Production of Metallic Bipolar Plates Made of Stainless Steel by Incremental Hollow Embossing Using Rollers

As the main functional element of the fuel cell, the bipolar plate ensures the functions of media distribution, electron conduction, and mechanical stability of the entire fuel cell stack. Currently, metallic bipolar half-plates are manufactured using clocked, shaping processes (stretch forming). A transfer to a continuous forming process, such as incremental hollow embossing using rollers, promises a significant increase in productivity and, thus, profitability. Based on experimentally determined material parameters, a realistic forming simulation was set up. Significant evaluation parameters are geometric accuracy, sheet thinning, and springback. In addition, specific requirements for the manufacturing equipment have to be derived.