首先想了解不銹鋼沖壓、彎曲和連續沖裁加工工藝，必須要知道以下幾點：
a. 極限拉深比－－拉深加工時，相對于容器直徑d可能拉深的最大原料板直徑為Dmax時，Dmax/d則稱為極限拉深比（LDR).
b. 平(ping)均r值(zhi)－－塑性為異向性的材料深拉深成形特(te)性評價的重(zhong)要指(zhi)標。鐵素體系列不銹鋼中，其(qi)平(ping)均r值(zhi)越大，其(qi)極(ji)限拉深比就越高。
c. 拉深皺(zhou)折(zhe)－鐵素體系(xi)列不(bu)銹鋼在(zai)沖床上(shang)進行(xing)深拉深加工(gong)時，在(zai)其表面上(shang)容易產生凹(ao)凸不(bu)平的皺(zhou)折(zhe)。可認(ren)為是組合結構不(bu)同而引(yin)起的塑(su)性(xing)異向性(xing)。
d. 時效(xiao)性斷裂－奧氏體(ti)系(xi)列不銹鋼(gang)SUS304等準穩定型(xing)奧氏體(ti)系(xi)列不銹鋼(gang)，在(zai)加工后(hou)有發生時效(xiao)性裂紋(wen)的現(xian)象。它與晶(jing)界晶(jing)粒無關。一般認(ren)為是由于(yu)加工感應而引起的馬(ma)氏體(ti)、氫和殘余應力所(suo)致。
1. 沖壓加工
沖(chong)(chong)壓(ya)加工(gong)(gong)(gong)(gong)行業是家庭式作坊工(gong)(gong)(gong)(gong)業的(de)(de)代表性產(chan)業，多是從(cong)單(dan)獨(du)一(yi)個一(yi)個地加工(gong)(gong)(gong)(gong)西餐具(ju)、器(qi)(qi)皿(min)等所(suo)謂的(de)(de)“洋人筷子”等開始，發(fa)(fa)展(zhan)到(dao)餐飲業的(de)(de)廚(chu)房(fang)用具(ju)以及(ji)廚(chu)房(fang)中(zhong)所(suo)使用的(de)(de)水槽(cao)、洗滌盆(pen)、深(shen)(shen)拉(la)深(shen)(shen)加工(gong)(gong)(gong)(gong)的(de)(de)澡(zao)盆(pen)以及(ji)汽車、電機領域(yu)中(zhong)的(de)(de)零部件等。主要工(gong)(gong)(gong)(gong)藝方法是采用剪(jian)切(qie)、沖(chong)(chong)孔、拉(la)深(shen)(shen)等進行連(lian)續(xu)加工(gong)(gong)(gong)(gong)。洋餐具(ju)、器(qi)(qi)皿(min)和鍋的(de)(de)沖(chong)(chong)壓(ya)加工(gong)(gong)(gong)(gong)，基本上(shang)是屬于圓(yuan)筒拉(la)深(shen)(shen)制(zhi)成。原材(cai)料板直徑(jing)D對容器(qi)(qi)（產(chan)品(pin)(pin)）直徑(jing)d之比(bi)，D/d稱(cheng)為拉(la)深(shen)(shen)比(bi)。以可能拉(la)深(shen)(shen)的(de)(de)最大(da)原材(cai)料板直徑(jing)為Dmax時(shi)，則Dmax/d稱(cheng)為極限拉(la)深(shen)(shen)比(bi)（LDR: Limiting Drawing Ratio)作為衡量加工(gong)(gong)(gong)(gong)性的(de)(de)指標。不銹鋼(gang)(gang)(gang)(gang)產(chan)品(pin)(pin)得以大(da)幅度(du)的(de)(de)增(zeng)加需求與沖(chong)(chong)壓(ya)加工(gong)(gong)(gong)(gong)技術(shu)的(de)(de)發(fa)(fa)展(zhan)有很(hen)大(da)關(guan)系。不銹鋼(gang)(gang)(gang)(gang)產(chan)品(pin)(pin)生產(chan)廠家在(zai)深(shen)(shen)拉(la)深(shen)(shen)加工(gong)(gong)(gong)(gong)等方面，由(you)于塑(su)性加工(gong)(gong)(gong)(gong)技術(shu)和材(cai)料技術(shu)的(de)(de)進展(zhan)。使得鐵(tie)素體系列不銹鋼(gang)(gang)(gang)(gang)高加工(gong)(gong)(gong)(gong)性鋼(gang)(gang)(gang)(gang)種，已經產(chan)品(pin)(pin)化了(le)。可以選定平均r值在(zai)1.2~1.8,LDR為2.2~2.5的(de)(de)鋼(gang)(gang)(gang)(gang)種。
