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<p>To address lateral-edge wrinkling in 0.1&#xa0;mm-thick 316L stainless steel metallic bipolar plates during roller embossing, this study investigates the wrinkling mechanism and optimizes key forming parameters. A finite element wrinkling model was established and combined with energy-based analysis and shell bending theory to analyze wrinkle evolution and instability behavior during roller embossing. Experimental validation was further conducted under different mold and constraint conditions. The results indicate that wrinkling is mainly induced by compressive stress instability on both sides of the transverse deformation zone, while shear stress contributes to the inclined wrinkle morphology. Multi-channel forming coupling intensifies residual compressive stress concentration and promotes nonlinear wrinkle amplification. Parametric analysis shows that increasing the blank-holder diameter reduces wrinkling, whereas increasing the mold fillet radius aggravates wrinkling. In contrast, the influence of mold side clearance exhibits a non-monotonic trend. Based on response surface methodology, multi-objective optimization of the process parameters was performed. Statistical analysis shows that the blank-holder diameter is the most significant factor affecting wrinkling under the investigated conditions. The optimized parameter combination was obtained as follows: mold fillet radius of 0.1&#xa0;mm, mold side clearance of 0.27&#xa0;mm, and blank-holder diameter of 49.90&#xa0;mm. Compared with the parameter set showing the lowest wrinkling level in the experimental design, the optimized condition reduced the wrinkle amplitude and fluctuation index by 6.12% and 10.04%, respectively. These results provide a mechanistic understanding and parameter selection reference for reducing lateral-edge wrinkling in metallic bipolar plate channel roller embossing.</p>

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Study on wrinkling behavior and process optimization of 316L stainless steel bipolar plate channel Roller embossing

  • 期刊论文

  • 发表日期：

    2026年8月3日

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  • Shengqi Gao,
  • Fuqiang Zhao,
  • Shengqian Chen,
  • Qingxue Huang

摘要

To address lateral-edge wrinkling in 0.1 mm-thick 316L stainless steel metallic bipolar plates during roller embossing, this study investigates the wrinkling mechanism and optimizes key forming parameters. A finite element wrinkling model was established and combined with energy-based analysis and shell bending theory to analyze wrinkle evolution and instability behavior during roller embossing. Experimental validation was further conducted under different mold and constraint conditions. The results indicate that wrinkling is mainly induced by compressive stress instability on both sides of the transverse deformation zone, while shear stress contributes to the inclined wrinkle morphology. Multi-channel forming coupling intensifies residual compressive stress concentration and promotes nonlinear wrinkle amplification. Parametric analysis shows that increasing the blank-holder diameter reduces wrinkling, whereas increasing the mold fillet radius aggravates wrinkling. In contrast, the influence of mold side clearance exhibits a non-monotonic trend. Based on response surface methodology, multi-objective optimization of the process parameters was performed. Statistical analysis shows that the blank-holder diameter is the most significant factor affecting wrinkling under the investigated conditions. The optimized parameter combination was obtained as follows: mold fillet radius of 0.1 mm, mold side clearance of 0.27 mm, and blank-holder diameter of 49.90 mm. Compared with the parameter set showing the lowest wrinkling level in the experimental design, the optimized condition reduced the wrinkle amplitude and fluctuation index by 6.12% and 10.04%, respectively. These results provide a mechanistic understanding and parameter selection reference for reducing lateral-edge wrinkling in metallic bipolar plate channel roller embossing.