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(zhi)－－塑性為異(yi)向性的(de)材料深(shen)拉(la)深(shen)成形特性評價的(de)重(zhong)要指標。鐵素體系列不銹鋼(gang)中，其(qi)平均r值(zhi)越大，其(qi)極(ji)限拉(la)深(shen)比就越高(gao)。
c. 拉(la)深(shen)皺折－鐵素體系列不銹鋼在(zai)沖床上(shang)進(jin)行(xing)深(shen)拉(la)深(shen)加工時，在(zai)其(qi)表面上(shang)容易產生(sheng)凹凸不平的皺折。可認為(wei)是組合結構不同而(er)引起的塑性異(yi)向性。
d. 時效性(xing)斷裂－奧氏體系(xi)列(lie)不銹(xiu)鋼SUS304等準穩定型奧氏體系(xi)列(lie)不銹(xiu)鋼，在(zai)加工后有發生時效性(xing)裂紋的(de)現象。它與晶界(jie)晶粒無關。一般認為是由于加工感應而(er)引起的(de)馬(ma)氏體、氫(qing)和殘余應力所致。
1. 沖壓加工
沖(chong)壓加(jia)工(gong)(gong)(gong)(gong)(gong)(gong)行業(ye)是(shi)家庭式作坊(fang)工(gong)(gong)(gong)(gong)(gong)(gong)業(ye)的(de)(de)代表性產(chan)業(ye)，多是(shi)從單獨一個一個地加(jia)工(gong)(gong)(gong)(gong)(gong)(gong)西餐具、器(qi)皿等(deng)(deng)所謂(wei)的(de)(de)“洋人筷子”等(deng)(deng)開始，發(fa)(fa)展(zhan)(zhan)到餐飲業(ye)的(de)(de)廚房(fang)用具以(yi)及(ji)廚房(fang)中所使用的(de)(de)水槽、洗(xi)滌盆、深(shen)拉(la)(la)深(shen)加(jia)工(gong)(gong)(gong)(gong)(gong)(gong)的(de)(de)澡(zao)盆以(yi)及(ji)汽車、電(dian)機(ji)領域中的(de)(de)零部件(jian)等(deng)(deng)。主要工(gong)(gong)(gong)(gong)(gong)(gong)藝方法是(shi)采用剪切(qie)、沖(chong)孔、拉(la)(la)深(shen)等(deng)(deng)進行連續加(jia)工(gong)(gong)(gong)(gong)(gong)(gong)。洋餐具、器(qi)皿和(he)鍋的(de)(de)沖(chong)壓加(jia)工(gong)(gong)(gong)(gong)(gong)(gong)，基本上是(shi)屬于圓筒拉(la)(la)深(shen)制成。原(yuan)材(cai)料(liao)(liao)板直徑(jing)(jing)D對容器(qi)（產(chan)品(pin)(pin)）直徑(jing)(jing)d之(zhi)比(bi)，D/d稱為拉(la)(la)深(shen)比(bi)。以(yi)可能拉(la)(la)深(shen)的(de)(de)最大(da)(da)原(yuan)材(cai)料(liao)(liao)板直徑(jing)(jing)為Dmax時，則Dmax/d稱為極限(xian)拉(la)(la)深(shen)比(bi)（LDR: Limiting Drawing Ratio)作為衡量加(jia)工(gong)(gong)(gong)(gong)(gong)(gong)性的(de)(de)指標。不銹(xiu)鋼(gang)產(chan)品(pin)(pin)得以(yi)大(da)(da)幅(fu)度的(de)(de)增加(jia)需求(qiu)與沖(chong)壓加(jia)工(gong)(gong)(gong)(gong)(gong)(gong)技術的(de)(de)發(fa)(fa)展(zhan)(zhan)有(you)很大(da)(da)關系。