Micro-stamping process is one of the most cost-effective methods to manufacture metallic bipolar plates (BPPs). This research investigates the forming of titanium thin sheet as a potential candidate for BPPs in proton exchange membrane fuel cell (PEMFC). In this regard, the process was first simulated using finite element (FE) code Abaqus. Afterward, experimental tests were implemented and the ...

Abstract: In this paper, the forming process of a central hub by radial-forward extrusion is analyzed by using the finite element software, ABAQUS. Radial-forward extrusion is used to produce hollow parts that generally feature a central hub with radial protrusions. Effective design factors such as mandrel diameter, die corner radius, die fillet radius, mandrel corner radius, tube wall thick...

Strain distribution of Al 1100 was numerically investigated during cyclic expansion extrusion (CEE) process using finite element method (FEM). Die angle, corner fillet radius and die chamber diameter were considered as die parameters and friction factor and number of passes as process parameters. The effects of these parameters were investigated on the effective strain and strain homogeneity in...

In recent years, hydroforming process has been applied in different industries such as aerospace, automotive and military industries due to its advantages, such as high dimensional accuracy, capability of forming complicated parts and high drawing ratio. Hydrodynamic deep drawing with radial pressure is one type of hydroforming process. In this paper, forming of cylindrical cups in hydrodynamic...

Two decades of operating experience have shown that reducing the corner radius from 12–16 mm to 3 or 4 mm A finite element thermal stress model to compute is beneficial in reducing longitudinal corner cracking.4 In the thermomechanical state of the solidifying shell addition to lessening crack frequency, decreasing the corner during continuous casting of steel in a square billet radius also ten...

Deformation of the material during cyclic expansion extrusion (CEE) is investigated using upper-bound theorem. The analytical approximation of forming loads agrees very well with the FEM results for different amounts of chamber diameter, friction factor and also for lower die angles. However, the difference between analytical and numerical solution increases at higher die angles which are expla...

In most of the sheet forming processes, production of the parts with minimum thickness variation and low required force is important. In this research, minimization of the sheet thinning and forming force in the hydraulic deep drawing process has been studied. Firstly, the process is simulated using the finite element method (FEM) and simulation model is verified using the experimental results....

Aluminum alloys are considered a lot in the automotive and aerospace industry because of their high strength to weight ratio. In this manuscript, the gas forming process of aluminum AA6063 tubes at high temperatures up to 500°C is investigated, through experimental and numerical tests. Therefore, an experimental setup is prepared and so, tube specimens are formed in a die with square cross sect...

Wrinkling and fracture are the important defects in deep drawing operation, which can be prevented using blank holding force (BHF) which has to be optimized as lower BHF promotes wrinkles formation and higher BHF promotes fracturing. Hence the limits of wrinkling and fracture have to be established. These limits depend on various tooling and process parameters. In this work the effect of toolin...