1Stage 성형시 Bipolar Plate 측벽부 한계각도에 대한 해석적 연구 = Analytical Study on the Limiting Sidewall Angle of Bipolar Plates in One-Stage Forming

다국어 초록 (Multilingual Abstract)

Hydrogen fuel cells have emerged as a next-generation clean energy solution due to their high efficiency and zero-emission characteristics. Among their core components, the bipolar plate plays a critical role in both conducting electrons and forming flow channels for reactive gases. Since the contact area directly affects electrical conductivity, highly precise sheet forming processes are essential. This study investigates how the sidewall angle and corner radius (R value) in a one-stage forming process influence the final geometry of metal bipolar plates, aiming to optimize bottom length and ensure forming stability.
The material used in the simulations was austenitic stainless steel 316L. Finite element analysis was performed using the AutoForm Forming R11 software, with sidewall angles ranging from 60° to 80° and various corner radius values under two thickness conditions (0.5t and 1.0t). The analysis focused on bottom surface area, sidewall springback behavior, and material thinning at corner regions to evaluate correlations between formability and geometric accuracy.
The results showed that higher sidewall angles increased springback, and smaller corner radii led to greater local thinning due to concentrated plastic deformation. While the thinner 0.5t condition showed more pronounced numerical changes, it followed similar trends to the 1.0t model. All conditions exhibited stable forming without cracks. Additionally, future studies are suggested to apply a two-stage forming approach incorporating pre-forming to further enhance shape accuracy and formability.