Numerical study on a new forming method for manufacturing large metallic bipolar plates

Fuel cell technology offers a sustainable power supply solution for heavy-duty vehicles, aviation and shipping as well as stationary application. Manufacturing of metallic bipolar plates (MBPP) as a key component of fuel cells is nowadays one of the main topics in production-based research and processing industry. One reason for this is that although stamping of thin stainless-steel foils enables an economic large-scale production of metallic bipolar plates, tooling and press technologies required for embossing and shear cut operations are highly demanding and thus continuously being developed. Particular challenges are posed by the embossing of the complex flow field structure, which can cause forming defects and pronounced springback phenomena.