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Numerical Study of Process-Specific Disturbances in Hollow Embossing Rolling

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Abstract:

Hollow embossing rolling (HER) is a promising continuous forming technology for producing thin metallic bipolar half plates (BPHP) with micro-channel structures used in fuel cells and electrolyzers. This study presents a simulation-based analysis of process-specific disturbances influencing the forming accuracy and quality of HER-formed BPHP. Using a validated LS-DYNA shell-based model, the effects of six disturbance variables, roller misalignments (axial, tangential, angular), roller gap variation, initial sheet thickness deviation, and changes in friction coefficient, were systematically investigated. Results show that even small roller misalignments of ±10 µm or manufacturing related roller gap deviations of +5 µm lead to significant changes in rolling force, strip draw-in, and sheet thinning behavior. Variations in friction coefficient notably affect draw-in and wrinkling tendencies. Overall, the study highlights the high sensitivity of the HER process to geometric and frictional disturbances and provides quantitative tolerance limits crucial for precision manufacturing and robust continuous BPHP forming.

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Periodical:

Solid State Phenomena (Volume 389)

Pages:

65-74

DOI:

https://doi.org/10.4028/p-P58jF8

Citation:

Cite this paper

Online since:

April 2026

Authors:

Franz Reuther*, Verena Psyk, Verena Kräusel

Keywords:

Bipolar Plates, Disturbances, Hollow Embossing Rolling, Simulation

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RIS, BibTeX

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Creative Commons CC BY 4.0

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* - Corresponding Author

References

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