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. 平均r值－－塑(su)性(xing)為異向性(xing)的(de)材料深(shen)拉深(shen)成形特(te)性(xing)評(ping)價的(de)重(zhong)要指標。鐵(tie)素體系列不銹鋼中，其(qi)平均r值越(yue)大(da)，其(qi)極限拉深(shen)比就(jiu)越(yue)高。
c. 拉(la)深(shen)皺折(zhe)－鐵素體系列不銹鋼在(zai)沖床上進行(xing)深(shen)拉(la)深(shen)加工時(shi)，在(zai)其表(biao)面上容易產(chan)生凹凸不平的皺折(zhe)。可認(ren)為是組合結(jie)構不同而(er)引起的塑性異向性。
d. 時效性(xing)斷裂－奧氏體(ti)系列不銹鋼SUS304等準穩定型奧氏體(ti)系列不銹鋼，在(zai)加(jia)工后(hou)有發生(sheng)時效性(xing)裂紋的現象。它與晶界晶粒無關。一般認為是由于加(jia)工感(gan)應而引起的馬氏體(ti)、氫和殘(can)余(yu)應力所致。
1. 沖壓加工
沖(chong)壓加(jia)工(gong)(gong)(gong)行(xing)業是(shi)(shi)家(jia)庭式作(zuo)坊工(gong)(gong)(gong)業的(de)(de)(de)(de)(de)代表性(xing)產(chan)(chan)業，多是(shi)(shi)從(cong)單獨一個(ge)(ge)一個(ge)(ge)地加(jia)工(gong)(gong)(gong)西餐(can)具(ju)、器(qi)皿等(deng)所謂的(de)(de)(de)(de)(de)“洋人筷子”等(deng)開(kai)始，發(fa)展到餐(can)飲業的(de)(de)(de)(de)(de)廚房用(yong)具(ju)以(yi)及廚房中所使(shi)用(yong)的(de)(de)(de)(de)(de)水槽(cao)、洗(xi)滌盆、深(shen)(shen)(shen)拉(la)深(shen)(shen)(shen)加(jia)工(gong)(gong)(gong)的(de)(de)(de)(de)(de)澡盆以(yi)及汽車、電機領(ling)域(yu)中的(de)(de)(de)(de)(de)零部(bu)件等(deng)。主要工(gong)(gong)(gong)藝方法(fa)是(shi)(shi)采(cai)用(yong)剪(jian)切、沖(chong)孔、拉(la)深(shen)(shen)(shen)等(deng)進(jin)行(xing)連續加(jia)工(gong)(gong)(gong)。洋餐(can)具(ju)、器(qi)皿和鍋的(de)(de)(de)(de)(de)沖(chong)壓加(jia)工(gong)(gong)(gong)，基本上(shang)是(shi)(shi)屬于(yu)圓筒(tong)拉(la)深(shen)(shen)(shen)制成。原材料(liao)板(ban)直徑D對容器(qi)（產(chan)(chan)品）直徑d之(zhi)比(bi)，D/d稱(cheng)(cheng)為(wei)拉(la)深(shen)(shen)(shen)比(bi)。以(yi)可(ke)能拉(la)深(shen)(shen)(shen)的(de)(de)(de)(de)(de)最(zui)大原材料(liao)板(ban)直徑為(wei)Dmax時，則Dmax/d稱(cheng)(cheng)為(wei)極限拉(la)深(shen)(shen)(shen)比(bi)（LDR: Limiting Drawing Ratio)作(zuo)為(wei)衡量加(jia)工(gong)(gong)(gong)性(xing)的(de)(de)(de)(de)(de)指標。不(bu)銹鋼產(chan)(chan)品得以(yi)大幅度的(de)(de)(de)(de)(de)增加(jia)需求與沖(chong)壓加(jia)工(gong)(gong)(gong)技(ji)術(shu)的(de)(de)(de)(de)(de)發(fa)展有很(hen)大關系。