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(su)性為異向性的(de)材(cai)料深拉(la)(la)深成形特性評價(jia)的(de)重要指標。鐵素體(ti)系列不銹鋼中(zhong)，其(qi)平(ping)均r值(zhi)越大，其(qi)極限拉(la)(la)深比就越高。
c. 拉深(shen)皺折－鐵素體系列不銹鋼在沖床上(shang)進行深(shen)拉深(shen)加工時，在其表面上(shang)容易產生凹凸不平(ping)的皺折。可(ke)認為是組合結構不同而引(yin)起的塑性異向性。
d. 時(shi)效性(xing)斷(duan)裂－奧(ao)氏體系列不銹鋼SUS304等準穩定型奧(ao)氏體系列不銹鋼，在加工(gong)后有發生時(shi)效性(xing)裂紋的現(xian)象。它與晶(jing)(jing)界晶(jing)(jing)粒無關(guan)。一般認為是由于加工(gong)感應而引起的馬(ma)氏體、氫和(he)殘余應力(li)所致。
1. 沖壓加工
沖(chong)壓(ya)加(jia)(jia)(jia)工(gong)(gong)(gong)(gong)(gong)行業(ye)(ye)(ye)是(shi)(shi)家庭式作坊(fang)工(gong)(gong)(gong)(gong)(gong)業(ye)(ye)(ye)的代表性(xing)(xing)(xing)產(chan)業(ye)(ye)(ye)，多是(shi)(shi)從(cong)單獨一(yi)個一(yi)個地加(jia)(jia)(jia)工(gong)(gong)(gong)(gong)(gong)西餐(can)具、器(qi)皿(min)等(deng)所謂的“洋人筷子”等(deng)開始，發展(zhan)(zhan)到餐(can)飲(yin)業(ye)(ye)(ye)的廚(chu)房(fang)用(yong)具以(yi)及廚(chu)房(fang)中所使(shi)用(yong)的水槽、洗滌盆、深(shen)(shen)(shen)拉(la)深(shen)(shen)(shen)加(jia)(jia)(jia)工(gong)(gong)(gong)(gong)(gong)的澡盆以(yi)及汽車、電機領域中的零部件等(deng)。主要工(gong)(gong)(gong)(gong)(gong)藝方法是(shi)(shi)采用(yong)剪切、沖(chong)孔(kong)、拉(la)深(shen)(shen)(shen)等(deng)進行連(lian)續加(jia)(jia)(jia)工(gong)(gong)(gong)(gong)(gong)。洋餐(can)具、器(qi)皿(min)和(he)鍋的沖(chong)壓(ya)加(jia)(jia)(jia)工(gong)(gong)(gong)(gong)(gong)，基本上是(shi)(shi)屬(shu)于(yu)圓筒拉(la)深(shen)(shen)(shen)制(zhi)成。原材(cai)料(liao)板(ban)直(zhi)徑D對容器(qi)（產(chan)品）直(zhi)徑d之比(bi)，D/d稱為(wei)拉(la)深(shen)(shen)(shen)比(bi)。以(yi)可能拉(la)深(shen)(shen)(shen)的最(zui)大(da)原材(cai)料(liao)板(ban)直(zhi)徑為(wei)Dmax時，則Dmax/d稱為(wei)極限(xian)拉(la)深(shen)(shen)(shen)比(bi)（LDR: Limiting Drawing Ratio)作為(wei)衡量加(jia)(jia)(jia)工(gong)(gong)(gong)(gong)(gong)性(xing)(xing)(xing)的指標(biao)。不銹鋼(gang)(gang)產(chan)品得(de)以(yi)大(da)幅度的增(zeng)加(jia)(jia)(jia)需求(qiu)與沖(chong)壓(ya)加(jia)(jia)(jia)工(gong)(gong)(gong)(gong)(gong)技術的發展(zhan)(zhan)有很大(da)關(guan)系。