Fracture prediction in the stamping of titanium bipolar plate for PEM fuel cells

Modanloo, Vahid; Talebi-Ghadikolaee, Hossein; Alimirzaloo, Vali; Elyasi, Majid

doi:10.1016/j.ijhydene.2020.11.088

Cited by 42 publications

(13 citation statements)

References 24 publications

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“…To account for this difference in the material properties along the rolling and transversal directions, the anisotropic coefficients according to the von Mises criterion, defined as planar anisotropy in the ABAQUS software, were determined according to Equation (1-4). [36] In Equation (1-4), R values are the yield strength ratios whereas r 0 , r 45 , and r 90 denote the ratios of width (ε w ) to thickness strain (ε t ) (Lankford coefficients) in the rolling direction, diagonal direction, and transverse direction, respectively. [37] The yield strength ratios for the DIN 1.0338 steel are reported in Table 3 and, according to the assumption of planar anisotropy, R 13 = R 23 = 1.…”

Section: Finite-element Modelingmentioning

confidence: 99%

Section: Finite‐element Modelingmentioning

confidence: 99%

“…In the HDDRP experiments, a cylindrical cup (ϕ80 mm), formed from a 2.5 mm sheet made of two materials, pure copper and DIN 1.0338 steel, respectively, was considered. In addition, to further investigate the pressure medium influence on key process variables, namely final thickness, sheet thinning, and maximum punch force, FEM simulations have been implemented in ABAQUS/Explicit [31] and validated through experiments on both materials. Laboratory experiments were carried out considering both media and showed that the application of the SMG resulted in a higher accuracy between FEM and experimental results, especially in terms of thickness distribution at the radius closest to the blank holder.…”

Section: Introductionmentioning

confidence: 99%

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On Improving Sheet Metal Formability in Hydrodynamic Deep Drawing Process through a Solid‐Oil‐Type Mineral Grease Pressure Medium

Modanloo,

Akhoundi,

Lee

et al. 2023

steel research int.

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In this research, the improvement in sheet metal formability obtained through the utilization of a mineral grease in solid oil type (SMG) pressure medium in the hydrodynamic deep drawing process assisted by radial pressure (HDDRP) was investigated by experiments and finite element method (FEM) simulations on flat‐bottom cups realized with pure copper and DIN 1.0338 steel. To determine the process parameters ranges, a FEM model was developed in ABAQUS/Explicit and validated against experimental results. Afterward, experiments were carried out using two pressure mediums with different viscosities, id est water, and SMG. Considering the results relevant for both sheet materials, the SMG medium allowed an average reduction of the sheet metal thinning of 15% and 10% on the corner edges while also granting a negligible thickness variation on the cup walls. On the other hand, the higher viscosity of the SMG, in comparison to the water medium, also resulted in an average 16% increase in the forming force when compared to the water pressure medium.This article is protected by copyright. All rights reserved.

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Section: Finite-element Modelingmentioning

confidence: 99%

Section: Finite‐element Modelingmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

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On Improving Sheet Metal Formability in Hydrodynamic Deep Drawing Process through a Solid‐Oil‐Type Mineral Grease Pressure Medium

Modanloo,

Akhoundi,

Lee

et al. 2023

steel research int.

Self Cite

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“…They found that the dominant stress state in micro-stamping was a combination of biaxial and plane strain. Modanloo et al [15] studied the micro stamping of titanium bipolar plates with parallel flow channels and predicted fracture using different ductile fracture criteria in combination with a 3D FE model.…”

Section: Introductionmentioning

confidence: 99%

Finite element model for micro-stamping titanium bipolar plate

KHADEMI

2023

Materials Research Proceedings

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Abstract. Bipolar plates are the essential components of a Proton Exchange Membrane Fuel Cell. Lightweight bipolar plates can be micro-stamped from an ultrathin metallic foil. A major concern is the manufacturability of the foil in the micro-stamping process. The typical stamped micro-channels have end cavities or corners where the deformation mode can be different from the two-dimensional plane strain conditions that occur at the straight sections of the micro-channels. The thin foil has a large ratio of length (or width) to thickness, and shell elements were often used for three-dimensional models. Currently, it is unknown if the shell elements available in commercial software packages are able to predict the ultrathin material behaviour correctly. In addition, the deformation behaviour and forming limits of titanium foil in the micro-stamping process are not well understood. The current study uses a micro-stamping tool to produce straight micro-channels from commercially pure titanium foil. The experimental data are used to validate a two-dimensional and a three-dimensional finite element model of the process. It is shown that there are deviations between the experimental and the numerical thinning results. Material thinning is different between the straight and the cavity end sections suggesting that three-dimensional process models are required to accurately analyze forming.

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“…It is worth noting that besides rubber pad forming, the stamping process has also been considered a feasible technique for the fabrication of metallic BPPs, as demonstrated by Ahmadi Khatir et al 24 They investigated the effects of geometrical parameters on thinning and filling percentages. In another study, Modanloo et al 25 explored fracture prediction during the stamping of titanium BPPs.…”

Section: Introductionmentioning

confidence: 99%

Multiple criteria decision support analysis for manufacturing process parameters selection of metallic bipolar plates for polymer electrolyte membrane fuel cells

Talebi-Ghadikolaee,

Modanloo,

Elyasi

et al. 2023

Proceedings of the Institution of Mechanical Engineers, Part L:

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The multi-criteria decision-making method, along with experimental and finite-element (FE) methods, was employed to determine the optimal process parameter values for rubber pad forming of metallic bipolar plates. To achieve this aim, the rubber pad forming process was modeled by FE software, and the results were validated by conducting experimental tests. Three significant rubber pad forming parameters—punch force, hardness, and the thickness of the rubber layer—were considered as input variables. A full-factorial design involving 27 experiments was used to assess the alternatives. Filling percentage, thinning ratio, and stress were considered as distinct evaluation criteria. To solve the multi-criteria decision-making problem, a hybrid approach was used to weigh the alternatives. According to the results, the applied method was capable of selecting the optimal values of process parameters while considering different criteria simultaneously. The results demonstrated that a punch force of 50 kN, rubber hardness of 55 Shore A, and rubber thickness of 3.5 mm were the best processing conditions. For these parameters, the filling percentage, thinning ratio, and stress were 97.6%, 28.5%, and 1005 MPa, respectively.

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Fracture prediction in the stamping of titanium bipolar plate for PEM fuel cells

Cited by 42 publications

References 24 publications

On Improving Sheet Metal Formability in Hydrodynamic Deep Drawing Process through a Solid‐Oil‐Type Mineral Grease Pressure Medium

On Improving Sheet Metal Formability in Hydrodynamic Deep Drawing Process through a Solid‐Oil‐Type Mineral Grease Pressure Medium

Finite element model for micro-stamping titanium bipolar plate

Multiple criteria decision support analysis for manufacturing process parameters selection of metallic bipolar plates for polymer electrolyte membrane fuel cells

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