Effect of dimensional error of metallic bipolar plate on the GDL pressure distribution in the PEM fuel cell

Recently, the metallic bipolar plate (BPP) has received considerable attention because of its advantageous electrical and mechanical properties. In this study, a methodology based on FEA model and Monte Carlo simulation is developed to investigate the effect of dimensional error of the metallic BPP on the pressure distribution of gas diffusion layer (GDL). At first, a parameterized FEA model of metallic BPP/GDL assembly is established, and heights of the channel and rib are considered to be randomly varying parameters of normal distribution due to the dimensional error. Then, GDL pressure distributions with different dimensional errors are obtained respectively based on the Monte Carlo simulation, and the desirability function method is employed to evaluate them. At last, a regression equation between the GDL pressure distribution and the dimensional error is modeled. With the regression equation, the allowed maximum dimensional error for the metallic BPP is calculated. The methodology in this study can be applied to guide the design and manufacturing of the metallic BPP.