不銹鋼(gang)(gang)產(chan)品生(sheng)產(chan)廠家在深(shen)(shen)(shen)拉(la)深(shen)(shen)(shen)加(jia)(jia)(jia)工(gong)(gong)(gong)(gong)(gong)等(deng)方面，由于(yu)塑(su)性(xing)(xing)(xing)加(jia)(jia)(jia)工(gong)(gong)(gong)(gong)(gong)技術和(he)材(cai)料(liao)技術的進展(zhan)(zhan)。使(shi)得(de)鐵素體系列(lie)不銹鋼(gang)(gang)高加(jia)(jia)(jia)工(gong)(gong)(gong)(gong)(gong)性(xing)(xing)(xing)鋼(gang)(gang)種(zhong)，已經產(chan)品化了。可以(yi)選定平均r值(zhi)在1.2~1.8,LDR為(wei)2.2~2.5的鋼(gang)(gang)種(zhong)。
在(zai)不銹鋼(gang)(gang)(gang)制品的(de)沖壓加(jia)工中，如果使用奧氏體系(xi)(xi)列不銹鋼(gang)(gang)(gang)或鐵素體系(xi)(xi)列不銹鋼(gang)(gang)(gang)的(de)高加(jia)工性能鋼(gang)(gang)(gang)種(zhong)時，可以進行一定(ding)程度的(de)深拉(la)(la)深加(jia)工。奧氏體系(xi)(xi)列不銹鋼(gang)(gang)(gang)的(de)代表型鋼(gang)(gang)(gang)種(zhong) SUS 304(18Cr -18Ni),因(yin)為它的(de)LDR為2.5,可以進行相對(dui)較大的(de)深拉(la)(la)深加(jia)工。
但由(you)于加(jia)工(gong)(gong)硬化(hua)傾向大而急劇地增加(jia)了(le)加(jia)工(gong)(gong)難度(du)，有(you)時竟(jing)發生(sheng)裂紋(wen)或斷裂。為此，沖(chong)壓廠家就在中(zhong)間加(jia)上一(yi)道熱處理工(gong)(gong)序之(zhi)后(hou)再進行深拉深加(jia)工(gong)(gong)。還必(bi)須注意，奧氏(shi)體系列不銹鋼(gang)的奧氏(shi)體穩(wen)定度(du)低的鋼(gang)種經過拉深后(hou)，有(you)可能發生(sheng)時效斷裂現(xian)象。
近(jin)年來(lai)，新(xin)潟縣燕市的沖(chong)(chong)壓(ya)(ya)加(jia)(jia)工(gong)(gong)(gong)廠和新(xin)鴻縣工(gong)(gong)(gong)業技(ji)(ji)術中心共同(tong)開發不銹鋼熱(re)沖(chong)(chong)壓(ya)(ya)技(ji)(ji)術，實現了超深拉深加(jia)(jia)工(gong)(gong)(gong)。熱(re)沖(chong)(chong)壓(ya)(ya)技(ji)(ji)術就是將凹模或者凸模其中之一進(jin)行加(jia)(jia)熱(re)，這樣不銹鋼原來(lai)的拉深程(cheng)度就可以提高1.5~2.0倍。熱(re)沖(chong)(chong)壓(ya)(ya)加(jia)(jia)工(gong)(gong)(gong)設備的工(gong)(gong)(gong)作原理如(ru)圖6-9所(suo)示(shi)(shi)。其加(jia)(jia)工(gong)(gong)(gong)特性(xing)如(ru)圖6-10所(suo)示(shi)(shi)。
2. 彎曲與連(lian)續沖裁(cai)
奧氏體系(xi)列(lie)不(bu)(bu)(bu)(bu)銹(xiu)鋼(gang)(gang)(gang)進(jin)行彎(wan)曲加(jia)(jia)(jia)工(gong)(gong)是(shi)件(jian)(jian)簡單之(zhi)事，可以制作角鋼(gang)(gang)(gang)、槽(cao)鋼(gang)(gang)(gang)等(deng)型(xing)材使(shi)用(yong)(yong)。鐵素體系(xi)列(lie)，馬(ma)氏體系(xi)列(lie)不(bu)(bu)(bu)(bu)銹(xiu)鋼(gang)(gang)(gang)作為(wei)(wei)(wei)型(xing)材加(jia)(jia)(jia)工(gong)(gong)，一(yi)(yi)般情況下沒有(you)問題，但當彎(wan)曲半徑R小的(de)時(shi)候，在(zai)(zai)折(zhe)彎(wan)處(chu)有(you)時(shi)會發(fa)生斷(duan)裂(lie)。