Study on a Novel High Pressure Hydroforming Apparatus and Its Applications
|關鍵字:||高靜水壓板金成形;微流道;高壓承載筒;高壓密封元件;sheet forming of high pressure hydroforming;micro-flow channels;high-pressure container;high-pressure seal component|
Recently, semiconductor and electronics have been becoming smaller and denser, and micro-fabrication techniques and dimension precision of workpieces have become more important. Compared with stamping technique, hydroforming has advantages on forming thin sheets with high aspect ratio. However, there still exist some problems in building high pressure hydroforming device and only few researches about high pressure hydroforming technique have been released. Therefore, a novel and patented high pressure hydroforming machine will be developed and applied to form both micro flow channels on metal bipolar plates for fuel cells and capillary structures for plate heat pipes in this proposal. Scheduled for totally three years, this proposal will accomplish the following tasks: In the first year, the research will focus on the basics of high pressure hydroforming process. A novel apparatus which can offer 1000MPa working pressure will be designed and manufactured. Then, hydroforming experiments will be conducted to test the forming capability of this new apparatus. Forming parameters such as workpiece thickness, width and depth of micro flow channels, channel gap, forming pressure, and the time of holding pressure will be tested. Finally, the forming characteristic and capability of this high pressure hydroforming apparatus will be verified to satisfy the designed specifications. In the second year, according to the results of the first-year research, precise finite element simulation module of high pressure hydroforming process will be established, combined with the optimum software to complete the system which can design and analyze all kinds of optimal forming parameters. And then the micro flow channels on metal bipolar plate for both small portable PEM fuel cells and solid oxide fuel cells will be designed and manufactured by high pressure hydroforming on stainless sheets. The mold used in this process will be machined by micro EDM. Finally, the cell performance of fuel cells with the above thin stainless bipolar plate will be tested. In the third year, with the help of last two years’ research, the high pressure hydroforming technique will be applied to plate heat pipe and radial heat pipe, and several forming parameters such as materials (copper and aluminum), geometries of groove-wick, and aspect ratio of capillary structure will be tested. The finite element analysis and optimum analysis will also be used to seek for the optimal forming parameters. Finally, heat pipes with wick structure will be manufactured by means of high pressure hydroforming, and their performances will be tested.