Simulation and experimental researches on multi-plate rubber pad forming of two-step micro-channel based on different forming driving models

Surface micro-channels with different structures have a variety of functions. In order to further develop these functions, micro-channel design and forming process are constantly being innovated. In this paper, the advanced rubber pad forming technology is used to manufacture the new two-step micro-channel structure. Forced convection can be caused by this kind of micro-channel in three dimensions of the gas, which can reduce the flow rate and make the gas evenly distributed. Therefore, it can be used in bipolar plates of PEMFC (proton exchange membrane fuel cell). According to the driving mode, forming mode is divided into active forming and passive forming. The metal plates formed in these ways are studied, and the advantages and differences of forming results are discussed. The 304 stainless steel sheet with the thickness of 0.1 mm is used in the manufacturing process. Polyurethane with shore A70 hardness and 60 mm total thickness is selected as rubber pad. And then, two models of forming two metal plates simultaneously in one time are presented. In order to verify the accuracy of the model, finite element method and forming experiment are carried out. It is shown that the rubber pad forming process is a feasible process for producing multiple two-step micro-channel metal plates in one time.