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The use of high-speed forming technologies can contribute to satisfying current social and political demands on production technology such as sustainability and climate protection in manufacturing. These technologies have a very high potential for shaping complex, sharp-edged parts and constitute a key means of reducing a component’s weight. One exemplary high-speed forming technology is electromagnetic forming. It uses the energy density of pulsed magnetic fields to impose forces on electrically conductive materials, which leads to plastic deformation when reaching the yield stress of the material. However, for very thin sheet materials this effect can result in an uncontrolled deformation of the work piece. In order to overcome this effect, electromagnetically driven tools the use of can be appropriate. An additional benefit is that this process is no longer restricted to electrically highly conductive work piece materials. This paper describes a media-based process using electromagnetically driven tools to form micro-flow channels, which are often used in bipolar plates, into thin sheet metals. The principles are explained and first results are shown.

Media-based forming of micro-flow channels into thin sheet metal by electromagnetically driven tools