不銹(xiu)鋼(gang)產(chan)品(pin)(pin)生產(chan)廠(chang)家在(zai)深(shen)拉(la)(la)深(shen)加(jia)工(gong)(gong)(gong)(gong)(gong)(gong)等(deng)(deng)方面，由于塑(su)性加(jia)工(gong)(gong)(gong)(gong)(gong)(gong)技術和(he)材(cai)料(liao)(liao)技術的(de)(de)進展(zhan)(zhan)。使得鐵素(su)體系列不銹(xiu)鋼(gang)高加(jia)工(gong)(gong)(gong)(gong)(gong)(gong)性鋼(gang)種(zhong)，已經(jing)產(chan)品(pin)(pin)化了。可以(yi)選定平均r值在(zai)1.2~1.8,LDR為2.2~2.5的(de)(de)鋼(gang)種(zhong)。
在(zai)不(bu)(bu)銹鋼(gang)制(zhi)品的沖壓(ya)加工(gong)中，如果使用奧氏體(ti)系列不(bu)(bu)銹鋼(gang)或鐵素體(ti)系列不(bu)(bu)銹鋼(gang)的高加工(gong)性能鋼(gang)種(zhong)時，可以進行一定程度的深(shen)拉深(shen)加工(gong)。奧氏體(ti)系列不(bu)(bu)銹鋼(gang)的代表型鋼(gang)種(zhong) SUS 304(18Cr -18Ni),因為它的LDR為2.5,可以進行相對較大的深(shen)拉深(shen)加工(gong)。
但由(you)于加(jia)工(gong)硬化傾向大而急劇地(di)增加(jia)了(le)加(jia)工(gong)難度(du)，有時(shi)竟發生(sheng)裂紋或斷裂。為此，沖壓廠家(jia)就(jiu)在中間加(jia)上一道熱(re)處理工(gong)序(xu)之(zhi)后(hou)再進行(xing)深拉(la)深加(jia)工(gong)。還必須注意，奧氏體(ti)系列不銹鋼(gang)的奧氏體(ti)穩定度(du)低的鋼(gang)種經過拉(la)深后(hou)，有可能發生(sheng)時(shi)效斷裂現象。
近年來，新(xin)潟縣(xian)燕市的(de)沖(chong)(chong)壓加(jia)(jia)工廠和新(xin)鴻(hong)縣(xian)工業技術中(zhong)心(xin)共同開發不銹(xiu)鋼(gang)熱(re)(re)沖(chong)(chong)壓技術，實現了超(chao)深拉(la)深加(jia)(jia)工。熱(re)(re)沖(chong)(chong)壓技術就(jiu)是將凹模或者凸模其(qi)(qi)中(zhong)之一(yi)進行加(jia)(jia)熱(re)(re)，這樣(yang)不銹(xiu)鋼(gang)原來的(de)拉(la)深程度(du)就(jiu)可以(yi)提高1.5~2.0倍。熱(re)(re)沖(chong)(chong)壓加(jia)(jia)工設備的(de)工作原理如圖6-9所示。其(qi)(qi)加(jia)(jia)工特性如圖6-10所示。
2. 彎曲與(yu)連續沖裁
奧氏(shi)(shi)體(ti)系(xi)(xi)(xi)列(lie)不(bu)(bu)銹(xiu)(xiu)鋼進行彎(wan)(wan)(wan)(wan)曲加(jia)(jia)(jia)工(gong)(gong)是件簡單之事，可(ke)以制(zhi)作(zuo)角鋼、槽鋼等(deng)型材(cai)(cai)使(shi)用(yong)(yong)(yong)。鐵素體(ti)系(xi)(xi)(xi)列(lie)，馬氏(shi)(shi)體(ti)系(xi)(xi)(xi)列(lie)不(bu)(bu)銹(xiu)(xiu)鋼作(zuo)為(wei)型材(cai)(cai)加(jia)(jia)(jia)工(gong)(gong)，一(yi)般情況(kuang)下沒有(you)問(wen)題(ti)，但當(dang)彎(wan)(wan)(wan)(wan)曲半徑R小(xiao)的(de)(de)(de)時(shi)候，在(zai)折彎(wan)(wan)(wan)(wan)處有(you)時(shi)會發生斷裂。在(zai)JIS標(biao)準中，對鐵素體(ti)、馬氏(shi)(shi)體(ti)系(xi)(xi)(xi)列(lie)的(de)(de)(de)不(bu)(bu)銹(xiu)(xiu)鋼彎(wan)(wan)(wan)(wan)曲試(shi)驗標(biao)準規定，彎(wan)(wan)(wan)(wan)曲半徑R為(wei)1.0t(t為(wei)板(ban)(ban)(ban)材(cai)(cai)厚度）不(bu)(bu)應發生彎(wan)(wan)(wan)(wan)曲斷裂。