CN113190925A - Processing and forming method, system and simulation method for metal bipolar plate formed by polyurethane soft mold - Google Patents
Processing and forming method, system and simulation method for metal bipolar plate formed by polyurethane soft mold Download PDFInfo
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Abstract
The embodiment of the invention discloses a processing and forming method, a processing and forming system and a simulation method of a polyurethane flexible mold formed metal bipolar plate, wherein the metal bipolar plate at least has a plurality of second-order flow channel structures; and the method comprises: s1, determining a plurality of stress analysis areas, wherein the stress analysis areas are determined according to the stress condition required by the metal bipolar plate to be processed; s2, analyzing each stress analysis area one by one to obtain respective corresponding stress parameters, wherein the stress parameters are used for representing design parameters of a second-order flow channel segmented structure corresponding to each stress analysis area; s3, determining all design parameters of the second-order flow channel structure based on the design parameters; s4, constructing the metal bipolar plate through a soft mold forming process; in the soft die forming process, a rubber pad and a male die are matched to form a second-order runner structure. The invention adopts a second-order flow channel structure with higher power density to replace the traditional first-order flow channel, and forms the metal bipolar plate in a low-cost and high-efficiency mode.
Description
Technical Field
The invention relates to the technical field of metal bipolar plate structure design and forming, in particular to an analysis system and a simulation method for a processing and forming method of a metal bipolar plate formed by a polyurethane soft mold.
Background
The existing processing and forming methods of the metal bipolar plate mainly comprise precise stamping, roll forming, electronic engraving and chemical corrosion; and the existing bipolar plate is mostly composed of a structure with a common first-order flow channel. But such flow channels have a low power density.
Among them, the precision press method is a forming method in which a press machine and a precision press die are used to apply an external force to a plate material to cause plastic deformation or separation, thereby obtaining a workpiece (a pressed part) having a desired shape and size. However, this method requires a high mold and therefore is expensive to produce.
The roll forming method is a process for forming various complex parts by adopting a roll extrusion principle depending on the plastic movement characteristic of a material. However, the bipolar plate produced in this way has poor surface flatness and low production efficiency.
The electronic engraving method is a process of converting an optical signal or a digital signal into mechanical motion of an engraving knife through photoelectric conversion and electromagnetic conversion so as to form a plate. However, this method is inefficient and expensive.
The chemical etching method is a forming method in which an excess metal material is chemically reacted with a surrounding etching medium to obtain a desired shape. However, this method is expensive and inefficient.
Disclosure of Invention
Based on the above, in order to solve the defects existing in the prior art, a processing and forming method of the metal bipolar plate formed by the flexible polyurethane mold is especially provided.
In order to achieve the purpose, the technical scheme of the invention is as follows:
a processing and forming method of a metal bipolar plate formed by a polyurethane soft mold is characterized in that the metal bipolar plate at least has a plurality of second-order flow channel structures; and the processing and forming method at least comprises the following steps:
s1, determining a plurality of stress analysis areas, wherein the stress analysis areas are determined according to the stress condition required by the metal bipolar plate to be processed;
s2, analyzing each stress analysis area one by one to obtain respective corresponding stress parameters, wherein the stress parameters are used for representing design parameters of a second-order flow channel segmented structure corresponding to each stress analysis area;
s3, determining all design parameters of the second-order flow channel structure based on the design parameters;
s4, constructing the metal bipolar plate through a soft mold forming process; in the soft die forming process, a rubber pad and a male die are matched to form a second-order runner structure.
Optionally, in one embodiment, the rubber pad is a polyurethane rubber pad.
Optionally, in one embodiment, the process of analyzing the force analysis area includes: firstly, establishing a stress balance differential model corresponding to each stress analysis area, and secondly, determining a stress analysis model corresponding to each stress analysis area based on a yield criterion corresponding to each stress analysis area; the second-order flow channel structure is at least divided into 7 stress analysis areas.