在(zai)不(bu)銹(xiu)(xiu)鋼制品的(de)沖壓加工(gong)中(zhong)，如果使用奧氏(shi)體系(xi)列(lie)不(bu)銹(xiu)(xiu)鋼或鐵素(su)體系(xi)列(lie)不(bu)銹(xiu)(xiu)鋼的(de)高加工(gong)性能鋼種時，可以(yi)進行(xing)一定程度的(de)深拉深加工(gong)。奧氏(shi)體系(xi)列(lie)不(bu)銹(xiu)(xiu)鋼的(de)代表型鋼種 SUS 304(18Cr -18Ni),因為(wei)它(ta)的(de)LDR為(wei)2.5,可以(yi)進行(xing)相(xiang)對較大的(de)深拉深加工(gong)。
但由于加(jia)工(gong)硬化傾向大(da)而急劇地(di)增加(jia)了加(jia)工(gong)難度，有時竟發生裂(lie)(lie)紋或斷(duan)裂(lie)(lie)。為此，沖壓廠家(jia)就(jiu)在中間加(jia)上一(yi)道熱處理(li)工(gong)序之后再進(jin)行(xing)深拉深加(jia)工(gong)。還必須注意(yi)，奧(ao)氏體系列(lie)不銹鋼的(de)奧(ao)氏體穩定度低的(de)鋼種(zhong)經過拉深后，有可(ke)能發生時效斷(duan)裂(lie)(lie)現(xian)象。
近年來，新潟縣燕(yan)市的(de)沖(chong)壓(ya)加(jia)(jia)工(gong)(gong)(gong)廠和新鴻縣工(gong)(gong)(gong)業技術(shu)中(zhong)心(xin)共(gong)同開發不銹鋼(gang)熱沖(chong)壓(ya)技術(shu)，實(shi)現了超深(shen)拉深(shen)加(jia)(jia)工(gong)(gong)(gong)。熱沖(chong)壓(ya)技術(shu)就(jiu)是將凹模或者凸模其中(zhong)之(zhi)一進行加(jia)(jia)熱，這樣不銹鋼(gang)原來的(de)拉深(shen)程度就(jiu)可以提高1.5~2.0倍。熱沖(chong)壓(ya)加(jia)(jia)工(gong)(gong)(gong)設(she)備的(de)工(gong)(gong)(gong)作原理如(ru)圖6-9所示。其加(jia)(jia)工(gong)(gong)(gong)特性如(ru)圖6-10所示。
2. 彎曲與連續(xu)沖裁
奧氏體(ti)系列(lie)不(bu)銹(xiu)鋼(gang)進(jin)行(xing)彎(wan)(wan)(wan)(wan)曲加(jia)工(gong)(gong)是件(jian)簡單之事，可以制(zhi)作角鋼(gang)、槽鋼(gang)等(deng)(deng)型材(cai)(cai)使(shi)用(yong)(yong)。鐵素體(ti)系列(lie)，馬氏體(ti)系列(lie)不(bu)銹(xiu)鋼(gang)作為(wei)(wei)(wei)型材(cai)(cai)加(jia)工(gong)(gong)，一般情況(kuang)下(xia)沒有(you)問題，但當彎(wan)(wan)(wan)(wan)曲半徑R小的(de)(de)(de)(de)(de)時(shi)候，在折彎(wan)(wan)(wan)(wan)處(chu)有(you)時(shi)會發生斷裂。在JIS標準中，對鐵素體(ti)、馬氏體(ti)系列(lie)的(de)(de)(de)(de)(de)不(bu)銹(xiu)鋼(gang)彎(wan)(wan)(wan)(wan)曲試驗標準規定，彎(wan)(wan)(wan)(wan)曲半徑R為(wei)(wei)(wei)1.0t(t為(wei)(wei)(wei)板(ban)材(cai)(cai)厚(hou)度）不(bu)應(ying)發生彎(wan)(wan)(wan)(wan)曲斷裂。