還(huan)有(you)，必須注意(yi)不(bu)(bu)銹(xiu)(xiu)鋼彎(wan)(wan)(wan)(wan)曲加(jia)(jia)(jia)工(gong)(gong)回彈量大的(de)(de)(de)特(te)點。落料(liao)（俗稱下料(liao)）或稱為(wei)沖(chong)裁加(jia)(jia)(jia)工(gong)(gong)，大多數是采用(yong)(yong)(yong)沖(chong)床連續(xu)加(jia)(jia)(jia)工(gong)(gong)的(de)(de)(de)方式，有(you)時(shi)在(zai)沖(chong)切斷面上(shang)，發生塌邊現象（即沖(chong)切面與(yu)基準平面不(bu)(bu)垂(chui)直(zhi)）。精(jing)密(mi)落料(liao)是從變(bian)壓器等(deng)使(shi)用(yong)(yong)(yong)疊層(ceng)的(de)(de)(de)電磁鋼板(ban)(ban)(ban)的(de)(de)(de)加(jia)(jia)(jia)工(gong)(gong)技(ji)術(shu)開展起來的(de)(de)(de)技(ji)術(shu)，對粒子加(jia)(jia)(jia)速(su)器的(de)(de)(de)套(tao)環（collar)或電子零部件中的(de)(de)(de)引線(xian)框（lead frame)等(deng)等(deng)，從較(jiao)厚的(de)(de)(de)板(ban)(ban)(ban)材(cai)(cai)到(dao)超薄材(cai)(cai)，精(jing)密(mi)落料(liao)得到(dao)廣泛應用(yong)(yong)(yong)。沖(chong)壓加(jia)(jia)(jia)工(gong)(gong)機械亦可(ke)以進行精(jing)密(mi)沖(chong)壓（落料(liao)）加(jia)(jia)(jia)工(gong)(gong)，但由于沖(chong)壓塌邊的(de)(de)(de)問(wen)題(ti)，一(yi)般不(bu)(bu)能作(zuo)為(wei)成品(pin)直(zhi)接使(shi)用(yong)(yong)(yong)。在(zai)精(jing)密(mi)沖(chong)壓中，為(wei)控(kong)制(zhi)塌邊，就需加(jia)(jia)(jia)一(yi)道機械控(kong)制(zhi)的(de)(de)(de)工(gong)(gong)藝措(cuo)施，這(zhe)需要按產品(pin)用(yong)(yong)(yong)途以及成本兩方面來權(quan)衡(heng)。在(zai)加(jia)(jia)(jia)工(gong)(gong)方法(fa)競(jing)爭上(shang)，還(huan)有(you)一(yi)種“蝕刻”方法(fa)，在(zai)電子產品(pin)的(de)(de)(de)接線(xian)框等(deng)超薄產品(pin)中，在(zai)加(jia)(jia)(jia)工(gong)(gong)廠(chang)家(jia)的(de)(de)(de)技(ji)術(shu)競(jing)爭中，兩者(zhe)幾乎各占一(yi)半。
3. 加工油、表面保護薄膜和其他(ta)潤滑
a. 表(biao)面保(bao)護薄(bo)膜(mo)－為(wei)了保(bao)持不銹(xiu)鋼的匠藝性、防止產生瑕疵以及作為(wei)潤滑而(er)敷于材料表(biao)面的聚(ju)氯(lv)乙烯(xi)或(huo)聚(ju)乙烯(xi)等薄(bo)膜(mo)。
b. 揮(hui)發性(xing)加工(gong)(gong)油－－加工(gong)(gong)時有潤滑效果而后又能揮(hui)發掉的加工(gong)(gong)油。使用完全揮(hui)發型的，可(ke)以(yi)省掉清洗工(gong)(gong)序。