在(zai)(zai)JIS標準中(zhong)(zhong)，對鐵素體、馬(ma)氏體系(xi)列(lie)的(de)不(bu)(bu)(bu)(bu)銹(xiu)鋼(gang)(gang)(gang)彎(wan)曲試驗標準規定，彎(wan)曲半徑R為(wei)(wei)(wei)1.0t(t為(wei)(wei)(wei)板(ban)(ban)材厚度）不(bu)(bu)(bu)(bu)應(ying)發(fa)生彎(wan)曲斷(duan)裂(lie)。還有(you)，必(bi)須注(zhu)意不(bu)(bu)(bu)(bu)銹(xiu)鋼(gang)(gang)(gang)彎(wan)曲加(jia)(jia)(jia)工(gong)(gong)回彈量大的(de)特點(dian)。落(luo)料(liao)(liao)（俗稱下料(liao)(liao)）或(huo)稱為(wei)(wei)(wei)沖(chong)裁加(jia)(jia)(jia)工(gong)(gong)，大多數是(shi)采(cai)用(yong)(yong)沖(chong)床(chuang)連續加(jia)(jia)(jia)工(gong)(gong)的(de)方(fang)式，有(you)時(shi)在(zai)(zai)沖(chong)切斷(duan)面(mian)上(shang)，發(fa)生塌邊(bian)現象（即沖(chong)切面(mian)與基(ji)準平面(mian)不(bu)(bu)(bu)(bu)垂(chui)直(zhi)）。精(jing)密(mi)(mi)落(luo)料(liao)(liao)是(shi)從(cong)變(bian)壓(ya)器(qi)等(deng)使(shi)用(yong)(yong)疊層(ceng)的(de)電磁(ci)鋼(gang)(gang)(gang)板(ban)(ban)的(de)加(jia)(jia)(jia)工(gong)(gong)技術開展起來(lai)的(de)技術，對粒(li)子(zi)加(jia)(jia)(jia)速器(qi)的(de)套環（collar)或(huo)電子(zi)零部件(jian)(jian)中(zhong)(zhong)的(de)引線框（lead frame)等(deng)等(deng)，從(cong)較厚的(de)板(ban)(ban)材到超(chao)薄材，精(jing)密(mi)(mi)落(luo)料(liao)(liao)得(de)到廣泛(fan)應(ying)用(yong)(yong)。沖(chong)壓(ya)加(jia)(jia)(jia)工(gong)(gong)機(ji)(ji)械(xie)亦可以進(jin)行精(jing)密(mi)(mi)沖(chong)壓(ya)（落(luo)料(liao)(liao)）加(jia)(jia)(jia)工(gong)(gong)，但由于沖(chong)壓(ya)塌邊(bian)的(de)問題，一(yi)(yi)般不(bu)(bu)(bu)(bu)能(neng)作為(wei)(wei)(wei)成品直(zhi)接使(shi)用(yong)(yong)。在(zai)(zai)精(jing)密(mi)(mi)沖(chong)壓(ya)中(zhong)(zhong)，為(wei)(wei)(wei)控制塌邊(bian)，就需加(jia)(jia)(jia)一(yi)(yi)道機(ji)(ji)械(xie)控制的(de)工(gong)(gong)藝措施，這需要按產(chan)品用(yong)(yong)途(tu)以及成本兩方(fang)面(mian)來(lai)權衡。在(zai)(zai)加(jia)(jia)(jia)工(gong)(gong)方(fang)法(fa)競爭上(shang)，還有(you)一(yi)(yi)種“蝕(shi)刻”方(fang)法(fa)，在(zai)(zai)電子(zi)產(chan)品的(de)接線框等(deng)超(chao)薄產(chan)品中(zhong)(zhong)，在(zai)(zai)加(jia)(jia)(jia)工(gong)(gong)廠家的(de)技術競爭中(zhong)(zhong)，兩者幾乎(hu)各占一(yi)(yi)半。
3. 加(jia)工油、表面保(bao)護薄膜和其他潤(run)滑
