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<p>Springback in stamping processes of 304 stainless steel fuel cell bipolar plates induces significant dimensional inaccuracies and geometric distortions, adversely affecting both assembly precision and functional performance. To address springback challenges in bipolar plate fabrication, finite element analysis (FEA) was implemented to characterize two-dimensional sheet deformation behavior, with quantitative evaluation of springback displacement and angular variation throughout the complete forming cycle. The investigation systematically compared multi-stage forming sequences involving arc-shaped and rectangular channels through implicit static analysis, elucidating their distinct influences on springback magnitude and stress distribution patterns. A comprehensive mechanical model was developed for springback prediction in 0.1&#xa0;mm thick stainless steel sheets, encompassing the complete forming-to-springback transition. Numerical simulations using ABAQUS software accurately replicated the stamping and springback phenomena, with experimental validations confirming model reliability. Analysis revealed maximum springback displacements of 19.2&#xa0;μm for single-step forming, 14.8&#xa0;μm for dual rectangular channel forming, and 12.7&#xa0;μm for the arc-rectangular channel sequence. The optimized forming sequence achieved 33.8% springback reduction compared to conventional single-step processing. In terms of post-springback stress, peak values measured 739&#xa0;MPa for single-stage forming, 614&#xa0;MPa for dual rectangular-channel stamping, and 549&#xa0;MPa for the arc-to-rectangular channel sequence. The optimal forming sequence reduced post-springback stress by up to 25.7% relative to single-stage forming. Compared with single-step stamping, multi-step stamping effectively optimizes stress distribution through staged forming, reducing stress concentration and the accumulation of springback stress. Experimental measurements demonstrated agreement with simulated springback predictions.</p>

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Finite element simulation of multi-process stamping springback process of 304 stainless steel thin plate

  • 期刊论文

  • 发表日期：

    2026年3月30日

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  • Yu Liu,
  • Xiaofeng Zhang,
  • Jingzhou Qin,
  • Xiuming Wang,
  • Jialiang Qi,
  • Shengfang Zhang

摘要

Springback in stamping processes of 304 stainless steel fuel cell bipolar plates induces significant dimensional inaccuracies and geometric distortions, adversely affecting both assembly precision and functional performance. To address springback challenges in bipolar plate fabrication, finite element analysis (FEA) was implemented to characterize two-dimensional sheet deformation behavior, with quantitative evaluation of springback displacement and angular variation throughout the complete forming cycle. The investigation systematically compared multi-stage forming sequences involving arc-shaped and rectangular channels through implicit static analysis, elucidating their distinct influences on springback magnitude and stress distribution patterns. A comprehensive mechanical model was developed for springback prediction in 0.1 mm thick stainless steel sheets, encompassing the complete forming-to-springback transition. Numerical simulations using ABAQUS software accurately replicated the stamping and springback phenomena, with experimental validations confirming model reliability. Analysis revealed maximum springback displacements of 19.2 μm for single-step forming, 14.8 μm for dual rectangular channel forming, and 12.7 μm for the arc-rectangular channel sequence. The optimized forming sequence achieved 33.8% springback reduction compared to conventional single-step processing. In terms of post-springback stress, peak values measured 739 MPa for single-stage forming, 614 MPa for dual rectangular-channel stamping, and 549 MPa for the arc-to-rectangular channel sequence. The optimal forming sequence reduced post-springback stress by up to 25.7% relative to single-stage forming. Compared with single-step stamping, multi-step stamping effectively optimizes stress distribution through staged forming, reducing stress concentration and the accumulation of springback stress. Experimental measurements demonstrated agreement with simulated springback predictions.