c. 潤(run)滑不(bu)銹(xiu)(xiu)鋼板(ban)－具有透明石蠟(la)涂裝的(de)不(bu)銹(xiu)(xiu)鋼，它比(bi)加(jia)(jia)工油或表(biao)面保護膜有更(geng)好的(de)加(jia)(jia)工性。
在(zai)(zai)沖床(chuang)上進(jin)(jin)行不銹鋼(gang)板(ban)彎曲、沖裁（落料(liao)(liao)）等加(jia)工(gong)(gong)時，可使(shi)用(yong)(yong)(yong)加(jia)工(gong)(gong)油(you)、表(biao)面(mian)保(bao)(bao)(bao)護(hu)(hu)(hu)薄(bo)(bo)(bo)膜(mo)或直接使(shi)用(yong)(yong)(yong)潤(run)滑(hua)鋼(gang)板(ban)。在(zai)(zai)表(biao)6-1中(zhong)，對(dui)加(jia)工(gong)(gong)油(you)、表(biao)面(mian)保(bao)(bao)(bao)護(hu)(hu)(hu)薄(bo)(bo)(bo)膜(mo)和潤(run)滑(hua)鋼(gang)板(ban)進(jin)(jin)行比較。表(biao)面(mian)保(bao)(bao)(bao)護(hu)(hu)(hu)薄(bo)(bo)(bo)膜(mo)是(shi)不銹鋼(gang)保(bao)(bao)(bao)持匠藝性的一項重要措施。所用(yong)(yong)(yong)樹脂為聚(ju)氯乙(yi)烯系(xi)列或聚(ju)乙(yi)烯系(xi)列。材(cai)料(liao)(liao)運轉自始至終都是(shi)用(yong)(yong)(yong)表(biao)面(mian)保(bao)(bao)(bao)護(hu)(hu)(hu)薄(bo)(bo)(bo)膜(mo)對(dui)材(cai)料(liao)(liao)表(biao)面(mian)施行保(bao)(bao)(bao)護(hu)(hu)(hu)。使(shi)用(yong)(yong)(yong)表(biao)面(mian)保(bao)(bao)(bao)護(hu)(hu)(hu)薄(bo)(bo)(bo)膜(mo)，最容(rong)易發生的問題就是(shi)殘留糊狀物，貼附后長期(qi)保(bao)(bao)(bao)存(cun)在(zai)(zai)倉庫內的或者是(shi)不具備耐候性能的薄(bo)(bo)(bo)膜(mo)放置在(zai)(zai)室外的，則容(rong)易發生損(sun)壞(huai)。表(biao)面(mian)保(bao)(bao)(bao)護(hu)(hu)(hu)薄(bo)(bo)(bo)膜(mo)要根據(ju)用(yong)(yong)(yong)途和加(jia)工(gong)(gong)方(fang)法選定(ding)(ding)。主要廠家生產的表(biao)面(mian)保(bao)(bao)(bao)護(hu)(hu)(hu)薄(bo)(bo)(bo)膜(mo)性能及(ji)其有關事(shi)項如表(biao)6-2所示。不使(shi)用(yong)(yong)(yong)表(biao)面(mian)保(bao)(bao)(bao)護(hu)(hu)(hu)薄(bo)(bo)(bo)膜(mo)時，一般(ban)情況下要使(shi)用(yong)(yong)(yong)加(jia)工(gong)(gong)油(you)。當使(shi)用(yong)(yong)(yong)加(jia)工(gong)(gong)油(you)加(jia)工(gong)(gong)后，需進(jin)(jin)行洗凈。洗凈的方(fang)法有多種，最近在(zai)(zai)保(bao)(bao)(bao)護(hu)(hu)(hu)地球(qiu)環(huan)(huan)境(jing)問題當中(zhong)，規定(ding)(ding)了保(bao)(bao)(bao)護(hu)(hu)(hu)環(huan)(huan)境(jing)條例，對(dui)于破壞(huai)臭(chou)氧層的清洗劑做出了限制。