不(bu)銹鋼產(chan)(chan)品生產(chan)(chan)廠家(jia)在深(shen)(shen)(shen)拉(la)深(shen)(shen)(shen)加(jia)工(gong)(gong)(gong)等(deng)方面，由于(yu)塑性(xing)加(jia)工(gong)(gong)(gong)技(ji)術(shu)和材料(liao)技(ji)術(shu)的(de)(de)(de)(de)(de)進(jin)展。使(shi)得鐵素體系列不(bu)銹鋼高加(jia)工(gong)(gong)(gong)性(xing)鋼種，已經產(chan)(chan)品化了。可(ke)以(yi)選(xuan)定平(ping)均(jun)r值在1.2~1.8,LDR為(wei)2.2~2.5的(de)(de)(de)(de)(de)鋼種。
在不(bu)銹(xiu)鋼制品(pin)的(de)(de)沖壓加(jia)工中(zhong)，如果(guo)使用奧氏體(ti)系(xi)列不(bu)銹(xiu)鋼或鐵素體(ti)系(xi)列不(bu)銹(xiu)鋼的(de)(de)高加(jia)工性(xing)能(neng)鋼種(zhong)時，可以(yi)進行(xing)一定程度的(de)(de)深(shen)(shen)拉(la)深(shen)(shen)加(jia)工。奧氏體(ti)系(xi)列不(bu)銹(xiu)鋼的(de)(de)代表型鋼種(zhong) SUS 304(18Cr -18Ni),因(yin)為它(ta)的(de)(de)LDR為2.5,可以(yi)進行(xing)相對較大的(de)(de)深(shen)(shen)拉(la)深(shen)(shen)加(jia)工。
但由于(yu)加工(gong)(gong)硬化(hua)傾向大而急劇(ju)地增加了(le)加工(gong)(gong)難度，有(you)時竟發生(sheng)裂紋或斷(duan)裂。為此，沖壓廠家(jia)就(jiu)在中間加上一(yi)道(dao)熱處理工(gong)(gong)序之后(hou)(hou)再進行深(shen)拉(la)深(shen)加工(gong)(gong)。還必須注(zhu)意，奧氏體系(xi)列不銹鋼的(de)奧氏體穩定度低的(de)鋼種經過拉(la)深(shen)后(hou)(hou)，有(you)可能發生(sheng)時效斷(duan)裂現象(xiang)。
近(jin)年來，新潟縣燕(yan)市的沖(chong)(chong)壓(ya)加工(gong)廠和新鴻(hong)縣工(gong)業(ye)技術(shu)中(zhong)心(xin)共同(tong)開發(fa)不銹(xiu)鋼(gang)熱(re)沖(chong)(chong)壓(ya)技術(shu)，實現了(le)超深(shen)拉(la)深(shen)加工(gong)。熱(re)沖(chong)(chong)壓(ya)技術(shu)就(jiu)是將凹模(mo)或者凸模(mo)其中(zhong)之(zhi)一進(jin)行(xing)加熱(re)，這樣(yang)不銹(xiu)鋼(gang)原來的拉(la)深(shen)程度就(jiu)可(ke)以提高1.5~2.0倍。熱(re)沖(chong)(chong)壓(ya)加工(gong)設備的工(gong)作(zuo)原理如圖(tu)6-9所(suo)示(shi)(shi)。其加工(gong)特性如圖(tu)6-10所(suo)示(shi)(shi)。
2. 彎曲與連續沖裁
奧氏體(ti)(ti)系列(lie)不(bu)(bu)銹鋼(gang)(gang)進行彎(wan)(wan)(wan)(wan)曲(qu)(qu)加(jia)(jia)(jia)(jia)(jia)工(gong)(gong)(gong)是件(jian)簡單(dan)之事，可以(yi)制(zhi)(zhi)作(zuo)角鋼(gang)(gang)、槽鋼(gang)(gang)等型材(cai)使用(yong)(yong)。鐵素體(ti)(ti)系列(lie)，馬(ma)氏體(ti)(ti)系列(lie)不(bu)(bu)銹鋼(gang)(gang)作(zuo)為(wei)型材(cai)加(jia)(jia)(jia)(jia)(jia)工(gong)(gong)(gong)，一(yi)(yi)般(ban)情況下沒有(you)問(wen)題，但當彎(wan)(wan)(wan)(wan)曲(qu)(qu)半徑R小的(de)(de)(de)時候，在(zai)折(zhe)彎(wan)(wan)(wan)(wan)處有(you)時會發(fa)(fa)生(sheng)斷(duan)裂。