Influence of Friction Coefficient on Roll-stamping Composite Forming of High-aspect-ratio Flow Channels for 316L Stainless-steel Bipolar Plates

CHEN Xueyan; YANG Liu; ZHAO Fuqiang; LIU Hao

doi:10.3969/j.issn.1674-6457.2026.10.013

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Journal of Netshape Forming Engineering ›› 2026, Vol. 18 ›› Issue (10) : 132-139. DOI: 10.3969/j.issn.1674-6457.2026.10.013

Iron and Steel Forming

Influence of Friction Coefficient on Roll-stamping Composite Forming of High-aspect-ratio Flow Channels for 316L Stainless-steel Bipolar Plates

CHEN Xueyan^1,2,3, YANG Liu¹, ZHAO Fuqiang^1,*, LIU Hao^1,2,3

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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.

Key words

bipolar plate / roll-stamping composite forming / coefficient of friction / thickness uniformity / forming quality

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CHEN Xueyan, YANG Liu, ZHAO Fuqiang, LIU Hao. Influence of Friction Coefficient on Roll-stamping Composite Forming of High-aspect-ratio Flow Channels for 316L Stainless-steel Bipolar Plates[J]. Journal of Netshape Forming Engineering. 2026, 18(10): 132-139 https://doi.org/10.3969/j.issn.1674-6457.2026.10.013

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Funding

Key R&D Project of Shanxi Province (2025051); Key Technologies of High-Performance Metal Bipolar Plate Fuel Cells for Major Science and Technology Special Project of Xinjiang Uygur Autonomous Region (2025A01014-3); Development and Process Research on Metal Bipolar Plates project (2025068)