因此(ci)，當(dang)使用加(jia)(jia)(jia)(jia)(jia)工(gong)(gong)(gong)(gong)油時，要考慮(lv)到(dao)(dao)洗(xi)凈(jing)和存(cun)放問題。在加(jia)(jia)(jia)(jia)(jia)工(gong)(gong)(gong)(gong)油選(xuan)定(ding)方面，從前(qian)認為由于(yu)不(bu)銹(xiu)鋼(gang)(gang)硬度比(bi)普(pu)通鋼(gang)(gang)要高，加(jia)(jia)(jia)(jia)(jia)工(gong)(gong)(gong)(gong)不(bu)銹(xiu)鋼(gang)(gang)比(bi)普(pu)通鋼(gang)(gang)困(kun)難(nan)(nan)，所以(yi)要選(xuan)用有(you)黏(nian)性(xing)(xing)(xing)(xing)的(de)加(jia)(jia)(jia)(jia)(jia)工(gong)(gong)(gong)(gong)油。具有(you)黏(nian)性(xing)(xing)(xing)(xing)的(de)加(jia)(jia)(jia)(jia)(jia)工(gong)(gong)(gong)(gong)油往往是黏(nian)糊糊的(de)，在加(jia)(jia)(jia)(jia)(jia)工(gong)(gong)(gong)(gong)過程(cheng)中(zhong)(zhong)不(bu)但(dan)變黑而且難(nan)(nan)以(yi)清(qing)洗(xi)。另(ling)外，其中(zhong)(zhong)多數情況(kuang)下加(jia)(jia)(jia)(jia)(jia)入氯系列添加(jia)(jia)(jia)(jia)(jia)劑。因此(ci)，更(geng)有(you)必(bi)要進行(xing)充分(fen)地清(qing)洗(xi)。近(jin)年來，開發了許多水溶性(xing)(xing)(xing)(xing)加(jia)(jia)(jia)(jia)(jia)工(gong)(gong)(gong)(gong)油，在深拉深等加(jia)(jia)(jia)(jia)(jia)工(gong)(gong)(gong)(gong)中(zhong)(zhong)，其潤滑性(xing)(xing)(xing)(xing)堪比(bi)原(yuan)用油性(xing)(xing)(xing)(xing)的(de)加(jia)(jia)(jia)(jia)(jia)工(gong)(gong)(gong)(gong)油。水溶性(xing)(xing)(xing)(xing)加(jia)(jia)(jia)(jia)(jia)工(gong)(gong)(gong)(gong)油比(bi)較(jiao)容易清(qing)洗(xi)，應(ying)用效果很好。作為新技術，雖然(ran)加(jia)(jia)(jia)(jia)(jia)工(gong)(gong)(gong)(gong)條件(jian)受到(dao)(dao)某種程(cheng)度的(de)限制，免清(qing)洗(xi)的(de)揮發型加(jia)(jia)(jia)(jia)(jia)工(gong)(gong)(gong)(gong)油仍得到(dao)(dao)推廣。
在(zai)揮發(fa)性加工(gong)油(you)中，有完(wan)全(quan)揮發(fa)型(xing)和部分殘留(liu)型(xing)等產品。需根(gen)據加工(gong)條件選擇，使用(yong)(yong)完(wan)全(quan)揮發(fa)型(xing)的可(ke)以省掉加工(gong)后的清(qing)洗。在(zai)家(jia)電(dian)生(sheng)產廠中，沖制(zhi)(zhi)全(quan)自動洗衣(yi)機不銹鋼洗衣(yi)桶(tong)時就是采用(yong)(yong)完(wan)全(quan)揮發(fa)型(xing)加工(gong)油(you)。在(zai)其他領域中，完(wan)全(quan)揮發(fa)型(xing)加工(gong)油(you)已實際運(yun)用(yong)(yong)到沖孔、內緣翻邊、壓制(zhi)(zhi)筋(jin)板、彎曲(qu)和卷邊等沖壓工(gong)藝(yi)中。
