A High-Precision Micro-Roll Forming Facility for Fuel Cell Metal Bipolar Plate Production
The metal bipolar plate is a critical component of the hydrogen fuel cell stack used in proton exchange membrane fuel cells. Bipolar plates must have high accuracy micro-channels with a high aspect ratio (<i>AR</i>) between the channel depth and the half periodic width to achieve optimal...
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MDPI AG
2025-01-01
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| Online Access: | https://www.mdpi.com/2072-666X/16/1/91 |
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| author | Matthias Weiss Peng Zhang Michael Pereira |
| author_facet | Matthias Weiss Peng Zhang Michael Pereira |
| author_sort | Matthias Weiss |
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| description | The metal bipolar plate is a critical component of the hydrogen fuel cell stack used in proton exchange membrane fuel cells. Bipolar plates must have high accuracy micro-channels with a high aspect ratio (<i>AR</i>) between the channel depth and the half periodic width to achieve optimal cell performance. Conventional forming methods, such as micro-stamping, hydroforming, and rubber pad forming, cannot achieve these high ARs given that in these processes, material deformation is dominated by stretch deformation. In micro-roll forming the major deformation mode is bending, and this enables production of channels with higher <i>ARs</i> than is currently possible. However, micro-roll forming uses multiple sets of forming roll stands to form the part and this leads to technological challenges related to tool alignment and roll tool precision that must be overcome before widespread application can be achieved. This study presents a new methodology to achieve tight tool tolerances when producing micro-roll tooling by utilizing wire-EDM and micro-turning techniques. This is combined with a new micro-roll former design that enables high-precision tool alignment across multiple roll stations. Proof of concept is provided through micro-roll forming trials performed on ultra-thin titanium sheets that show that the proposed technology can achieve tight dimensional tolerances in the sub-millimeter scale that suits bipolar plate applications. |
| format | Article |
| id | doaj-art-e728c1590c4b4f248af59fc547b844b5 |
| institution | Kabale University |
| issn | 2072-666X |
| language | English |
| publishDate | 2025-01-01 |
| publisher | MDPI AG |
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| series | Micromachines |
| spelling | doaj-art-e728c1590c4b4f248af59fc547b844b52025-01-24T13:42:07ZengMDPI AGMicromachines2072-666X2025-01-011619110.3390/mi16010091A High-Precision Micro-Roll Forming Facility for Fuel Cell Metal Bipolar Plate ProductionMatthias Weiss0Peng Zhang1Michael Pereira2Institute for Frontier Materials, Deakin University, 75 Pigdons Rd., Waurn Ponds, Geelong, VIC 3216, AustraliaInstitute for Frontier Materials, Deakin University, 75 Pigdons Rd., Waurn Ponds, Geelong, VIC 3216, AustraliaSchool of Engineering, Deakin University, 75 Pigdons Rd., Waurn Ponds, Geelong, VIC 3216, AustraliaThe metal bipolar plate is a critical component of the hydrogen fuel cell stack used in proton exchange membrane fuel cells. Bipolar plates must have high accuracy micro-channels with a high aspect ratio (<i>AR</i>) between the channel depth and the half periodic width to achieve optimal cell performance. Conventional forming methods, such as micro-stamping, hydroforming, and rubber pad forming, cannot achieve these high ARs given that in these processes, material deformation is dominated by stretch deformation. In micro-roll forming the major deformation mode is bending, and this enables production of channels with higher <i>ARs</i> than is currently possible. However, micro-roll forming uses multiple sets of forming roll stands to form the part and this leads to technological challenges related to tool alignment and roll tool precision that must be overcome before widespread application can be achieved. This study presents a new methodology to achieve tight tool tolerances when producing micro-roll tooling by utilizing wire-EDM and micro-turning techniques. This is combined with a new micro-roll former design that enables high-precision tool alignment across multiple roll stations. Proof of concept is provided through micro-roll forming trials performed on ultra-thin titanium sheets that show that the proposed technology can achieve tight dimensional tolerances in the sub-millimeter scale that suits bipolar plate applications.https://www.mdpi.com/2072-666X/16/1/91micro-roll formingultra-thin metal sheetbipolar platetool manufacturing |
| spellingShingle | Matthias Weiss Peng Zhang Michael Pereira A High-Precision Micro-Roll Forming Facility for Fuel Cell Metal Bipolar Plate Production Micromachines micro-roll forming ultra-thin metal sheet bipolar plate tool manufacturing |
| title | A High-Precision Micro-Roll Forming Facility for Fuel Cell Metal Bipolar Plate Production |
| title_full | A High-Precision Micro-Roll Forming Facility for Fuel Cell Metal Bipolar Plate Production |
| title_fullStr | A High-Precision Micro-Roll Forming Facility for Fuel Cell Metal Bipolar Plate Production |
| title_full_unstemmed | A High-Precision Micro-Roll Forming Facility for Fuel Cell Metal Bipolar Plate Production |
| title_short | A High-Precision Micro-Roll Forming Facility for Fuel Cell Metal Bipolar Plate Production |
| title_sort | high precision micro roll forming facility for fuel cell metal bipolar plate production |
| topic | micro-roll forming ultra-thin metal sheet bipolar plate tool manufacturing |
| url | https://www.mdpi.com/2072-666X/16/1/91 |
| work_keys_str_mv | AT matthiasweiss ahighprecisionmicrorollformingfacilityforfuelcellmetalbipolarplateproduction AT pengzhang ahighprecisionmicrorollformingfacilityforfuelcellmetalbipolarplateproduction AT michaelpereira ahighprecisionmicrorollformingfacilityforfuelcellmetalbipolarplateproduction AT matthiasweiss highprecisionmicrorollformingfacilityforfuelcellmetalbipolarplateproduction AT pengzhang highprecisionmicrorollformingfacilityforfuelcellmetalbipolarplateproduction AT michaelpereira highprecisionmicrorollformingfacilityforfuelcellmetalbipolarplateproduction |