Media-based impulse forming of channel structures

• Applicants: Dr.-Ing. Lasse Langstädtler; Dr.-Ing. Verena Psyk
• Subject Area: Primary Shaping and Reshaping Technology, Additive Manufacturing
• Term: since 2023
• Project identifier: Deutsche Forschungsgemeinschaft (DFG) - Project number 529030284

The production of complex channel structures is relevant for components of different size dimensions. Application examples range from heat exchangers, stiffening beads, design elements on a macroscopic level to microanalysis systems (lab on a chip) and holograms on a microscopic level. In the course of the development of fuel cells as an environmentally friendly alternative to combustion engines, the production of bipolar plates has come into focus in recent years. Conventional forming processes with two-sided forming dies are only suitable to a limited extent for the production of filigree channel structures in ultra-thin sheets. For the production of components with complex channel structures, media-based impulse forming processes promise considerable advantages in terms of achievable edge radii and aspect ratios as well as homogeneity of the sheet thickness distribution. When used as bipolar plates, this leads to higher efficiencies with lower component weight. However, due to complex interactions of different physical disciplines (e.g. electromagnetism, structural mechanics, and fluid dynamics) during pressure generation, pressure propagation in the fluid and component forming, an exact description and design of media-based impulse forming processes is currently not possible. Therefore, the aim of the project is to fundamentally analyze the interactions between adjustable process parameters, transient pressure field in the medium, forming process and forming result and to identify the process limits in the forming of channel structures. In this way, it will be possible to adjust the pressure of the forming medium in such a way that high-quality components can be produced.

• DFG Programme: Research Grants
• Co-Investigator: Professor Dr.-Ing. Andreas Fischer