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Deformation in micro roll forming of bipolar plate

Zhang, Peng, Pereira, Michael, Rolfe, Bernard, Wilkosz, D and Weiss, Matthias 2017, Deformation in micro roll forming of bipolar plate, in IDDRG 2017 : Materials modelling and testing for sheet metal forming : Proceedings of the 36th IDDRG 2017 Conference, IOP Publishing, Bristol, Eng., pp. 1-8, doi: 10.1088/1742-6596/896/1/012115.

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Title Deformation in micro roll forming of bipolar plate
Author(s) Zhang, Peng
Pereira, MichaelORCID iD for Pereira, Michael orcid.org/0000-0002-7885-5901
Rolfe, BernardORCID iD for Rolfe, Bernard orcid.org/0000-0001-8516-6170
Wilkosz, D
Weiss, MatthiasORCID iD for Weiss, Matthias orcid.org/0000-0002-1845-6343
Conference name International Deep Drawing Research Group. Conference (36th : 2017 : Munich, Germany)
Conference location Munich, Germany
Conference dates 2017/07/02 - 2017/07/06
Title of proceedings IDDRG 2017 : Materials modelling and testing for sheet metal forming : Proceedings of the 36th IDDRG 2017 Conference
Editor(s) Volk, Wolfram
Publication date 2017
Series International Deep Drawing Research Group Conference
Start page 1
End page 8
Total pages 8
Publisher IOP Publishing
Place of publication Bristol, Eng.
Keyword(s) micro roll forming
Proton Exchange Membrane Fuel Cells (PEMFC)
science & technology
technology
engineering, manufacturing
engineering
materials science
Summary Micro roll forming is a new processing technology to produce bipolar plates for Proton Exchange Membrane Fuel Cells (PEMFC) from thin stainless steel foil. To gain a better understanding of the deformation of the material in this process, numerical studies are necessary before experimental implementation. In general, solid elements with several layers through the material thickness are required to analyse material thinning in processes where the deformation mode is that of bending combined with tension, but this results in high computational costs. This pure solid element approach is especially time-consuming when analysing roll forming processes which generally involves feeding a long strip through a number of successive roll stands. In an attempt to develop a more efficient modelling approach without sacrificing accuracy, two solutions are numerically analysed with ABAQUS/Explicit in this paper. In the first, a small patch of solid elements over the strip width and in the centre of the "pre-cut" sheet is coupled with shell elements while in the second approach pure shell elements are used to discretize the full sheet. In the first approach, the shell element enables accounting for the effect of material being held in the roll stands on material flow while solid elements can be applied to analyse material thinning in a small discrete area of the sheet. Experimental micro roll forming trials are performed to prove that the coupling of solid and shell elements can give acceptable model accuracy while using shell elements alone is shown to result in major deviations between numerical and experimental results.
ISSN 1742-6588
Language eng
DOI 10.1088/1742-6596/896/1/012115
Field of Research 091006 Manufacturing Processes and Technologies (excl Textiles)
091207 Metals and Alloy Materials
02 Physical Sciences
09 Engineering
Socio Economic Objective 861205 Sheet Metal Products
HERDC Research category E1 Full written paper - refereed
ERA Research output type E Conference publication
Copyright notice ©2017, P Zhang et al.
Free to Read? Yes
Use Rights Creative Commons Attribution licence
Persistent URL http://hdl.handle.net/10536/DRO/DU:30102969

Document type: Conference Paper
Collections: School of Architecture and Built Environment
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