Microforming Technology and Its Applications

A special issue of Micromachines (ISSN 2072-666X). This special issue belongs to the section "D:Materials and Processing".

Deadline for manuscript submissions: 31 March 2025 | Viewed by 906

Special Issue Editor


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Guest Editor
Department of Mechanical Engineering, Northern Illinois University, DeKalb, IL 60115, USA
Interests: sheet/foil metal forming; forging; microforming; adiabatic impact net-shape forming; adiabatic impact powder forming; high strain rate deformation

Special Issue Information

Dear Colleagues,

Due to the miniaturization of metallic parts with an extremely tight tolerance and complex features in micro/nano scales, LIGA and micromachining have been widely utilized in industry to produce these type of parts; however, they are not suitable for mass production due to their low production rate and high cost. However, microforming is the most suitable and cost-effective manufacturing process used to fabricate micrometallic components with an extremely tight tolerance and complex features during mass production. In addition, the mechanical properties of the microscale metallic parts are enhanced due to plastic deformation. Unfortunately, our experience of macroscale metal forming cannot be applied directly due to the so-called size effects. Thus, this area of research requires the achievement of significant breakthroughs. Therefore, this Special Issue aims to present original research papers and reviews that address the following topics (1) novel processes for microsheet forming and microbulk forming; (2) new models for size effects; (3) formability; (4) springback; (5) microdie design and fabrication; and (6) the modeling and simulation of microforming processes. We look forward to receiving your contributions.

Prof. Dr. Jenn-Terng Gau
Guest Editor

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Keywords

  • microforming
  • size effect
  • micro formability
  • microchannels
  • microtool and die design
  • microfabrication
  • springback
  • modeling and simulations
  • micro tribology
  • strain rate

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Published Papers (1 paper)

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Research

21 pages, 10698 KiB  
Article
A High-Precision Micro-Roll Forming Facility for Fuel Cell Metal Bipolar Plate Production
by Matthias Weiss, Peng Zhang and Michael Pereira
Micromachines 2025, 16(1), 91; https://doi.org/10.3390/mi16010091 - 14 Jan 2025
Viewed by 628
Abstract
The metal bipolar plate is a critical component of the hydrogen fuel cell stack used in proton exchange membrane fuel cells. Bipolar plates must have high accuracy micro-channels with a high aspect ratio (AR) between the channel depth and the half [...] Read more.
The metal bipolar plate is a critical component of the hydrogen fuel cell stack used in proton exchange membrane fuel cells. Bipolar plates must have high accuracy micro-channels with a high aspect ratio (AR) between the channel depth and the half periodic width to achieve optimal cell performance. Conventional forming methods, such as micro-stamping, hydroforming, and rubber pad forming, cannot achieve these high ARs given that in these processes, material deformation is dominated by stretch deformation. In micro-roll forming the major deformation mode is bending, and this enables production of channels with higher ARs than is currently possible. However, micro-roll forming uses multiple sets of forming roll stands to form the part and this leads to technological challenges related to tool alignment and roll tool precision that must be overcome before widespread application can be achieved. This study presents a new methodology to achieve tight tool tolerances when producing micro-roll tooling by utilizing wire-EDM and micro-turning techniques. This is combined with a new micro-roll former design that enables high-precision tool alignment across multiple roll stations. Proof of concept is provided through micro-roll forming trials performed on ultra-thin titanium sheets that show that the proposed technology can achieve tight dimensional tolerances in the sub-millimeter scale that suits bipolar plate applications. Full article
(This article belongs to the Special Issue Microforming Technology and Its Applications)
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