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<p>Ultra-thin-walled microchannel structures are widely applied in fields such as micro-bioreactors and bipolar plates of hydrogen fuel cells. The soft mold roll forming process for fabricating microchannel structures offers the advantages of being non-damaging and highly efficient, yet it also presents drawbacks such as a low depth-to-width ratio and shape asymmetry defects. Therefore, this study proposes to introduce radial ultrasonic vibration into the soft mold roll forming process and investigates its effect on mitigating deformation defects of microchannel structures. The results reveal that under radial ultrasonic vibration, the peak contact pressure between the foil and the microstructured roller is significantly reduced, while the intrusion volume of the soft mold increases, leading to an enhanced depth-to-width ratio of the microchannels. The application of radial ultrasonic vibration induces a divergent characteristic in the synthetic vector of the soft mold, markedly reducing unilateral impact forces and thereby alleviating asymmetry defects. At an ultrasonic amplitude of 1.6&#xa0;μm, the microchannel structure with a <i>t/d</i> of 1.5 achieved the maximum increase in depth-to-width ratio (13.4%) and the maximum reduction in asymmetry degree (8.9%). Ultrasonic vibration has no effect on the deformation of the crown region of the microchannels. Owing to stress penetration and impact rolling induced by ultrasonic vibration, the hardness and surface quality of the bending region are significantly improved, which is beneficial for extending the service life of microchannel structures. These findings provide a novel approach for the efficient and high-quality fabrication of microchannel structures.</p>

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Radial ultrasonic-assisted soft mold roll forming for high-quality microchannel structures: defect mitigation and surface enhancement

  • 期刊论文

  • 发表日期：

    2026年5月19日

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  • Zhenwu Ma,
  • Qiansen Lv,
  • Zhuangzhuang Wang,
  • Jialin Zhu,
  • Quanwei Ma,
  • Chunju Wang,
  • Yuanjing Zhang

摘要

Ultra-thin-walled microchannel structures are widely applied in fields such as micro-bioreactors and bipolar plates of hydrogen fuel cells. The soft mold roll forming process for fabricating microchannel structures offers the advantages of being non-damaging and highly efficient, yet it also presents drawbacks such as a low depth-to-width ratio and shape asymmetry defects. Therefore, this study proposes to introduce radial ultrasonic vibration into the soft mold roll forming process and investigates its effect on mitigating deformation defects of microchannel structures. The results reveal that under radial ultrasonic vibration, the peak contact pressure between the foil and the microstructured roller is significantly reduced, while the intrusion volume of the soft mold increases, leading to an enhanced depth-to-width ratio of the microchannels. The application of radial ultrasonic vibration induces a divergent characteristic in the synthetic vector of the soft mold, markedly reducing unilateral impact forces and thereby alleviating asymmetry defects. At an ultrasonic amplitude of 1.6 μm, the microchannel structure with a t/d of 1.5 achieved the maximum increase in depth-to-width ratio (13.4%) and the maximum reduction in asymmetry degree (8.9%). Ultrasonic vibration has no effect on the deformation of the crown region of the microchannels. Owing to stress penetration and impact rolling induced by ultrasonic vibration, the hardness and surface quality of the bending region are significantly improved, which is beneficial for extending the service life of microchannel structures. These findings provide a novel approach for the efficient and high-quality fabrication of microchannel structures.