在(zai)JIS標準中(zhong)(zhong)，對鐵素體(ti)(ti)、馬(ma)氏體(ti)(ti)系列(lie)的(de)(de)(de)不(bu)(bu)銹鋼(gang)(gang)彎(wan)(wan)(wan)(wan)曲(qu)(qu)試(shi)驗標準規定，彎(wan)(wan)(wan)(wan)曲(qu)(qu)半徑R為(wei)1.0t(t為(wei)板(ban)材(cai)厚度）不(bu)(bu)應發(fa)(fa)生(sheng)彎(wan)(wan)(wan)(wan)曲(qu)(qu)斷(duan)裂。還有(you)，必須注(zhu)意(yi)不(bu)(bu)銹鋼(gang)(gang)彎(wan)(wan)(wan)(wan)曲(qu)(qu)加(jia)(jia)(jia)(jia)(jia)工(gong)(gong)(gong)回彈量大的(de)(de)(de)特點。落料(liao)（俗稱(cheng)下料(liao)）或稱(cheng)為(wei)沖(chong)(chong)(chong)裁加(jia)(jia)(jia)(jia)(jia)工(gong)(gong)(gong)，大多數是采用(yong)(yong)沖(chong)(chong)(chong)床連續加(jia)(jia)(jia)(jia)(jia)工(gong)(gong)(gong)的(de)(de)(de)方(fang)式，有(you)時在(zai)沖(chong)(chong)(chong)切斷(duan)面(mian)上，發(fa)(fa)生(sheng)塌(ta)邊(bian)現象（即沖(chong)(chong)(chong)切面(mian)與基(ji)準平面(mian)不(bu)(bu)垂直）。精密落料(liao)是從(cong)(cong)變(bian)壓(ya)(ya)器等使用(yong)(yong)疊層的(de)(de)(de)電(dian)磁鋼(gang)(gang)板(ban)的(de)(de)(de)加(jia)(jia)(jia)(jia)(jia)工(gong)(gong)(gong)技術(shu)開展起來(lai)的(de)(de)(de)技術(shu)，對粒子加(jia)(jia)(jia)(jia)(jia)速(su)器的(de)(de)(de)套環(huan)（collar)或電(dian)子零部件(jian)中(zhong)(zhong)的(de)(de)(de)引線框(kuang)（lead frame)等等，從(cong)(cong)較厚的(de)(de)(de)板(ban)材(cai)到超薄材(cai)，精密落料(liao)得到廣(guang)泛應用(yong)(yong)。沖(chong)(chong)(chong)壓(ya)(ya)加(jia)(jia)(jia)(jia)(jia)工(gong)(gong)(gong)機械(xie)亦可以(yi)進行精密沖(chong)(chong)(chong)壓(ya)(ya)（落料(liao)）加(jia)(jia)(jia)(jia)(jia)工(gong)(gong)(gong)，但由于沖(chong)(chong)(chong)壓(ya)(ya)塌(ta)邊(bian)的(de)(de)(de)問(wen)題，一(yi)(yi)般(ban)不(bu)(bu)能作(zuo)為(wei)成品直接(jie)使用(yong)(yong)。在(zai)精密沖(chong)(chong)(chong)壓(ya)(ya)中(zhong)(zhong)，為(wei)控制(zhi)(zhi)塌(ta)邊(bian)，就需(xu)加(jia)(jia)(jia)(jia)(jia)一(yi)(yi)道(dao)機械(xie)控制(zhi)(zhi)的(de)(de)(de)工(gong)(gong)(gong)藝措施，這(zhe)需(xu)要(yao)按產品用(yong)(yong)途以(yi)及成本兩方(fang)面(mian)來(lai)權衡(heng)。在(zai)加(jia)(jia)(jia)(jia)(jia)工(gong)(gong)(gong)方(fang)法競爭上，還有(you)一(yi)(yi)種“蝕刻”方(fang)法，在(zai)電(dian)子產品的(de)(de)(de)接(jie)線框(kuang)等超薄產品中(zhong)(zhong)，在(zai)加(jia)(jia)(jia)(jia)(jia)工(gong)(gong)(gong)廠家的(de)(de)(de)技術(shu)競爭中(zhong)(zhong)，兩者幾乎各占(zhan)一(yi)(yi)半。
