目的 为提升质子交换膜燃料电池316L不锈钢双极板流道的成形精度与质量,解决传统单工步成形工艺中存在的几何精度低、厚度分布不均、残余应力集中等关键问题,提出了一种辊压预成形与冲压整形相结合的复合成形工艺。方法 以0.1 mm的316L不锈钢薄板为材料,先利用辊压成形工艺形成初步流道轮廓,再通过冲压整形对几何形状进行精确定型。通过有限元模拟与物理实验协同验证的方法,系统研究了模具摩擦系数对高深宽比流道成形质量的影响规律。结果 当摩擦系数为0.1时,预成形阶段最大减薄率为4.7%,终整形后减薄率控制在11.3%以内,侧壁形状更接近设计目标所需的90°,左侧与右侧的侧壁角分别提升2.1%与2.7%,流道的成形深度也进一步提升1.2%,辊压复合成形工艺重新分配并优化了板材内部的残余应力场,整体应力降低了12%~15%。结论 摩擦系数通过影响界面剪切应力,进而改变材料流动行为与模具填充效果,最终影响流道的应力应变、厚度分布和几何精度,为质子交换膜燃料电池金属双极板的高质量、高一致性精密成形提供了可行的工艺路径与理论支撑。
Abstract
The work aims to propose a hybrid forming process that combines roll forming for pre-forming with stamping for precision shaping, to improve the forming accuracy and quality of 316L stainless steel bipolar plate flow channels in proton exchange membrane fuel cells, addressing key issues such as low geometric precision, uneven thickness distribution, and concentrated residual stress inherent in traditional single-step forming processes. Using 0.1 mm thick 316L stainless steel sheets as materials, the preliminary channel profile was first formed via roll forming, followed by precise geometric definition through stamping. The influence of die friction coefficient on the forming quality of high-aspect-ratio flow channels was systematically investigated using a combined approach of finite element simulation and physical experiments. The results indicated that at a friction coefficient of 0.1, the maximum thinning rate during the pre-forming stage was 4.7%, and the final thinning rate after finishing was controlled within 11.3%. The sidewall shape more closely approximated the designed 90° target, with the left and right sidewall angles increasing by 2.1% and 2.7%, respectively. The formed channel depth was further increased by 1.2%. The roll-stamping hybrid process effectively redistributed and optimized the internal residual stress field, resulting in an overall stress reduction of 12%-15%. In conclusion, the friction coefficient influences the interfacial shear stress, which in turn changes the material flow behavior and mold filling effect, ultimately affecting the stress-strain state, thickness distribution, and geometric accuracy of the flow channels. This provides a feasible process route and theoretical support for the high-quality and high-consistency precision forming of metallic bipolar plates for proton exchange membrane fuel cells.
关键词
双极板 /
辊压复合成形 /
摩擦系数 /
厚度均匀性 /
成形质量
Key words
bipolar plate /
roll-stamping composite forming /
coefficient of friction /
thickness uniformity /
forming quality
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基金
山西重点研发项目（2025051）; 新疆维吾尔自治区重大科技专项项目（2025A01014-3）; 金属双极板开发与工艺研究项目（2025068）
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