Active media-based pulse forming of channel structures (WirKan)

Project Description

In the production of components with complex channel structures, active media-based impulse forming processes promise considerable advantages in terms of achievable edge radii and aspect ratios as well as homogeneity of the sheet thickness distribution. When used as a bipolar plate, this leads to higher efficiencies with a lower component weight. However, due to the complex interactions between different physical disciplines (e.g. electromagnetism, structural mechanics, fluid dynamics) during pressure generation, pressure propagation in the fluid and component forming, an exact description and design of active-media-based impulse forming processes is not yet possible. The aim of the project is therefore to fundamentally analyze the interactions between adjustable process parameters, transient pressure field in the active medium, forming process and forming result and to identify the process limits in the forming of channel structures.This will make it possible in the future to adjust the die pressure in a targeted manner so that high-quality components can be produced. With regard to a possible application for bipolar plates, semi-finished products made of 1.4404 with a wall thickness of 0.1 mm are considered. In order to demonstrate the transferability of the results to other materials, investigations on EN AW1050 sheets are planned on a smaller scale. The research work is being carried out in close cooperation between the Bremen Institute of Structural Mechanics and Production Systems (bime) and the Fraunhofer Institute for Machine Tools and Forming Technology (IWU) in Chemnitz.