Investigation on Forming of Titanium Bipolar Plates Using Micro-stamping Process

Micro-stamping process is one of the most cost-effective methods to manufacture metallic bipolar plates (BPPs). This research investigates the forming of titanium thin sheet as a potential candidate for BPPs in proton exchange membrane fuel cell (PEMFC). In this regard, the process was first simulated using finite element (FE) code Abaqus. Afterward, experimental tests were implemented and the validation of the FE model was confirmed using the experimental results. In the simulations, the corner radius of the die, draft angle, and friction coefficient at die/sheet interface were selected as variable factors. Forming force and thickness reduction as response functions were evaluated. It is demonstrated that the die corner radius has more influence on the maximum punch force compared to the draft angle and friction coefficient. The maximum punch force decreases with increasing the die corner radius. On the other hand, in order to have a lower thickness reduction, a high die corner radius, higher draft angle, and low friction coefficient are required.