Optionally, in one embodiment, the specific process of analyzing the force analysis area includes:
s21, creating a stress balance differential model corresponding to the first stress analysis area, wherein the stress balance differential model formula is as follows:
the corresponding force analysis model is:
wherein the first stress analysis region plate thickness t1＝t0，t0The thickness of the steel sheet is the initial thickness,
is the friction force between the metal die and the surface of the plate,
is the friction force between the plate and the surface of the rubber pad,
k is the shear yield stress, m1And m2Respectively coefficient of friction between different surfaces, σ1Radial tensile stress, L, for the first force analysis zone1Length of sheet material for the first force analysis zone, σ1-fFinal radial tensile stress of the first force analysis area, a1The boundary point of the second stress analysis area and the first stress analysis area in the width direction is set;
s22, creating a stress balance differential model corresponding to the second stress analysis area, wherein the stress balance differential model formula is as follows:
the corresponding yield criterion equation:
according to the formula, the following results are obtained:
because the final thickness of the first stress analysis area is equal to the initial thickness of the two stress analysis areas, the corresponding stress analysis model is finally obtained as
Wherein, t2The second stress analysis region is the plate thickness r1Fillet radius, σ, of sheet thickness for the second force analysis region2The radial tensile stress corresponding to the second stress analysis area is provided, and P is the vertical stress applied to the plate; a is2A dividing point in the width direction of the second stress analysis area and the third stress analysis area; t is t1-fThe final thickness of the plate in the first stress analysis area; t is t2-fFinal thickness of the sheet for the second force analysis zone, θ1The corner angle of the plate in the second stress analysis area is used; the range of the intermediate variable x in the second stress analysis area is x epsilon [ a1，a2]；
S23, creating a stress balance differential model corresponding to the third stress analysis area, wherein the stress balance differential model formula is as follows:
the corresponding yield criterion equation:
since the final thickness of the second force analysis area is equal to the initial thickness of the third force analysis area, i.e. t3-i＝t2-fAccording to the formula, the corresponding stress analysis model is obtained as follows:
wherein, t3Thickness of the plate for the third stress analysis region, r1Fillet radius, σ, of sheet thickness for the second force analysis region3The radial tensile stress corresponding to the third stress analysis area, P is the vertical stress applied to the plate, a3A dividing point in the width direction of the third stress analysis area and the fourth stress analysis area; t is t3-fThe final thickness of the plate in the third force analysis area; the range of the intermediate variable x in the third stress analysis area is x epsilon [ a2，a3]；L2The length of the sheet in the third force analysis area;
s24, creating a first stress balance differential model corresponding to the fourth stress analysis area, wherein the first stress balance differential model formula is as follows:
the corresponding yield criterion equation:
since the final thickness of the third force analysis area is equal to the initial thickness of the fourth force analysis area, i.e. t4-i＝t3-fAccording to the formula, the following results are obtained:
creating a second stress balance differential model corresponding to a fourth stress analysis area, wherein the second stress balance differential model formula comprises the following steps:
the corresponding yield criterion equation:
the final thickness of the fourth force analysis area is equal to the initial thickness of the fifth force analysis area, namely t4-f＝t5-iAccording to the formula, the following results are obtained:
combining the formulas (12) and (15), obtaining a corresponding stress analysis model as
Wherein, at-minThe position with the thinnest thickness of the plate; t is t4Thickness of the plate for the fourth stress analysis region, r2Fillet radius, σ, of sheet thickness for fourth force analysis area4Radial tensile stress corresponding to the fourth force analysis region, a4A dividing point in the width direction of the fourth stress analysis area and the fifth stress analysis area; t is t5-iInitial thickness of the sheet in the fifth force analysis zone, θ2Angle of rotation, theta, for the fourth force analysis zone3The corner angle is the angle of the sixth stress analysis area; the range of the intermediate variable x in the fourth stress analysis area is x epsilon [ a3，a4]；
S25, creating a stress balance differential model corresponding to the fifth stress analysis area, wherein the stress balance differential model formula is as follows:
the corresponding yield criterion equation:
the final thickness of the fifth stress analysis area is equal to the initial thickness of the sixth stress analysis area, namely t5-f＝t6-iAccording to the formula, the corresponding stress analysis model is obtained as follows:
wherein, t5Thickness of the plate in the fifth stress analysis region, [ theta ]3Angle of rotation, σ, of sheet thickness for the fifth force analysis region5Radial tensile stress corresponding to the fifth force analysis region, a5A dividing point in the width direction of the fifth stress analysis area and the sixth stress analysis area; the range of the intermediate variable x in the fifth stress analysis area is x epsilon [ a4，a5]；
S26, creating a stress balance differential model corresponding to the sixth stress analysis area, wherein the stress balance differential model formula is as follows:
the corresponding yield criterion equation:
the final thickness of the sixth force analysis area is equal to the initial thickness of the seventh force analysis area, namely t7-i＝t6-fAccording to the formula, the corresponding stress analysis model is obtained as follows:
wherein, t6For the sixth force analysis region of sheet thickness, r3Fillet radius, σ, of plate thickness for the sixth force analysis region6Radial tensile stress corresponding to the sixth force analysis region, a6Is a boundary point in the width direction between the sixth force analysis region and the seventh force analysis region, L3The length of the plate in the fifth stress analysis area; (ii) a
S27, creating a stress balance differential model corresponding to the seventh stress analysis area, wherein the stress balance differential model formula is as follows:
according to the formula, the corresponding stress analysis model is obtained as follows:
wherein, t7For the seventh stress analysis region of sheet thickness, σ7Radial tensile stress, L, corresponding to the seventh force analysis zone4The length of the plate in the seventh force analysis area.
Based on the same inventive concept, the invention also provides a simulation method for processing and forming the metal bipolar plate by the flexible polyurethane mold, which at least comprises the following steps: and sequentially constructing a polyurethane soft die finite element model, a steel male die finite element model and a metal plate finite element model for finite element analysis based on all the design parameters of the determined second-order runner structure, and selecting a manufacturing die of a metal double-plate structure according to a finite element simulation result.
Based on the same inventive concept, the invention also provides a processing and forming analysis system for the metal bipolar plate formed by the polyurethane soft mold, which is suitable for analyzing the processing and forming parameters of the metal bipolar plate, wherein the metal bipolar plate at least has a plurality of second-order flow channel structures; the method is characterized in that: at least comprises the following steps:
the area dividing unit is used for determining a plurality of stress analysis areas, and the stress analysis areas are determined according to the stress condition required by the metal bipolar plate to be processed;
the stress analysis unit is used for analyzing each stress analysis area one by one to obtain corresponding stress parameters, and the stress parameters are used for representing design parameters of a second-order runner segmented structure corresponding to each stress analysis area;
and the parameter acquisition unit is used for determining all design parameters of the second-order flow channel structure based on the design parameters.
Wherein, the process of analyzing the stress analysis area in the stress analysis unit comprises the following steps: firstly, a stress balance differential model corresponding to each stress analysis area is created, and secondly, the stress analysis model corresponding to each stress analysis area is determined based on the yield criterion corresponding to each stress analysis area.