3. 加工油、表面保護薄(bo)膜和其他潤(run)滑
a. 表(biao)面保護薄膜－為了保持不銹鋼的匠藝性、防(fang)止產生瑕疵以及作為潤滑而敷于材(cai)料表(biao)面的聚氯乙烯或(huo)聚乙烯等薄膜。
b. 揮發(fa)性加(jia)(jia)工(gong)油－－加(jia)(jia)工(gong)時(shi)有(you)潤滑效果而后又能揮發(fa)掉(diao)的加(jia)(jia)工(gong)油。使(shi)用完全揮發(fa)型的，可(ke)以省掉(diao)清(qing)洗工(gong)序。
c. 潤滑不銹鋼(gang)板－具有透(tou)明石蠟涂裝的不銹鋼(gang)，它比(bi)加(jia)工油或表面保(bao)護膜有更好的加(jia)工性。
在沖床上進(jin)(jin)行(xing)不銹鋼(gang)板(ban)彎曲、沖裁(cai)（落料）等(deng)加工(gong)(gong)(gong)(gong)時，可使(shi)(shi)用(yong)(yong)(yong)(yong)加工(gong)(gong)(gong)(gong)油、表(biao)面(mian)(mian)保護薄(bo)膜(mo)(mo)或(huo)直接使(shi)(shi)用(yong)(yong)(yong)(yong)潤(run)滑鋼(gang)板(ban)。在表(biao)6-1中(zhong)，對加工(gong)(gong)(gong)(gong)油、表(biao)面(mian)(mian)保護薄(bo)膜(mo)(mo)和潤(run)滑鋼(gang)板(ban)進(jin)(jin)行(xing)比(bi)較。表(biao)面(mian)(mian)保護薄(bo)膜(mo)(mo)是(shi)不銹鋼(gang)保持匠藝性的(de)(de)一項重(zhong)要措施(shi)。所用(yong)(yong)(yong)(yong)樹脂為聚氯(lv)乙(yi)烯(xi)系列或(huo)聚乙(yi)烯(xi)系列。材(cai)料運轉(zhuan)自始(shi)至終都是(shi)用(yong)(yong)(yong)(yong)表(biao)面(mian)(mian)保護薄(bo)膜(mo)(mo)對材(cai)料表(biao)面(mian)(mian)施(shi)行(xing)保護。使(shi)(shi)用(yong)(yong)(yong)(yong)表(biao)面(mian)(mian)保護薄(bo)膜(mo)(mo)，最(zui)容易(yi)發生(sheng)的(de)(de)問題(ti)就是(shi)殘留(liu)糊狀(zhuang)物，貼附(fu)后長期保存在倉庫內的(de)(de)或(huo)者是(shi)不具備耐候性能的(de)(de)薄(bo)膜(mo)(mo)放置在室外的(de)(de)，則容易(yi)發生(sheng)損壞。表(biao)面(mian)(mian)保護薄(bo)膜(mo)(mo)要根據用(yong)(yong)(yong)(yong)途和加工(gong)(gong)(gong)(gong)方法選定。主要廠家生(sheng)產的(de)(de)表(biao)面(mian)(mian)保護薄(bo)膜(mo)(mo)性能及其(qi)有關事項如表(biao)6-2所示。不使(shi)(shi)用(yong)(yong)(yong)(yong)表(biao)面(mian)(mian)保護薄(bo)膜(mo)(mo)時，一般(ban)情況(kuang)下要使(shi)(shi)用(yong)(yong)(yong)(yong)加工(gong)(gong)(gong)(gong)油。當(dang)使(shi)(shi)用(yong)(yong)(yong)(yong)加工(gong)(gong)(gong)(gong)油加工(gong)(gong)(gong)(gong)后，需進(jin)(jin)行(xing)洗(xi)凈。洗(xi)凈的(de)(de)方法有多種，最(zui)近在保護地球環境問題(ti)當(dang)中(zhong)，規定了保護環境條例，對于破壞臭氧層(ceng)的(de)(de)清(qing)洗(xi)劑做出了限(xian)制。
