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Optimizing die parameters of microstamping process for PEMFC 316L bipolar plate using NCL fracture criterion and response surface methodology

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Abstract

We investigated the impact of die fillet shape, fillet size, die clearance, and die height on the microstamping of ultrathin 316L bipolar plates (BPPs) with stepped flow channels. Using the normalized Cockcroft–Latham damage fracture criterion combined with the response surface method, we developed an effective predictive model for the fracture behavior of ultrathin 316L BPPs. This model was employed to optimize the mold parameters. Numerical simulation results reveal that different fillet shapes—90° sector, irregular sector, ellipse, and parabola—significantly affect the formation of ultrathin 316L BPPs. Among these, the elliptical fillet shape yielded the best results. Further analysis indicated that increasing the radius of the die fillet while reducing the die height led to decreases in the stress, strain, thinning rate, and damage value of the BPPs. Conversely, the draft angle increased linearly. However, with varying die clearance, the stress, strain, thinning rate, and damage value of the BPPs initially decreased and then increased, while the draft angle continued to rise linearly. The optimized die parameters were identified using the damage prediction model: a fillet radius of 0.2 mm, clearance of 0.26 mm, height of 0.49 mm, and stepped height of 0.24 mm. The validity of these optimized parameters was confirmed experimentally.

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Acknowledgements

This work was supported by the Major Special Projects of Public Bidding in Shanxi Province (No. 20201101020) and the Central Guidance on Local Science and Technology Development Fund Project (No.YDZJSX2022A053).

Funding

This work was supported by the Major Special Projects of Public Bidding in Shanxi Province (No. 20201101020) and the Central Guidance on Local Science and Technology Development Fund Project (No.YDZJSX2022A053).

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Authors and Affiliations

  1. Engineering Research Center Heavy Machinery Ministry of Education, Taiyuan University of Science and Technology, Taiyuan, 030024, People’s Republic of China

    Fuqiang Zhao, Zhiying Gao, Qingxue Huang, Xiujian Cheng & Xiaofeng Ding

  2. College of Mechanical and Vehicle Engineering, Taiyuan University of Technology, Taiyuan, 030024, People’s Republic of China

    Qingxue Huang & Heng Zhang

  3. Xinyan Hydrogen Energy Technology Co., Ltd, Taiyuan, 030024, People’s Republic of China

    Chunhong Ma

  4. Shi-Changxu Innovation Center for Advanced Materials, Institute of Metal Research, Chinese Academy of Sciences, Shenyang, 110016, People’s Republic of China

    Shuaifeng Chen

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  1. Fuqiang Zhao
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Contributions

Fuqiang Zhao offered the project, were in charge of the guidance and final check. Zhiying Gao was in charge of the whole research and wrote the manuscript. Qingxue Huang, Xiujian Cheng and Heng Zhang assisted with the analysis and validation. Chunhong Ma, Shuaifeng Chen and Xiaofeng Ding gave some advice on the manuscript. All authors read and approved the final manuscript.

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Correspondence to Zhiying Gao.

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Zhao, F., Gao, Z., Huang, Q. et al. Optimizing die parameters of microstamping process for PEMFC 316L bipolar plate using NCL fracture criterion and response surface methodology. Int J Adv Manuf Technol 132, 1679–1696 (2024). https://doi.org/10.1007/s00170-024-13461-7

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