The embodiment of the invention has the following beneficial effects:
the invention is suitable for manufacturing the bipolar plate by adopting the metal material, and the metal bipolar plate is produced by adopting the soft die stamping process, so that the production cost can be greatly reduced; and a second-order runner structure with higher power density is adopted to replace the traditional first-order runner, so that the gas utilization rate and the reaction efficiency are improved. It can be seen from the above that the present invention forms a metal bipolar plate in a low-cost and high-efficiency manner. The method has important significance for the development of proton exchange membrane fuel cell technology and the promotion of new energy application.
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In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings used in the description of the embodiments or the prior art will be briefly described below, it is obvious that the drawings in the following description are only some embodiments of the present invention, and for those skilled in the art, other drawings can be obtained according to the drawings without creative efforts.
Wherein:
FIG. 1 is a flow diagram of an implementation technique in one embodiment;
FIGS. 2a and 2b are schematic structural views of the second-order flow channel structure according to an embodiment;
FIGS. 3 a-3 b are schematic structural views of the angled flow channel in one embodiment;
FIG. 4 is a schematic diagram illustrating a stress condition of a first force analysis region in one embodiment;
FIG. 5 is a diagram illustrating a stress condition of a second force analysis region in accordance with an embodiment;
FIG. 6 is a schematic diagram illustrating a stress condition of a third force analysis region in one embodiment;
FIGS. 7 a-7 b are schematic stress conditions for a fourth force analysis region according to an embodiment;
FIG. 8 is a schematic diagram illustrating a stress condition of a fifth force analysis region in one embodiment;
FIG. 9 is a diagram illustrating a stress condition in a sixth force analysis region, according to an embodiment;
FIG. 10 is a schematic diagram illustrating a stress condition in a seventh force analysis region in accordance with an exemplary embodiment;
FIG. 11 is a schematic diagram illustrating a panel segment formed by seven force analysis zones according to an exemplary embodiment;
FIGS. 12a and 12b are schematic diagrams of nine/seven force analysis zones, respectively, as described in one embodiment;
FIG. 13 is a schematic view of a finite element model of the finite element analysis in one embodiment;
FIG. 14 is a graph of analysis results of the finite element analysis in one embodiment;
FIG. 15 is a cross-sectional view of a second step flow channel formed by a stamping test according to an embodiment;
in the figure: 1. a first-order runner structure 2, a tip structure (pyramid-shaped structure), 3, a tip structure (pitched roof-shaped structure), 4, runner width, 5, an inner chamfer, 6, an outer chamfer, 7, a corner, 8, a mirror symmetry line, 9 and a fillet;
Detailed Description
In order to make the objects, technical solutions and advantages of the present invention more apparent, the present invention is described in further detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative of the invention and are not intended to limit the invention.
Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. The terminology used in the description of the invention herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. It will be understood that, as used herein, the terms "first," "second," and the like may be used herein to describe various elements, but these elements are not limited by these terms. These terms are only used to distinguish one element from another. For example, a first element could be termed a second element, and, similarly, a second element could be termed a first element, without departing from the scope of the present application. The first and second elements are both elements, but they are not the same element.
In view of the prior art, the proton exchange membrane fuel cell is a power generation device relying on chemical conversion, and has wide application prospect in the fields of traffic, communication, electronic equipment and the like; and the bipolar plate is a key component for assembling the proton exchange membrane fuel cells in series into an integral cell stack, so that further development of the bipolar plate technology is necessary. However, the wider application of pem fuel cells today is still limited by power density.
Therefore, in this embodiment, a method for processing and forming a metal bipolar plate by using a flexible polyurethane mold is proposed, as shown in fig. 1, wherein the metal bipolar plate has at least a plurality of second-order flow channel structures; and the processing and forming method at least comprises the following steps: s1, determining a plurality of stress analysis areas, wherein the stress analysis areas are determined according to the stress condition required by the metal bipolar plate to be processed; s2, analyzing each stress analysis area one by one to obtain respective corresponding stress parameters, wherein the stress parameters are used for representing design parameters of a second-order flow channel segmented structure corresponding to each stress analysis area; s3, determining all design parameters of the second-order flow channel structure based on the design parameters; s4, constructing the metal bipolar plate through a soft mold forming process; in the soft die forming process, a rubber pad and a male die are matched to form a second-order runner structure. Based on the scheme, the novel metal bipolar plate is formed by adopting the soft die forming technology, and the production cost can be greatly reduced by acquiring the adjustment parameters to guide the practice; the gas utilization rate and the reaction efficiency can be improved by adopting a second-order runner structural design; in conclusion, the method can provide theoretical support for producing the second-order runner metal bipolar plate.
In some specific embodiments, the second-order flow channel structure has a periodically distributed corrugated structure, and the corrugated structure includes a first-order flow channel structure 1 and a tip structure formed on the top of the first-order flow channel structure and approaching to the center; the first-order flow passage structure adopts the structural design of the conventional first-order flow passage, such as a straight passage, a snake shape, a spiral shape, an interdigital shape, a grid shape and the like; preferably, as shown in fig. 2a and 2b, the tip structure is a point-like or line-like distribution structure feature; further preferably, the tip structure is a pyramid-shaped structure 2 or a pitched roof-shaped structure 3. The corrugated structure distributed in a periodic manner is adopted because the structure can generate forced convection in the vertical direction in the flowing process of the gas, so that the residence time of the gas is increased; when the second-order flow channel is applied to the metal bipolar plate, the utilization rate and the reaction efficiency of the gas can be improved.