因(yin)此，當(dang)使用(yong)加(jia)(jia)(jia)工(gong)油(you)(you)時(shi)，要考慮到(dao)洗凈(jing)和存放問題。在(zai)加(jia)(jia)(jia)工(gong)油(you)(you)選定方面(mian)，從前(qian)認為由于不銹鋼硬度比(bi)普通鋼要高，加(jia)(jia)(jia)工(gong)不銹鋼比(bi)普通鋼困難，所以要選用(yong)有(you)(you)黏性(xing)的(de)加(jia)(jia)(jia)工(gong)油(you)(you)。具有(you)(you)黏性(xing)的(de)加(jia)(jia)(jia)工(gong)油(you)(you)往往是(shi)黏糊(hu)糊(hu)的(de)，在(zai)加(jia)(jia)(jia)工(gong)過程中(zhong)不但變(bian)黑而且難以清(qing)洗。另外，其中(zhong)多(duo)數情況下加(jia)(jia)(jia)入氯(lv)系(xi)列添加(jia)(jia)(jia)劑(ji)。因(yin)此，更有(you)(you)必要進行充分地清(qing)洗。近(jin)年來，開發(fa)了許多(duo)水(shui)溶(rong)(rong)性(xing)加(jia)(jia)(jia)工(gong)油(you)(you)，在(zai)深拉深等加(jia)(jia)(jia)工(gong)中(zhong)，其潤滑性(xing)堪比(bi)原用(yong)油(you)(you)性(xing)的(de)加(jia)(jia)(jia)工(gong)油(you)(you)。水(shui)溶(rong)(rong)性(xing)加(jia)(jia)(jia)工(gong)油(you)(you)比(bi)較(jiao)容易清(qing)洗，應用(yong)效(xiao)果很好。作(zuo)為新技術(shu)，雖(sui)然(ran)加(jia)(jia)(jia)工(gong)條件受到(dao)某種程度的(de)限制，免清(qing)洗的(de)揮發(fa)型加(jia)(jia)(jia)工(gong)油(you)(you)仍得到(dao)推廣。
在揮(hui)發性加(jia)工(gong)(gong)油中，有完全(quan)(quan)揮(hui)發型和(he)部(bu)分殘(can)留型等產品(pin)。需(xu)根(gen)據加(jia)工(gong)(gong)條件選擇，使用(yong)完全(quan)(quan)揮(hui)發型的可以省掉加(jia)工(gong)(gong)后的清洗。在家電生產廠中，沖(chong)制全(quan)(quan)自動洗衣(yi)機不銹(xiu)鋼洗衣(yi)桶(tong)時就是采用(yong)完全(quan)(quan)揮(hui)發型加(jia)工(gong)(gong)油。在其(qi)他領域中，完全(quan)(quan)揮(hui)發型加(jia)工(gong)(gong)油已實際(ji)運用(yong)到沖(chong)孔、內緣翻邊(bian)、壓(ya)制筋板(ban)、彎曲(qu)和(he)卷(juan)邊(bian)等沖(chong)壓(ya)工(gong)(gong)藝中。
由(you)于(yu)使用(yong)揮發(fa)性加(jia)(jia)(jia)工(gong)(gong)(gong)油(you)可(ke)以(yi)(yi)省掉(diao)清洗(xi)工(gong)(gong)(gong)序，在流水加(jia)(jia)(jia)工(gong)(gong)(gong)作業線上使用(yong)，可(ke)以(yi)(yi)降(jiang)低(di)成本(ben)(ben)。主要生產(chan)廠家(jia)的揮發(fa)性加(jia)(jia)(jia)工(gong)(gong)(gong)油(you)產(chan)品(pin)如表6-3所示。