Fabricating high-aspect ratio microchannels on metallic sheets using hydroforming

Chih Chia Lin, Jhen Jie Yan, Ching-Hua Hung, Jung Chung Hung

Research output: Chapter in Book/Report/Conference proceedingConference contributionpeer-review


High-aspect ratio microchannels on bipolar plates have the advantage of improving fuel cell performance. This study formed high-aspect ratio microchannels by increasing the forming pressure, and predicted excellent aspect ratio of micro-flow channels by optimization analysis during the hydroforming process. This study used an experimental high-pressure hydroforming apparatus that provides various pressures to form microchannels on 304 stainless steel sheets with 0.1 mm thickness. Simultaneously, finite element analysis software was used to analyze the hydroforming process. First, the precision of the finite element model was verified by comparing simulations with experiments. Subsequently, the optimization software was connected to the finite element software to determine the optimal aspect ratio of microchannels by changing the dimension of micro-flow channels and pressures. Furthermore, the results of the simulations, hydroforming experiments, and related literature were discussed. The result indicated that the high-pressure hydroforming technique was feasibility, which formed high aspect ratio microchannels with 200 MPa, and the optimization predicted aspect ratio could reach 0.478 when changing geometries of channels and pressures. This research proposed a design process through hydroforming experiments, finite element analysis, and optimization analysis when predicting and designing the dimensions of micro-flow channels on metallic bipolar plates.

Original languageEnglish
Title of host publicationProceedings of the 14th International Conference on Metal Forming, METAL FORMING 2012
PublisherWiley-VCH Verlag
Number of pages4
ISBN (Print)9783514007970
StatePublished - 1 Jan 2012
Event14th International Conference on Metal Forming, METAL FORMING 2012 - Krakow, Poland
Duration: 16 Sep 201219 Sep 2012


Conference14th International Conference on Metal Forming, METAL FORMING 2012


  • Finite element analysis
  • Hydroforming
  • Metallic bipolar plate
  • Micro-flow channel
  • Optimization analysis
  • Portable fuel cell


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