In some more specific embodiments, the second-order flow channel metal bipolar plate formed by the soft die stamping process has a second-order flow channel structure parameter test that: the following matters are adopted, and the forming effect is better: the length of the whole second-order runner structure is larger than 7mm, the width of the runner is larger than 1mm, and the distance between runners is larger than 1.3 mm; the height ratio of the first-stage runner to the second-stage structure, namely the tip structure, is maintained to be 1: 1; the edge chamfer of the second-stage structure ensures that the top of the second-stage runner is kept maximum when the top is in a point shape or a linear shape; and the distance between the second-order structures can be 0, so as to better realize a repeated periodic fluctuation structure (when the distance between the second-order structures is reduced, a larger number of second-order structures can be arranged on the plate, and the forced convection effect of the gas is better.) aiming at the content, a user selects a design scheme according to actual tests or use requirements.
In some more specific embodiments, the metallic bipolar plate, when provided with a curved flow channel structure, demonstrates: the following contents are adopted for forming, and the effect is better: the corner flow channel structure has the best formability when the corner 7 is 90 degrees; the larger the flow channel width 4 of the flow channel structure is, the better the formability is; when the inner chamfer 5 of the corner flow passage is 1mm, the corner flow passage has good formability; the larger the inner chamfer is, the poorer the forming property of the corner runner is; when the ratio of the inner chamfer 5 to the outer chamfer 6 is 1:1, the forming performance of the bent angle flow channel is the best. With reference to fig. 3a-b (while mirror symmetry lines 8 and fillets 9 are shown in the figures) for the above, the user makes design choices according to actual trial or use requirements.
In some more specific embodiments, the rubber mat (soft mold) is a polyurethane rubber mat; the polyurethane rubber is used because: when the soft mold is formed, the forming capacities of the selected concave-convex molds are different, and the applicant researches and discovers that the polyurethane rubber can be matched with the convex mold to form a flow channel better; therefore, a urethane rubber pad was selected as a male die to achieve continuous pressing of the plate by the urethane rubber under the pressure of the metal die when a load is applied.
In fact, in the soft mold forming process, the stress states of different deformation regions may be different; therefore, the second-order runner structure is divided into 7 different analysis areas according to the stress condition required by the designed plate; the method is suitable for analyzing the second-order runner structures with different shapes.
Based on the above principle and design objective, the process of analyzing the stress analysis area includes: firstly, establishing a stress balance differential model corresponding to each stress analysis area, and secondly, determining a stress (main stress) analysis model corresponding to each stress analysis area based on a yield criterion corresponding to each stress analysis area; namely, the second-order flow channel structure is at least divided into 7 stress analysis areas, and the friction generated on the contact surface influences the final analysis result in the analysis process; the stress analysis device comprises a first stress analysis area, a second stress analysis area, a third stress analysis area, a fourth stress analysis area, a fifth stress analysis area, a sixth stress analysis area and a seventh stress analysis area; the specific process comprises the following steps:
s21, creating a stress balance differential model corresponding to a first stress analysis area (AreaI), wherein the material of the first stress analysis area is generally positioned at the bottom of the second-stage structure; under the action of the pressure of the punch, the rubber is directly pressed; therefore, the material outward flowing tendency is restricted by the friction of the upper and lower surfaces, and according to the stress action situation, as shown in fig. 4, the stress balance differential model formula is obtained as follows:
the stress analysis microcell is set as follows: sigma1-iWhen the stress analysis model is 0, the corresponding stress analysis model is obtained as follows:
wherein the first stress analysis region plate thickness t1＝t0，t0The thickness of the steel sheet is the initial thickness,
is the friction force between the metal die and the surface of the plate,
is the friction force between the plate and the surface of the rubber pad,
k is the shear yield stress, m1And m2Respectively, the coefficient of friction between different surfaces, i.e. m1Is the friction factor m between the plate and the rigid mold2Is the friction factor between the plate and the polyurethane rubber, sigma1Radial tensile stress, L, for the first force analysis zone1Length of sheet material for the first force analysis zone, σ1-fFinal radial tensile stress of the first force analysis area, a1The boundary point of the second stress analysis area and the first stress analysis area in the width direction is set;
s22, creating a stress balance differential model corresponding to the second force analysis area (AreaII): given that the deformation of the material of the second force analysis region adjacent to the first force analysis region is more complex; therefore, in addition to having the same characteristics as the first force analysis zone, its thickness is also affected by the punch and the rubber (i.e. this zone is plastically deformed and the thickness of the material is reduced); as shown in fig. 5, the equation of the stress equilibrium differential model in the x direction in the coordinate system is obtained as follows:
according to pascal's law, when any point in an incompressible rigid fluid is subjected to an external force and an increasing pressure is applied, the increasing pressure is instantaneously transmitted to each point of the fluid. So that the magnitude of P will not follow theta1Is changed to obtain the corresponding yield criterion equation:
according to the formula, the following results are obtained:
the rotation angle theta is at the boundary of the first force analysis area and the second force analysis area1Considering as 0, the first force analysis area is equal to the initial thickness of the two force analysis areas, and the final result is
Wherein, t2The second stress analysis region is the plate thickness r1Fillet radius, σ, of sheet thickness for the second force analysis region2The radial tensile stress corresponding to the second stress analysis area is provided, and P is the vertical stress applied to the plate; a is2A dividing point in the width direction of the second stress analysis area and the third stress analysis area; t is t1-fThe final thickness of the plate in the first stress analysis area; t is t2-fFinal thickness of the sheet for the second force analysis zone, θ1The corner angle of the plate in the second stress analysis area is used; the range of the intermediate variable x in the second stress analysis area is x epsilon [ a1，a2]；
