Numerical Modelling of Tool Wear in Forming of Metallic Bipolar Plates for PEM Fuel Cells

As the demand for Proton Exchange Membrane Fuel Cells (PEMFCs) grows, it is crucial to ensure the durability of forming tools for producing metallic bipolar plates (BPPs) to support high-volume manufacturing. A typical PEMFC stack for an automotive application requires 600–800 half-BPPs, which potentially cause extensive wear on forming tools over millions of forming cycles. This study introduces a finite element-based simulation framework incorporating the Archard wear model to predict tool wear patterns and degrees. By iteratively updating tool geometries based on contact pressure and sliding distance, the model identifies maximum wear near tool radii. Experimental validation using a tool wear test bench confirms its predictive accuracy.