COMPLAS 2023

Efficient Virtual Process Modeling of Metallic Bipolar Plate Stamping

  • Gassler, Lukas (inspire AG)
  • Afrasiabi, Mohamadreza (inspire AG)
  • Bambach, Markus (ETH Zürich)

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Bipolar plates are an essential component of fuel cells. They conduct the fluids for the chemical reaction, conduct the electric current produced in the cell and provide the structural integrity of the cell stack. The mass production of metallic bipolar plates is still an economic and technological challenge. Currently, the design phase for customer-specific tooling is long and costly, which hinders the widespread commercialization of this technology. Particularly, the virtual process modeling incurs high computational cost to make accurate predictions for process-relevant quantities, such as the final sheet thickness and the geometry after springback. Finite element (FE) models for industrial bipolar plate geometries can easily require up to 10 Mio. elements and days or weeks of simulations times. To resolve this issue, we investigate the applicability of the Inverse Analysis (IA) for the multi-stage forming process of metallic bipolar plates in this work. Furthermore, a new method for the generation of the intermediate mesh based on the tool geometries, which takes the effects of bending along small radii into account, is presented. The use of the IA will help make faster assessments on the strain distribution of the stamped plate and therefore aiding the designer in evaluating the feasibility of the intended draw stages.