由(you)于(yu)使用揮(hui)(hui)發(fa)(fa)性加工(gong)(gong)油(you)可(ke)以(yi)(yi)省掉清洗工(gong)(gong)序，在流水加工(gong)(gong)作(zuo)業線(xian)上使用，可(ke)以(yi)(yi)降低(di)成(cheng)本(ben)。主(zhu)要生產(chan)廠(chang)家的(de)揮(hui)(hui)發(fa)(fa)性加工(gong)(gong)油(you)產(chan)品如(ru)(ru)表6-3所示。如(ru)(ru)將揮(hui)(hui)發(fa)(fa)性加工(gong)(gong)油(you)的(de)涂敷方式(shi)和加工(gong)(gong)條(tiao)件進(jin)行改進(jin)時(shi)(shi)，即可(ke)以(yi)(yi)完全省掉清洗工(gong)(gong)作(zuo)。但是(shi)，揮(hui)(hui)發(fa)(fa)性加工(gong)(gong)油(you)涂敷方式(shi)、加工(gong)(gong)條(tiao)件及(ji)加工(gong)(gong)夾具的(de)質量管理不善時(shi)(shi)，由(you)于(yu)加工(gong)(gong)夾具的(de)磨損等可(ke)能產(chan)生對不銹鋼的(de)鐵(tie)粉銹蝕事(shi)故。關于(yu)鐵(tie)粉銹蝕檢(jian)查方法(fa)，可(ke)參(can)照本(ben)書后部章節中(zhong)的(de)“使用時(shi)(shi)注意重占日惠(hui)執處理”由(you)的(de)說明(ming)。
先前在(zai)(zai)沖壓加工(gong)過(guo)程中(zhong)使用加工(gong)油。為了(le)(le)洗(xi)(xi)凈這些加工(gong)油而使用了(le)(le)破(po)壞臭(chou)氧(yang)層(ceng)的三(san)氯乙(yi)烷，三(san)氯乙(yi)烯(xi)等。后來，洗(xi)(xi)凈方法改(gai)為堿(jian)性(xing)洗(xi)(xi)凈方法。在(zai)(zai)1995年(nian)，考慮到保護地球環境問題，開發了(le)(le)潤(run)滑(hua)不銹(xiu)(xiu)鋼(gang)板(ban)。在(zai)(zai)汽車、電機、燃氣器具領域中(zhong)，積極推廣了(le)(le)省(sheng)掉清洗(xi)(xi)工(gong)序的潤(run)滑(hua)不銹(xiu)(xiu)鋼(gang)板(ban)。特別是(shi)在(zai)(zai)汽車領域中(zhong)的排氣分支管的不銹(xiu)(xiu)鋼(gang)化過(guo)程中(zhong)，實踐證(zheng)明，加工(gong)這種(zhong)形狀復雜的工(gong)件，認(ren)為潤(run)滑(hua)不銹(xiu)(xiu)鋼(gang)板(ban)比以前使用潤(run)滑(hua)油的加工(gong)性(xing)更(geng)優越。所(suo)以，潤(run)滑(hua)不銹(xiu)(xiu)鋼(gang)板(ban)的需要量(liang)大幅度增加。
潤滑(hua)不(bu)銹(xiu)鋼(gang)板(ban)(ban)，根據用(yong)途亦(yi)有不(bu)涂薄膜(mo)(mo)(mo)(mo)的。非脫(tuo)膜(mo)(mo)(mo)(mo)型和(he)脫(tuo)膜(mo)(mo)(mo)(mo)型兩類已經產品化了。潤滑(hua)不(bu)銹(xiu)鋼(gang)板(ban)(ban)種類和(he)特性如表(biao)6-4所示(shi)。在(zai)建筑材料領域中(zhong)，使用(yong)潤滑(hua)不(bu)銹(xiu)鋼(gang)板(ban)(ban)做(zuo)屋頂時，非脫(tuo)膜(mo)(mo)(mo)(mo)型和(he)脫(tuo)膜(mo)(mo)(mo)(mo)型一(yi)樣，其薄膜(mo)(mo)(mo)(mo)經過1~2年的紫(zi)外(wai)線照射就消失(shi)了。作為工(gong)(gong)程實(shi)例，用(yong)于西武百貨大樓和(he)福岡機(ji)場候機(ji)大廳。實(shi)踐證(zheng)明，潤滑(hua)不(bu)銹(xiu)鋼(gang)板(ban)(ban)的加工(gong)(gong)性比加工(gong)(gong)油還要優越，見表(biao)6-5。
不銹鋼板生產(chan)廠家的潤滑(hua)不銹鋼板產(chan)品，在(zai)透明涂(tu)裝不銹鋼項(xiang)目中有介紹。