還有(you)，必(bi)須(xu)注意不(bu)銹(xiu)鋼(gang)彎(wan)(wan)(wan)(wan)曲加(jia)工(gong)(gong)回彈量大的(de)(de)(de)(de)(de)特點。落(luo)料(liao)(liao)（俗稱下(xia)料(liao)(liao)）或稱為(wei)(wei)(wei)沖(chong)(chong)(chong)裁加(jia)工(gong)(gong)，大多數是采用(yong)(yong)沖(chong)(chong)(chong)床連(lian)續加(jia)工(gong)(gong)的(de)(de)(de)(de)(de)方式，有(you)時(shi)在沖(chong)(chong)(chong)切斷面上(shang)，發生塌邊(bian)(bian)現象（即沖(chong)(chong)(chong)切面與基準平面不(bu)垂直）。精(jing)密(mi)落(luo)料(liao)(liao)是從變(bian)壓(ya)器等(deng)(deng)使(shi)用(yong)(yong)疊層的(de)(de)(de)(de)(de)電磁(ci)鋼(gang)板(ban)的(de)(de)(de)(de)(de)加(jia)工(gong)(gong)技術(shu)開展起來(lai)的(de)(de)(de)(de)(de)技術(shu)，對粒子加(jia)速器的(de)(de)(de)(de)(de)套(tao)環（collar)或電子零部件(jian)中的(de)(de)(de)(de)(de)引(yin)線框（lead frame)等(deng)(deng)等(deng)(deng)，從較(jiao)厚(hou)的(de)(de)(de)(de)(de)板(ban)材(cai)(cai)到超薄材(cai)(cai)，精(jing)密(mi)落(luo)料(liao)(liao)得到廣泛應(ying)用(yong)(yong)。沖(chong)(chong)(chong)壓(ya)加(jia)工(gong)(gong)機械(xie)(xie)亦(yi)可以進(jin)行(xing)精(jing)密(mi)沖(chong)(chong)(chong)壓(ya)（落(luo)料(liao)(liao)）加(jia)工(gong)(gong)，但由于沖(chong)(chong)(chong)壓(ya)塌邊(bian)(bian)的(de)(de)(de)(de)(de)問題，一般不(bu)能作為(wei)(wei)(wei)成(cheng)品直接使(shi)用(yong)(yong)。在精(jing)密(mi)沖(chong)(chong)(chong)壓(ya)中，為(wei)(wei)(wei)控制(zhi)塌邊(bian)(bian)，就(jiu)需加(jia)一道(dao)機械(xie)(xie)控制(zhi)的(de)(de)(de)(de)(de)工(gong)(gong)藝措施，這需要按產品用(yong)(yong)途以及成(cheng)本兩方面來(lai)權(quan)衡。在加(jia)工(gong)(gong)方法競爭上(shang)，還有(you)一種“蝕刻(ke)”方法，在電子產品的(de)(de)(de)(de)(de)接線框等(deng)(deng)超薄產品中，在加(jia)工(gong)(gong)廠家的(de)(de)(de)(de)(de)技術(shu)競爭中，兩者幾乎(hu)各占(zhan)一半。
3. 加工油、表面保護薄膜(mo)和其他潤滑
a. 表面(mian)保護薄膜－為(wei)了保持不銹鋼的(de)匠(jiang)藝性、防止產生瑕疵以(yi)及作為(wei)潤(run)滑(hua)而敷于材料表面(mian)的(de)聚氯乙烯或(huo)聚乙烯等薄膜。
b. 揮發性加工(gong)油(you)－－加工(gong)時有潤滑(hua)效果(guo)而后又能(neng)揮發掉的加工(gong)油(you)。使(shi)用完全揮發型的，可以省掉清洗工(gong)序(xu)。
c. 潤(run)滑不(bu)銹鋼板－具有透明(ming)石蠟涂裝的不(bu)銹鋼，它比(bi)加(jia)工油(you)或表面保護膜(mo)有更好的加(jia)工性(xing)。
