Shape and position design of two-step micro-channel on plate during rubber pad forming process based on simulation

Abstract

Rubber pad forming is an advanced processing technology to form the metal sheet. The micro-channel on the plate can be formed by both rubber pad and the metal mold. With the development of micro-channel, a two-step micro-channel has been applied in more and more fields such as fuel cell bipolar plate. However, little attention was given to the forming strategy for these unique channels. In this paper, the rubber pad forming process is used to form the entire SS304 sheet with two-step channels. In order to design the micro-channel structure with good formability, the main parameters of the two-step micro-channel are discussed through finite element modeling (FEM) and forming experiment. Not only for the geometric parameters for structures like length, width, edge chamfer, and the height ratio of first to second step, but also for the spatial distribution like the number and distance of two-step micro-channels in the entire plate. In addition, MATLAB is used to study the influences on the final forming results because of the various parameters. And then, the plates can be precisely formed when the structure is suitable, while micro-channels with unsuitable structure cannot be formed as designed. Finally, based on the FEM and forming experiment results, a design strategy is provided in the conclusions.