S23, creating a stress balance differential model corresponding to a third stress analysis area (AreaIII): in view of the plastic deformation of the material of the third force analysis region adjacent to the second force analysis region, the thickness of the plate is also reduced,
as shown in fig. 6, the stress balance differential model formula is:
the corresponding yield criterion equation:
at the boundary of the second force analysis area and the third force analysis area, the final thickness of the second force analysis area is equal to the initial thickness of the third force analysis area, namely t3-i＝t2-fAccording to the formula, the following results are obtained:
wherein, t3Thickness of the plate for the third stress analysis region, r1Fillet radius, σ, of sheet thickness for the second force analysis region3The radial tensile stress corresponding to the third stress analysis area, P is the vertical stress applied to the plate, a3A dividing point in the width direction of the third stress analysis area and the fourth stress analysis area; t is t3-fThe final thickness of the plate in the third force analysis area; the range of the intermediate variable x in the third stress analysis area is x epsilon [ a2，a3]；L2The length of the sheet in the third force analysis area;
s24, in the fourth stress analysis area, the material is subjected to larger radial tensile stress, the pressure of the punch and the pressure generated by elastic deformation of the rubber; this region is therefore plastically deformed and the maximum reduction of the sheet occurs in this region, which is also the "dangerous section" of the soft-die stamping process, i.e. the leftmost and rightmost microcells of this region are not subjected to the same stress; the formulas obtained according to the stress action conditions are different; and when the x value of this region changes, the two thickness curves will intersect at a certain point (where the thickness of the entire flow channel is the thinnest).
Based on the above principle, a first stress balance differential model corresponding to the fourth stress analysis area (area iv) is created, as shown in fig. 7a, the first stress balance differential model formula:
the corresponding yield criterion equation:
due to the fact that the first stress analysis area and the second stress analysis area are arranged in the first stress analysis area and the second stress analysis areaThe final thickness of the third stress analysis area is equal to the initial thickness of the fourth stress analysis area, and t is obtained finally4-i＝t3-fAccording to the formula, the following results are obtained:
creating a second stress balance differential model corresponding to the fourth force analysis area, as shown in fig. 7b, where the second stress balance differential model formula:
the corresponding yield criterion equation:
when the boundary between the fourth stress analysis area and the fifth stress analysis area exists, the final thickness of the fourth stress analysis area is equal to the initial thickness of the fifth stress analysis area, and t is obtained finally4-f＝t5-iAccording to the formula, the following results are obtained:
considering that the graphs of the microcell formulas at the two sides characterize different trends, the corresponding stress analysis model is obtained by combining the formulas (12) and (15)
Wherein, at-minThe position with the thinnest thickness of the plate; t is t4Thickness of the plate for the fourth stress analysis region, r2Fillet radius, σ, of sheet thickness for fourth force analysis area4Is the fourth quiltRadial tensile stress corresponding to the force analysis area, a4A dividing point in the width direction of the fourth stress analysis area and the fifth stress analysis area; t is t5-iInitial thickness of the sheet in the fifth force analysis zone, θ2Angle of rotation, theta, for the fourth force analysis zone3The corner angle is the angle of the sixth stress analysis area; the range of the intermediate variable x in the fourth stress analysis area is x epsilon [ a3，a4]；
S25, creating a stress balance differential model corresponding to a fifth stress analysis area (AreaV): the area is also plastically deformed and the thickness of the plate in the area is increased, as shown in fig. 8, the equation of the stress balance differential model is:
the corresponding yield criterion equation:
because the final thickness of the fifth stress analysis area is equal to the initial thickness of the sixth stress analysis area at the boundary of the fifth stress analysis area and the sixth stress analysis area, t is finally obtained5-f＝t6-iAccording to the formula, the corresponding stress analysis model is obtained as follows:
wherein, t5Thickness of the plate in the fifth stress analysis region, [ theta ]3Angle of rotation, σ, of sheet thickness for the fifth force analysis region5Radial tensile stress corresponding to the fifth force analysis region, a5Is the division of the fifth force analysis area and the sixth force analysis area in the width directionA boundary point; the range of the intermediate variable x in the fifth stress analysis area is x epsilon [ a4，a5]；
S26, creating a stress balance differential model corresponding to a sixth force analysis area (AreaVI): the area is considered as a corner area, the thickness of the plate continuously rises, and when the plate is deformed by the area, the thickness returns to the initial thickness; as shown in fig. 9, the stress balance differential model formula is:
the corresponding yield criterion equation:
because the final thickness of the sixth force analysis area is equal to the initial thickness of the seventh force analysis area at the boundary of the sixth force analysis area and the seventh force analysis area, t is finally obtained7-i＝t6-fAccording to the formula, the corresponding stress analysis model is obtained as follows:
wherein, t6For the sixth force analysis region of sheet thickness, r3Fillet radius, σ, of plate thickness for the sixth force analysis region6Radial tensile stress corresponding to the sixth force analysis region, a6Is a boundary point in the width direction between the sixth force analysis region and the seventh force analysis region, L3The length of the plate in the fifth stress analysis area;
s27, creating a stress balance differential model corresponding to the seventh force analysis area (area vii), as shown in fig. 10, where the stress balance differential model formula is:
since the stress-acting situation does not satisfy the yield criterion, no plastic deformation of this region occurs. Therefore, the thickness of the sheet material is unchanged; then according to the above formula, the corresponding stress analysis model is obtained as follows:
wherein, t7For the seventh stress analysis region of sheet thickness, σ7Radial tensile stress, L, corresponding to the seventh force analysis zone4Length of sheet material for seventh force analysis zone, σ6-fFinal radial tensile stress, σ, for the sixth force analysis region7-fThe final radial tensile stress corresponding to the seventh force analysis area.