在(zai)沖(chong)床上進行(xing)(xing)不銹鋼(gang)板彎曲、沖(chong)裁（落料(liao)）等(deng)加(jia)(jia)工(gong)(gong)時，可使(shi)用(yong)(yong)(yong)(yong)加(jia)(jia)工(gong)(gong)油(you)(you)、表(biao)(biao)面(mian)保(bao)(bao)(bao)(bao)護(hu)(hu)(hu)薄(bo)(bo)膜(mo)(mo)(mo)(mo)(mo)(mo)或直接(jie)使(shi)用(yong)(yong)(yong)(yong)潤(run)滑鋼(gang)板。在(zai)表(biao)(biao)6-1中，對(dui)加(jia)(jia)工(gong)(gong)油(you)(you)、表(biao)(biao)面(mian)保(bao)(bao)(bao)(bao)護(hu)(hu)(hu)薄(bo)(bo)膜(mo)(mo)(mo)(mo)(mo)(mo)和潤(run)滑鋼(gang)板進行(xing)(xing)比較。表(biao)(biao)面(mian)保(bao)(bao)(bao)(bao)護(hu)(hu)(hu)薄(bo)(bo)膜(mo)(mo)(mo)(mo)(mo)(mo)是不銹鋼(gang)保(bao)(bao)(bao)(bao)持(chi)匠藝(yi)性的(de)(de)(de)(de)(de)(de)一項重要(yao)(yao)措施。所用(yong)(yong)(yong)(yong)樹(shu)脂為聚氯乙烯(xi)系(xi)列(lie)或聚乙烯(xi)系(xi)列(lie)。材料(liao)運轉自始至終都是用(yong)(yong)(yong)(yong)表(biao)(biao)面(mian)保(bao)(bao)(bao)(bao)護(hu)(hu)(hu)薄(bo)(bo)膜(mo)(mo)(mo)(mo)(mo)(mo)對(dui)材料(liao)表(biao)(biao)面(mian)施行(xing)(xing)保(bao)(bao)(bao)(bao)護(hu)(hu)(hu)。使(shi)用(yong)(yong)(yong)(yong)表(biao)(biao)面(mian)保(bao)(bao)(bao)(bao)護(hu)(hu)(hu)薄(bo)(bo)膜(mo)(mo)(mo)(mo)(mo)(mo)，最容(rong)(rong)易發(fa)生的(de)(de)(de)(de)(de)(de)問(wen)題就是殘留(liu)糊(hu)狀物，貼(tie)附(fu)后長(chang)期保(bao)(bao)(bao)(bao)存(cun)在(zai)倉庫內(nei)的(de)(de)(de)(de)(de)(de)或者是不具備耐候性能(neng)的(de)(de)(de)(de)(de)(de)薄(bo)(bo)膜(mo)(mo)(mo)(mo)(mo)(mo)放置在(zai)室外(wai)的(de)(de)(de)(de)(de)(de)，則容(rong)(rong)易發(fa)生損壞。表(biao)(biao)面(mian)保(bao)(bao)(bao)(bao)護(hu)(hu)(hu)薄(bo)(bo)膜(mo)(mo)(mo)(mo)(mo)(mo)要(yao)(yao)根(gen)據用(yong)(yong)(yong)(yong)途和加(jia)(jia)工(gong)(gong)方(fang)法選定。主要(yao)(yao)廠家生產的(de)(de)(de)(de)(de)(de)表(biao)(biao)面(mian)保(bao)(bao)(bao)(bao)護(hu)(hu)(hu)薄(bo)(bo)膜(mo)(mo)(mo)(mo)(mo)(mo)性能(neng)及其(qi)有(you)關事項如表(biao)(biao)6-2所示。不使(shi)用(yong)(yong)(yong)(yong)表(biao)(biao)面(mian)保(bao)(bao)(bao)(bao)護(hu)(hu)(hu)薄(bo)(bo)膜(mo)(mo)(mo)(mo)(mo)(mo)時，一般情況(kuang)下要(yao)(yao)使(shi)用(yong)(yong)(yong)(yong)加(jia)(jia)工(gong)(gong)油(you)(you)。