氢燃料电池钛双极板液压成形机理研究

doi:10.12096/j.2096-4528.pgt.23127

摘要/Abstract

摘要：

目的钛双极板因材料各向异性，导致其加工难度大。液压成形工艺在国外双极板成形领域已商业化应用，而国内研究较少。为了揭示双极板液压成形工艺参数与成形质量之间的控制关系，亟需开展钛双极板液压成形机理研究。方法研究了蛇形流场钛双极板液压成形工艺，分析了液压成形过程中双极板力学特性，探究了模具外倒角、流道宽度、流道深度、板材厚度以及液压工艺参数对双极板成形质量的影响。结果双极板的蛇形流道转角区应力成分复杂，最容易发生破裂；增大双极板外倒角半径可降低其减薄率，外倒角半径应不小于0.20 mm；增加流道深度严重影响其减薄效果，流道深度不宜超过0.28 mm；当流道宽度和肋宽相等时，双极板的减薄率最小；液压力在板料底部接触模具前对减薄影响较大，接触后影响较小；随着极板厚度增加，双极板成形效果降低。结论液压成形工艺参数与结构参数的协同设计是保障双极板成形质量的关键，研究结果可为金属双极板成形工艺设计与优化提供理论依据。

关键词: 氢燃料电池, 质子交换膜燃料电池(PEMFC), 金属双极板, 液压成形, 减薄率, 应力分布

Abstract:

Objectives Due to the anisotropic nature of titanium bipolar plates, their manufacturing process is highly challenging. While hydroforming has been commercially applied in bipolar plate production abroad, research in this field remains limited domestically. In order to reveal the control relationship between hydroforming parameters and quality in bipolar plate fabrication, it is essential to investigate the hydroforming mechanism of titanium bipolar plates. Methods This study focuses on the hydroforming process of titanium bipolar plates with a serpentine flow field. It analyzes the mechanical properties of the bipolar plates during the hydroforming process and explores the effects of key parameters, including die fillet radius, flow channel width, flow channel depth, sheet thickness, and hydraulic pressure, on the final forming quality. Results The stress distribution in the corner regions of the serpentine flow channels is highly complex, making these areas most susceptible to fracture. Increasing the die fillet radius effectively reduces the thinning rate, with a recommended minimum radius of 0.2 mm. Increasing flow channel depth significantly worsens thinning, and the depth should not exceed 0.28 mm. When the flow channel width equals the rib width, the thinning rate reaches its minimum. Hydraulic pressure has a greater impact on thinning before the plate contacts the die bottom but its impact diminishes afterward. Additionally, as the plate thickness increases, the overall forming quality deteriorates. Conclusions The coordinated design of hydroforming parameters and structural parameters is critical for ensuring the forming quality of bipolar plates. These findings provide a theoretical foundation for the design and optimization of metal bipolar plate hydroforming process.

Key words: hydrogen fuel cell, proton exchange membrane fuel cell (PEMFC), metal bipolar plate, hydroforming, thinning rate, stress distribution

中图分类号:

TK 91

张杰, 王瑞川. 氢燃料电池钛双极板液压成形机理研究[J]. 发电技术, 2025, 46(4): 727-736.

Jie ZHANG, Ruichuan WANG. Study on Hydroforming Mechanism of Titanium Bipolar Plates for Hydrogen Fuel Cells[J]. Power Generation Technology, 2025, 46(4): 727-736.

图/表 13

图1 双极板液压成形结构

Fig. 1 Hydroforming structure of bipolar plate

表1 双极板结构参数

Tab. 1 Structural parameters of bipolar plate

参数	数值
板料厚度d/mm	0.1
模具周期长度L_d/mm	2
模具肋宽S_d/mm	0.6
模具深度h_d/mm	0.30
模具外倒角半径R_d/mm	0.2
拔模角/（°）	0

图2 双极板液压成形仿真模型

Fig. 2 Simulation model of bipolar plate hydroforming

图3 液压力加载曲线

Fig. 3 Hydraulic pressure loading curve

图4 液压成形过程中钛双极板应力变化

Fig. 4 Stress variation of titanium bipolar plate during hydroforming process

图5 双极板应力随加载时间变化

Fig. 5 Stress variation of bipolar plate with loading time

图6 钛双极板液压成形后残余应力分布

Fig. 6 Residual stress distribution of titanium bipolar plate after hydroforming

图7 双极板等效塑性应变与厚度变化

Fig. 7 Equivalent plastic strain and thickness variation of bipolar plate

图8 外倒角对双极板成形质量的影响

Fig. 8 Effect of fillet radius on forming quality of bipolar plate

图9 流道深度对双极板成形质量的影响

Fig. 9 Effect of flow channel depth on forming quality of bipolar plate

图10 流道宽度对双极板成形质量影响

Fig. 10 Effect of flow channel width on forming quality of bipolar plate

图11 板料厚度对双极板成形质量的影响

Fig. 11 Effect of sheet thickness on forming quality of bipolar plate

图12 液压力对双极板成形质量的影响

Fig. 12 Effect of hydraulic pressure on forming quality of bipolar plate

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