According to the steps, as shown in fig. 10, the thickness reduction rule of the bipolar plate is obtained by adopting the principal stress method analysis principle, and the stress concentration and the fracture tendency of the plate can be effectively predicted through the content, so that technical support is provided for the application of the soft mold forming technology to the production of the second-order runner metal bipolar plate; meanwhile, the maximum thinning amount of the bipolar plate is generated in the fourth stress analysis area, the whole plate of the plate formed by the technology is uniformly thinned, and the stress concentration and the cracking tendency are small.
Further, as shown in fig. 11, it can be determined that the nature of the second-order flow channel region division is that straight regions alternate with corner regions, each of which is separated by a straight region; the analysis of the straight line region is substantially the same, and the analysis of the angled region is substantially the same (except for the region where the thinnest point of the sheet material is present). Therefore, the analysis process of dividing the analysis area into seven areas can satisfy the analysis of most second-order flow channel structures. Meanwhile, it is to be noted that: even if a flow channel structure more complicated than the second-order flow channel structure is formed, the final analysis result can still be obtained by the set of analysis method. Specifically, the method comprises the following steps: in fig. 12a-12b, the corresponding flow channel structure can be divided into 9 analysis regions, but compared with the analysis of 7 analysis regions, only one straight line region and one corner region (region eight and region nine) are essentially added, and the analytical formulas of the two regions can still be analyzed by using the main stress analytical formulas of the straight line region and the corner region in the seven-region analysis. That is, the solution can meet the analytical requirements even if a second-order flow channel with a more complex structure is encountered. The main stress method analysis process of a certain region or a plurality of regions in the seven-region analysis is repeatedly applied only based on the analysis requirement, and the whole flow channel structure analysis result is obtained.
After the structural parameters of the second-order flow channel are researched, the soft die forming process of the metal bipolar plate based on polyurethane can also be determined; in order to verify the accuracy of the analysis of the main stress method, a finite element simulation experiment is carried out on the whole soft die stamping process; based on the same inventive concept, the invention also provides a simulation method for processing and forming the metal bipolar plate by the flexible polyurethane mold; at least comprises the following steps: and sequentially constructing a polyurethane soft die finite element model, a steel male die finite element model and a metal plate finite element model for finite element analysis based on all the design parameters of the determined second-order runner structure, and selecting a manufacturing die of a metal double-plate structure according to a finite element simulation result.
In some specific embodiments, as shown in fig. 13, an Abaqus software is used to establish a three-dimensional finite element model of the metal bipolar plate soft mold forming process, and the bipolar plate forming process is analyzed from a plurality of angles, such as a second-order runner width, a second-order runner length, a second-order runner edge chamfer angle, a second-order runner depth distribution ratio, a second-order runner geometric shape parameter, and the like; specifically, the method comprises the following steps: constructing a polyurethane soft die finite element model, a steel male die finite element model and a metal sheet finite element model; wherein a steel mold finite element model is placed uppermost in the entire device (both the shape and parameters of the second order runner are shown on the mold; in the simulation, the mold is defined as a non-deformable rigid body; specific dimensional parameters may be 60mm x 60 mm.); the metal plate finite element model is placed between the steel die finite element model and the polyurethane soft die finite element model; in the simulation, the sheet was subjected to the elastic force of urethane rubber while being pressed by the die, thereby obtaining a desired shape (the sheet was defined as stainless steel 304. specific dimensional parameters were 60mm 0.1 mm.); a polyurethane rubber finite element model, as a soft mold, was placed at the very bottom of the entire device (in the simulation, polyurethane was defined as a super elastomer; specific dimensional parameters 60 mm.); because the polyurethane has higher strength and superelasticity and can keep higher elasticity in a wider hardness range, the plate has good forming effect, few scratches and higher flatness; the polyurethane has high wear resistance which is about 2-10 times of that of natural rubber, and has excellent grease and chemical resistance, radiation resistance, oxygen and ozone resistance, fatigue resistance, impact resistance and shock resistance. This results in a very long service life for the polyurethane; meanwhile, the polyurethane does not need to be processed, and the molding and processing cost is low, so that the production cost of the bipolar plate is greatly reduced.
As shown in FIG. 14, the finite element simulation can obtain two main types of results, namely a displacement cloud chart and a stress cloud chart. The displacement cloud chart can visually display the forming result of the plate; the stress cloud chart can show the stress condition of each part of the plate. Through the finite element simulation, the forming effect of the plate is found to be good. Specific users can select the bipolar plate structure manufacturing mold with better forming effect according to the finite element simulation result.