當使(shi)用(yong)(yong)(yong)(yong)加(jia)(jia)工(gong)(gong)油(you)(you)加(jia)(jia)工(gong)(gong)后，需進行(xing)(xing)洗凈。洗凈的(de)(de)(de)(de)(de)(de)方(fang)法有(you)多(duo)種，最近(jin)在(zai)保(bao)(bao)(bao)(bao)護(hu)(hu)(hu)地球環(huan)境問(wen)題當中，規定了保(bao)(bao)(bao)(bao)護(hu)(hu)(hu)環(huan)境條例，對(dui)于破(po)壞臭氧(yang)層的(de)(de)(de)(de)(de)(de)清洗劑(ji)做出了限制。
因(yin)此，當(dang)使用(yong)(yong)加(jia)(jia)工(gong)(gong)油時，要考(kao)慮(lv)到洗(xi)凈和存放(fang)問(wen)題。在加(jia)(jia)工(gong)(gong)油選定方面，從前認為由于不銹(xiu)鋼硬度比普通鋼要高(gao)，加(jia)(jia)工(gong)(gong)不銹(xiu)鋼比普通鋼困(kun)難(nan)，所以(yi)要選用(yong)(yong)有黏(nian)性的(de)(de)加(jia)(jia)工(gong)(gong)油。具有黏(nian)性的(de)(de)加(jia)(jia)工(gong)(gong)油往(wang)往(wang)是黏(nian)糊糊的(de)(de)，在加(jia)(jia)工(gong)(gong)過(guo)程(cheng)中(zhong)不但變黑(hei)而且難(nan)以(yi)清(qing)洗(xi)。另外，其(qi)中(zhong)多數情(qing)況下加(jia)(jia)入氯(lv)系(xi)列添加(jia)(jia)劑。因(yin)此，更有必要進(jin)行充分地清(qing)洗(xi)。近年來，開(kai)發了(le)許(xu)多水溶(rong)(rong)性加(jia)(jia)工(gong)(gong)油，在深拉深等加(jia)(jia)工(gong)(gong)中(zhong)，其(qi)潤滑性堪(kan)比原用(yong)(yong)油性的(de)(de)加(jia)(jia)工(gong)(gong)油。水溶(rong)(rong)性加(jia)(jia)工(gong)(gong)油比較容易清(qing)洗(xi)，應用(yong)(yong)效果很好。作為新(xin)技術，雖然加(jia)(jia)工(gong)(gong)條件受(shou)到某種(zhong)程(cheng)度的(de)(de)限制(zhi)，免清(qing)洗(xi)的(de)(de)揮(hui)發型(xing)加(jia)(jia)工(gong)(gong)油仍得(de)到推廣(guang)。
在揮(hui)發(fa)(fa)性加(jia)工(gong)油(you)中，有完全(quan)揮(hui)發(fa)(fa)型(xing)(xing)和部(bu)分殘留型(xing)(xing)等(deng)產品。需根據加(jia)工(gong)條件選擇(ze)，使用完全(quan)揮(hui)發(fa)(fa)型(xing)(xing)的可以省掉加(jia)工(gong)后(hou)的清洗(xi)。在家電(dian)生產廠中，沖制全(quan)自動洗(xi)衣機(ji)不銹鋼洗(xi)衣桶時就(jiu)是采用完全(quan)揮(hui)發(fa)(fa)型(xing)(xing)加(jia)工(gong)油(you)。在其他領(ling)域中，完全(quan)揮(hui)發(fa)(fa)型(xing)(xing)加(jia)工(gong)油(you)已實際運用到沖孔、內緣翻邊、壓制筋板、彎(wan)曲和卷邊等(deng)沖壓工(gong)藝(yi)中。