如將揮發(fa)性加(jia)(jia)(jia)工(gong)(gong)(gong)油(you)的涂(tu)敷方式(shi)和加(jia)(jia)(jia)工(gong)(gong)(gong)條(tiao)件進(jin)行改進(jin)時，即可(ke)以(yi)(yi)完(wan)全省掉(diao)清洗(xi)工(gong)(gong)(gong)作。但是，揮發(fa)性加(jia)(jia)(jia)工(gong)(gong)(gong)油(you)涂(tu)敷方式(shi)、加(jia)(jia)(jia)工(gong)(gong)(gong)條(tiao)件及加(jia)(jia)(jia)工(gong)(gong)(gong)夾具的質(zhi)量管理(li)不善時，由(you)于(yu)加(jia)(jia)(jia)工(gong)(gong)(gong)夾具的磨(mo)損(sun)等(deng)可(ke)能產(chan)生對不銹(xiu)鋼的鐵(tie)粉銹(xiu)蝕事(shi)故。關(guan)于(yu)鐵(tie)粉銹(xiu)蝕檢查方法，可(ke)參照本(ben)(ben)書后部章節中的“使用(yong)時注意(yi)重占(zhan)日惠執(zhi)處(chu)理(li)”由(you)的說明。
先(xian)前在(zai)(zai)沖壓加工(gong)(gong)過程中使(shi)用加工(gong)(gong)油(you)。為(wei)了(le)洗(xi)凈這(zhe)些加工(gong)(gong)油(you)而使(shi)用了(le)破(po)壞臭氧層的(de)(de)(de)三氯乙烷，三氯乙烯等。后來(lai)，洗(xi)凈方法(fa)改為(wei)堿性(xing)洗(xi)凈方法(fa)。在(zai)(zai)1995年，考慮到保(bao)護地球環境問題，開(kai)發了(le)潤(run)(run)滑不銹鋼(gang)板(ban)。在(zai)(zai)汽(qi)車(che)、電機、燃氣器具領域中，積極推(tui)廣了(le)省掉(diao)清(qing)洗(xi)工(gong)(gong)序的(de)(de)(de)潤(run)(run)滑不銹鋼(gang)板(ban)。特別是(shi)在(zai)(zai)汽(qi)車(che)領域中的(de)(de)(de)排氣分支管的(de)(de)(de)不銹鋼(gang)化過程中，實踐(jian)證明(ming)，加工(gong)(gong)這(zhe)種形(xing)狀復(fu)雜的(de)(de)(de)工(gong)(gong)件，認為(wei)潤(run)(run)滑不銹鋼(gang)板(ban)比以(yi)前使(shi)用潤(run)(run)滑油(you)的(de)(de)(de)加工(gong)(gong)性(xing)更優(you)越。所以(yi)，潤(run)(run)滑不銹鋼(gang)板(ban)的(de)(de)(de)需要量(liang)大幅(fu)度(du)增加。
潤(run)滑(hua)不(bu)銹鋼板(ban)，根據用途亦(yi)有不(bu)涂薄膜(mo)(mo)的。非脫(tuo)膜(mo)(mo)型(xing)和(he)脫(tuo)膜(mo)(mo)型(xing)兩類(lei)已經(jing)(jing)產(chan)品化了(le)。潤(run)滑(hua)不(bu)銹鋼板(ban)種類(lei)和(he)特(te)性如表6-4所(suo)示。在(zai)建筑材(cai)料領域中，使用潤(run)滑(hua)不(bu)銹鋼板(ban)做屋頂(ding)時，非脫(tuo)膜(mo)(mo)型(xing)和(he)脫(tuo)膜(mo)(mo)型(xing)一樣，其薄膜(mo)(mo)經(jing)(jing)過1~2年的紫外(wai)線(xian)照(zhao)射就消(xiao)失了(le)。作為工程實(shi)例，用于西武百(bai)貨(huo)大樓(lou)和(he)福岡機場候(hou)機大廳。實(shi)踐證明，潤(run)滑(hua)不(bu)銹鋼板(ban)的加(jia)工性比(bi)加(jia)工油還(huan)要優越，見表6-5。
不(bu)銹鋼(gang)(gang)板生產廠家(jia)的潤滑不(bu)銹鋼(gang)(gang)板產品，在透明(ming)涂裝不(bu)銹鋼(gang)(gang)項目中有介紹。
