960-y
[12] Modanloo V, Talebi-Ghadikolaee H, Alimirzaloo V, Elyasi M. Fracture prediction in the stamping of titanium bipolar plate for PEM fuel cells. International Journal of Hydrogen Energy. 2021 Jan 27;46(7):5729-39. doi: 10.1016/j.ijhydene.2020.11.088
[13] Modanloo V, Mashayekhi A, Akhoundi B. Analysis of Formability in Stamping of Metallic Bipolar Plates with Parallel Flow Field for Proton Exchange Membrane Fuel Cells using Adaptive Neuro-fuzzy Inference System. Iranica Journal of Energy & Environment. 2024 Apr 1;15(2):170-6.
[14] Seddighi S, Barzegari MM, Talebi-Ghadikolaee H. Numerical-experimental investigation of using rubber blank holder on wrinkling of metallic bipolar plates formed by stamping process. International Journal of Hydrogen Energy. 2023 Mar 31. doi: 10.1016/j.ijhydene.2023.03.172
[15] Talebi-Ghadikolaee H, Elyasi M, Mirnia MJ. Investigation of failure during rubber pad forming of metallic bipolar plates. Thin-Walled Structures. 2020;150:106671. doi: 10.1016/j.tws.2020.106671
[16] Talebi-Ghadikolaee H, Elyasi M, Shahgaldi S, Seddighi S, Kasaei MM, da Silva LF. The Effect of Rubber Hardness on the Channel Depth of the Metallic Bipolar Plates Fabricated by Rubber Pad Forming. InMaterials Design and Applications IV 2022 Oct 30 (pp. 123-133). Cham: Springer International Publishing. doi: 10.1007/978-3-031-18130-6_9
[17] Talebi Ghadikolaee H, Seddighi S, Barzegari MM. Study of the forming process effects on the wrinkling and thinning percentage of the micro-channels with serpentine layout. Hydrogen, Fuel Cell & Energy Storage. 2023 Apr 1;10(1):81-93. doi: 10.22104/IJHFC.2023.6007.1255
[18] SUN Y-n, Min W, WU X-d. Friction coefficient in rubber forming process of Ti-15-3 alloy. Transactions of Nonferrous Metals Society of China. 2012;22(12):2952-9. doi: 10.1016/S1003-6326(11)61551-3
Iranian Journal of Manufacturing Engineering
Volume 10, Issue 2 - Serial Number 64
Best Paper of ICME 2022
April 2023
Pages 41-48

Files

Share

How to cite

Statistics