本研究旨在透過有限元素模擬分析，探討質子交換膜燃料電池（Proton Exchange Membrane Fuel Cell, PEMFC）不鏽鋼雙極板之最佳沖壓成形參數。研究中採用DYNAFORM模擬軟體結合LS-DYNA 求解器，系統性分析變徑流道之幾何與製程參數對成形性的影響，並以成形極限圖（Forming Limit Diagram, FLD）、變薄率、回彈量與成形深度誤差值作為評估指標，進而尋求兼具設計可行性與製程穩定性的參數組合。模擬所用雙極板材料為不鏽鋼 SUS304，外部尺寸為 242×84 mm²，反應區面積為100 ×70 mm²，流道總長為100 mm，流道與肋條寬度均為 2 mm，頂端設有半徑 1 mm 的圓角，變徑區總寬度為70 mm，並於相鄰流道間保留1 mm間距，整體幾何形狀近似於噴嘴結構。模擬結果顯示，在流道深度0.5 mm、模具圓角半徑0.4mm、拔模角50度、沖壓速度 500 mm/s、鈑件厚度0.25mm及壓料板壓力20kN的條件下，成形性表現最佳。整體趨勢顯示，流道深度愈大，回彈量與變薄率越高；模具圓角半徑愈大，有助於降低回彈；提高沖壓速度會增加變薄率，但可減少回彈；鈑件厚度愈厚雖會使回彈量上升，但可降低變薄率；而壓料板壓力則能有效抑制皺褶並提升成形穩定性。此研究結果可作為不鏽鋼雙極板沖壓製程參數設計之參考，並有助於提升 PEMFC關鍵零組件的成形品質與製造效率。;This study aims to investigate the optimal stamping parameters for stainless steel bipolar plates used in proton exchange membrane fuel cells (PEMFCs) through finite element simulation analysis. DYNAFORM simulation software, integrated with the LS-DYNA solver, was employed to systematically analyze the influence of variable-width flow channel geometries and stamping process parameters on formability. The simulation evaluation criteria included the forming limit diagram (FLD), thinning ratio, springback, and forming depth deviation, in order to assess the effects of various parameters on the forming quality of the bipolar plates and to determine the optimal parameter combination that ensures both design feasibility and process stability. The simulation results revealed that SUS304 stainless steel bipolar plates demonstrated optimal formability under the following conditions: a flow channel depth of 0.5 mm, die fillet radius of 0.4 mm, draft angle of 50°, stamping speed of 500 mm/s, sheet thickness of 0.25 mm, and blank holder force of 20 kN. The trends observed are as follows: increasing the flow channel depth leads to higher springback and thinning; a larger die fillet radius effectively reduces springback; increasing sheet thickness results in higher springback but lower thinning; and the application of a blank holder effectively suppresses wrinkling and enhances forming stability. This study provides a valuable reference for the design of stamping process parameters for stainless steel bipolar plates and contributes to improving the forming quality and manufacturing efficiency of key PEMFC components.