Based on the design content, the stamping test is also carried out, and the adopted stamping test device comprises four parts, namely a steel die, a polyurethane soft die, a metal plate and a containing frame; the required pressure is provided by a press machine, and the pressure provided by the press machine directly acts on the steel mould; during the experiment: the size parameters of each part of the device are the same as the finite element simulation parameters; the steel mould is made of mould steel; the containment frame wraps around and tightly fits around the steel mold, the sheet metal, and the polyurethane (in order to limit their displacement in any direction other than the direction of pressure). (ii) a Meanwhile, the total height of the steel mould, the metal plate and the polyurethane female mould is slightly higher than that of the containing frame; under the action of a press machine, the steel die is extruded downwards, so that the plate is subjected to plastic deformation, and the resilience force of the polyurethane is larger and larger along with the downward extrusion of the die and the plate under the action of pressure, and the polyurethane is uniformly loaded on the plate. The sheet is formed into the designed shape under the extrusion of the die and polyurethane. The whole process can combine a plurality of procedures in the traditional process.
As shown in fig. 15, after the press test was completed, the entire flow channel was clearly formed on the plate material. A plate is cut along the center of the second-order runner and is placed under an electron microscope for observation, and a second-order runner microscopic sectional view is obtained. And simultaneously, performing point drawing on the same position of the plate of the finite element simulation result to draw a shape curve and comparing the shape curve with the stamping test result. Experiments show that the forming effect of the plate is consistent with the height of the designed shape through macroscopic observation; the microcosmic comparison shows that the actual stamping experiment result is highly consistent with the finite element simulation result. The method provides data and experimental support for the application of the soft mold forming technology in the production of the second-order runner metal bipolar plate.
Based on the same inventive concept, the invention also provides a processing and forming analysis system for the metal bipolar plate formed by the polyurethane soft mold, which is suitable for analyzing the processing and forming parameters of the metal bipolar plate, wherein the metal bipolar plate at least has a plurality of second-order flow channel structures; the method is characterized in that: at least comprises the following steps:
the area dividing unit is used for determining a plurality of stress analysis areas, and the stress analysis areas are determined according to the stress condition required by the metal bipolar plate to be processed;
the stress analysis unit is used for analyzing each stress analysis area one by one to obtain corresponding stress parameters, and the stress parameters are used for representing design parameters of a second-order runner segmented structure corresponding to each stress analysis area;
and the parameter acquisition unit is used for determining all design parameters of the second-order flow channel structure based on the design parameters.
Wherein, the process of analyzing the stress analysis area in the stress analysis unit comprises the following steps: firstly, a stress balance differential model corresponding to each stress analysis area is created, and secondly, the stress analysis model corresponding to each stress analysis area is determined based on the yield criterion corresponding to each stress analysis area. For further analysis see the corresponding contents of the methods section.
The above-mentioned embodiments only express several embodiments of the present application, and the description thereof is more specific and detailed, but not construed as limiting the scope of the present application. It should be noted that, for a person skilled in the art, several variations and modifications can be made without departing from the concept of the present application, which falls within the scope of protection of the present application. Therefore, the protection scope of the present patent shall be subject to the appended claims.
Claims (8)
1. A processing and forming method of a metal bipolar plate formed by a polyurethane soft mold is characterized in that the metal bipolar plate at least has a plurality of second-order flow channel structures; and the processing and forming method at least comprises the following steps:
s1, determining a plurality of stress analysis areas, wherein the stress analysis areas are determined according to the stress condition required by the metal bipolar plate to be processed;
s2, analyzing each stress analysis area one by one to obtain respective corresponding stress parameters, wherein the stress parameters are used for representing design parameters of a second-order flow channel segmented structure corresponding to each stress analysis area;
s3, determining all design parameters of the second-order flow channel structure based on the design parameters;
s4, constructing the metal bipolar plate through a soft mold forming process; in the soft die forming process, a rubber pad and a male die are matched to form a second-order runner structure.
2. The method as claimed in claim 1, wherein the second-order flow channel structure has a periodically distributed corrugated structure, and the corrugated structure includes a first-order flow channel structure and a tip structure formed on the top of the first-order flow channel structure and converging toward the center.
3. The method as claimed in claim 1, wherein the rubber pad is a polyurethane rubber pad.
4. The method as claimed in claim 1, wherein the analyzing the force analysis area in S2 comprises: firstly, a stress balance differential model corresponding to each stress analysis area is created, and secondly, the stress analysis model corresponding to each stress analysis area is determined based on the yield criterion corresponding to each stress analysis area.