由(you)于(yu)使用揮(hui)發性加(jia)工(gong)(gong)(gong)油可(ke)以(yi)(yi)省(sheng)掉(diao)清洗(xi)工(gong)(gong)(gong)序，在流水加(jia)工(gong)(gong)(gong)作業(ye)線上使用，可(ke)以(yi)(yi)降低(di)成本(ben)。主要(yao)生產(chan)廠(chang)家的揮(hui)發性加(jia)工(gong)(gong)(gong)油產(chan)品如表(biao)6-3所(suo)示。如將揮(hui)發性加(jia)工(gong)(gong)(gong)油的涂(tu)(tu)敷(fu)方式和加(jia)工(gong)(gong)(gong)條(tiao)件進行改進時，即(ji)可(ke)以(yi)(yi)完全省(sheng)掉(diao)清洗(xi)工(gong)(gong)(gong)作。但是，揮(hui)發性加(jia)工(gong)(gong)(gong)油涂(tu)(tu)敷(fu)方式、加(jia)工(gong)(gong)(gong)條(tiao)件及加(jia)工(gong)(gong)(gong)夾具的質量(liang)管(guan)理(li)不善(shan)時，由(you)于(yu)加(jia)工(gong)(gong)(gong)夾具的磨損等可(ke)能產(chan)生對不銹鋼的鐵粉銹蝕(shi)事故。關于(yu)鐵粉銹蝕(shi)檢查方法，可(ke)參照本(ben)書后部章節中的“使用時注意重占日惠執處(chu)理(li)”由(you)的說明。
先前在沖(chong)壓加(jia)工(gong)(gong)過程中(zhong)使用(yong)加(jia)工(gong)(gong)油(you)。為了洗凈(jing)(jing)這(zhe)些加(jia)工(gong)(gong)油(you)而使用(yong)了破壞臭氧層的(de)三氯乙烷，三氯乙烯等。后來，洗凈(jing)(jing)方法改為堿性洗凈(jing)(jing)方法。在1995年，考慮到保護地球(qiu)環境(jing)問題(ti)，開發了潤(run)(run)(run)滑(hua)(hua)不(bu)銹(xiu)鋼板。在汽車、電機、燃氣器具領域中(zhong)，積極(ji)推廣了省掉(diao)清洗工(gong)(gong)序(xu)的(de)潤(run)(run)(run)滑(hua)(hua)不(bu)銹(xiu)鋼板。特別是在汽車領域中(zhong)的(de)排氣分支管的(de)不(bu)銹(xiu)鋼化過程中(zhong)，實踐證明，加(jia)工(gong)(gong)這(zhe)種形狀復雜(za)的(de)工(gong)(gong)件，認(ren)為潤(run)(run)(run)滑(hua)(hua)不(bu)銹(xiu)鋼板比(bi)以前使用(yong)潤(run)(run)(run)滑(hua)(hua)油(you)的(de)加(jia)工(gong)(gong)性更優越(yue)。所以，潤(run)(run)(run)滑(hua)(hua)不(bu)銹(xiu)鋼板的(de)需要量大幅度(du)增加(jia)。
潤滑(hua)不(bu)(bu)銹(xiu)鋼板(ban)(ban)(ban)，根(gen)據用(yong)途亦有不(bu)(bu)涂(tu)薄膜(mo)(mo)(mo)(mo)(mo)的。非脫膜(mo)(mo)(mo)(mo)(mo)型和脫膜(mo)(mo)(mo)(mo)(mo)型兩類已經產品化(hua)了(le)。潤滑(hua)不(bu)(bu)銹(xiu)鋼板(ban)(ban)(ban)種類和特性如表6-4所(suo)示。在建筑材料領域中，使用(yong)潤滑(hua)不(bu)(bu)銹(xiu)鋼板(ban)(ban)(ban)做屋頂時，非脫膜(mo)(mo)(mo)(mo)(mo)型和脫膜(mo)(mo)(mo)(mo)(mo)型一樣，其薄膜(mo)(mo)(mo)(mo)(mo)經過1~2年的紫外線照射(she)就消失了(le)。作為工(gong)程(cheng)實例(li)，用(yong)于西武(wu)百貨(huo)大(da)樓和福岡機場候機大(da)廳。實踐證明，潤滑(hua)不(bu)(bu)銹(xiu)鋼板(ban)(ban)(ban)的加(jia)工(gong)性比加(jia)工(gong)油還要優越(yue)，見表6-5。
不銹(xiu)(xiu)鋼(gang)板生產廠(chang)家(jia)的潤滑不銹(xiu)(xiu)鋼(gang)板產品(pin)，在透明(ming)涂裝不銹(xiu)(xiu)鋼(gang)項目(mu)中有介紹。