5. The method as claimed in claim 4, wherein the specific process of analyzing the force analysis area comprises:
s21, creating a stress balance differential model corresponding to the first stress analysis area, wherein the stress balance differential model formula is as follows:
the corresponding force analysis model is:
wherein the first stress analysis region plate thickness t1＝t0，t0The thickness of the steel sheet is the initial thickness,
is the friction force between the metal die and the surface of the plate,
is the friction force between the plate and the surface of the rubber pad,
k is the shear yield stress, m1And m2Respectively coefficient of friction between different surfaces, σ1Radial tensile stress, L, for the first force analysis zone1Length of sheet material for the first force analysis zone, σ1-fFinal radial tensile stress of the first force analysis area, a1The boundary point of the second stress analysis area and the first stress analysis area in the width direction is set;
s22, creating a stress balance differential model corresponding to the second stress analysis area, wherein the stress balance differential model formula is as follows:
the corresponding yield criterion equation:
according to the formula, the following results are obtained:
because the final thickness of the first stress analysis area is equal to the initial thickness of the two stress analysis areas, the corresponding stress analysis model is finally obtained as
Wherein, t2The second stress analysis region is the plate thickness r1Fillet radius, σ, of sheet thickness for the second force analysis region2The radial tensile stress corresponding to the second stress analysis area is provided, and P is the vertical stress applied to the plate; a is2A dividing point in the width direction of the second stress analysis area and the third stress analysis area; t is t1-fThe final thickness of the plate in the first stress analysis area; t is t2-fFinal thickness of the sheet for the second force analysis zone, θ1The corner angle of the plate in the second stress analysis area is used; the range of the intermediate variable x in the second stress analysis area is x epsilon [ a1，a2]；
S23, creating a stress balance differential model corresponding to the third stress analysis area, wherein the stress balance differential model formula is as follows:
the corresponding yield criterion equation:
since the final thickness of the second force analysis area is equal to the initial thickness of the third force analysis area, i.e. t3-i＝t2-fAccording to the formula, the corresponding stress analysis model is obtained as follows:
wherein, t3Thickness of the plate for the third stress analysis region, r1Fillet radius, σ, of sheet thickness for the second force analysis region3The radial tensile stress corresponding to the third stress analysis area, P is the vertical stress applied to the plate, a3A dividing point in the width direction of the third stress analysis area and the fourth stress analysis area; t is t3-fThe final thickness of the plate in the third force analysis area; the range of the intermediate variable x in the third stress analysis area is x epsilon [ a2，a3]；L2The length of the sheet in the third force analysis area;
s24, creating a first stress balance differential model corresponding to the fourth stress analysis area, wherein the first stress balance differential model formula is as follows:
the corresponding yield criterion equation:
since the final thickness of the third force analysis area is equal to the initial thickness of the fourth force analysis area, i.e. t4-i＝t3-fAccording to the formula, the following results are obtained:
creating a second stress balance differential model corresponding to a fourth stress analysis area, wherein the second stress balance differential model formula comprises the following steps:
the corresponding yield criterion equation:
the final thickness of the fourth force analysis area is equal to the initial thickness of the fifth force analysis area, namely t4-f＝t5-iAccording to the formula, the following results are obtained:
combining the formulas (12) and (15), obtaining a corresponding stress analysis model as
Wherein, at-minThe position with the thinnest thickness of the plate; t is t4Thickness of the plate for the fourth stress analysis region, r2Fillet radius, σ, of sheet thickness for fourth force analysis area4Radial tensile stress corresponding to the fourth force analysis region, a4A dividing point in the width direction of the fourth stress analysis area and the fifth stress analysis area; t is t5-iInitial thickness of the sheet in the fifth force analysis zone, θ2Angle of rotation, theta, for the fourth force analysis zone3The corner angle is the angle of the sixth stress analysis area; the range of the intermediate variable x in the fourth stress analysis area is x epsilon [ a3，a4]；
S25, creating a stress balance differential model corresponding to the fifth stress analysis area, wherein the stress balance differential model formula is as follows:
the corresponding yield criterion equation:
the final thickness of the fifth stress analysis area is equal to the initial thickness of the sixth stress analysis area, namely t5-f＝t6-iAccording to the formula, the corresponding stress analysis model is obtained as follows:
wherein, t5Thickness of the plate in the fifth stress analysis region, [ theta ]3Angle of rotation, σ, of sheet thickness for the fifth force analysis region5Radial tensile stress corresponding to the fifth force analysis region, a5A dividing point in the width direction of the fifth stress analysis area and the sixth stress analysis area; the range of the intermediate variable x in the fifth stress analysis area is x epsilon [ a4，a5]；
S26, creating a stress balance differential model corresponding to the sixth stress analysis area, wherein the stress balance differential model formula is as follows:
the corresponding yield criterion equation:
the final thickness of the sixth force analysis area is equal to the initial thickness of the seventh force analysis area, namely t7-i＝t6-fAccording to the formula, the corresponding stress analysis model is obtained as follows:
wherein, t6For the sixth force analysis region of sheet thickness, r3Fillet radius, σ, of plate thickness for the sixth force analysis region6Radial tensile stress corresponding to the sixth force analysis region, a6Is a boundary point in the width direction between the sixth force analysis region and the seventh force analysis region, L3The length of the plate in the fifth stress analysis area; (ii) a
S27, creating a stress balance differential model corresponding to the seventh stress analysis area, wherein the stress balance differential model formula is as follows:
according to the formula, the corresponding stress analysis model is obtained as follows:
wherein, t7For the seventh stress analysis region of sheet thickness, σ7Radial tensile stress, L, corresponding to the seventh force analysis zone4The length of the plate in the seventh force analysis area.
6. A simulation method for machining and forming a metal bipolar plate based on the flexible polyurethane mold as claimed in any one of claims 1 to 6, comprising at least the following steps: and sequentially constructing a polyurethane soft die finite element model, a steel male die finite element model and a metal plate finite element model for finite element analysis based on all the design parameters of the determined second-order runner structure, and selecting a manufacturing die of a metal double-plate structure according to a finite element simulation result.
7. A processing and forming system for a metal bipolar plate formed by a polyurethane soft die is characterized in that: at least comprises the following steps:
the area dividing unit is used for determining a plurality of stress analysis areas, and the stress analysis areas are determined according to the stress condition required by the metal bipolar plate to be processed;
the stress analysis unit is used for analyzing each stress analysis area one by one to obtain corresponding stress parameters, and the stress parameters are used for representing design parameters of a second-order runner segmented structure corresponding to each stress analysis area;
and the parameter acquisition unit is used for determining all design parameters of the second-order flow channel structure based on the design parameters.
8. The system of claim 8, wherein the process of analyzing the force analysis area in the force analysis unit comprises: firstly, a stress balance differential model corresponding to each stress analysis area is created, and secondly, the stress analysis model corresponding to each stress analysis area is determined based on the yield criterion corresponding to each stress analysis area.
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