a. 表(biao)(biao)面保護薄膜－為了(le)保持不銹鋼的匠藝性、防止產(chan)生(sheng)瑕(xia)疵以及作為潤滑而敷(fu)于(yu)材料表(biao)(biao)面的聚(ju)氯乙(yi)烯或聚(ju)乙(yi)烯等薄膜。
b. 揮發(fa)(fa)性加工(gong)(gong)油－－加工(gong)(gong)時有潤滑效果而后又(you)能揮發(fa)(fa)掉的加工(gong)(gong)油。使用完全(quan)揮發(fa)(fa)型的，可以(yi)省掉清洗工(gong)(gong)序。
c. 潤(run)滑不(bu)銹鋼(gang)板(ban)－具有(you)透明石蠟涂裝的(de)不(bu)銹鋼(gang)，它比加工油或表面保護膜有(you)更好的(de)加工性。
在沖床上(shang)進(jin)行(xing)(xing)不(bu)(bu)銹(xiu)鋼板(ban)彎(wan)曲、沖裁（落料(liao)）等加(jia)(jia)(jia)工(gong)時(shi)，可(ke)使(shi)(shi)(shi)用(yong)(yong)(yong)加(jia)(jia)(jia)工(gong)油、表(biao)面(mian)(mian)保(bao)(bao)(bao)護(hu)薄(bo)(bo)膜(mo)或直接(jie)使(shi)(shi)(shi)用(yong)(yong)(yong)潤滑鋼板(ban)。在表(biao)6-1中，對(dui)(dui)加(jia)(jia)(jia)工(gong)油、表(biao)面(mian)(mian)保(bao)(bao)(bao)護(hu)薄(bo)(bo)膜(mo)和潤滑鋼板(ban)進(jin)行(xing)(xing)比(bi)較。表(biao)面(mian)(mian)保(bao)(bao)(bao)護(hu)薄(bo)(bo)膜(mo)是(shi)不(bu)(bu)銹(xiu)鋼保(bao)(bao)(bao)持匠藝性(xing)的一(yi)項重要措施。所用(yong)(yong)(yong)樹脂為聚(ju)氯乙烯(xi)系列或聚(ju)乙烯(xi)系列。材(cai)料(liao)運轉自始至終(zhong)都是(shi)用(yong)(yong)(yong)表(biao)面(mian)(mian)保(bao)(bao)(bao)護(hu)薄(bo)(bo)膜(mo)對(dui)(dui)材(cai)料(liao)表(biao)面(mian)(mian)施行(xing)(xing)保(bao)(bao)(bao)護(hu)。使(shi)(shi)(shi)用(yong)(yong)(yong)表(biao)面(mian)(mian)保(bao)(bao)(bao)護(hu)薄(bo)(bo)膜(mo)，最容(rong)易發生(sheng)的問題就是(shi)殘(can)留糊狀物，貼附后(hou)長(chang)期保(bao)(bao)(bao)存在倉庫內(nei)的或者是(shi)不(bu)(bu)具備耐(nai)候性(xing)能的薄(bo)(bo)膜(mo)放置在室外的，則容(rong)易發生(sheng)損壞。表(biao)面(mian)(mian)保(bao)(bao)(bao)護(hu)薄(bo)(bo)膜(mo)要根據用(yong)(yong)(yong)途和加(jia)(jia)(jia)工(gong)方法選定。主要廠家生(sheng)產的表(biao)面(mian)(mian)保(bao)(bao)(bao)護(hu)薄(bo)(bo)膜(mo)性(xing)能及其有關事項如表(biao)6-2所示。不(bu)(bu)使(shi)(shi)(shi)用(yong)(yong)(yong)表(biao)面(mian)(mian)保(bao)(bao)(bao)護(hu)薄(bo)(bo)膜(mo)時(shi)，一(yi)般情(qing)況下要使(shi)(shi)(shi)用(yong)(yong)(yong)加(jia)(jia)(jia)工(gong)油。當使(shi)(shi)(shi)用(yong)(yong)(yong)加(jia)(jia)(jia)工(gong)油加(jia)(jia)(jia)工(gong)后(hou)，需進(jin)行(xing)(xing)洗凈。洗凈的方法有多種，最近在保(bao)(bao)(bao)護(hu)地(di)球環境問題當中，規定了(le)保(bao)(bao)(bao)護(hu)環境條例，對(dui)(dui)于破壞臭(chou)氧層(ceng)的清(qing)洗劑做(zuo)出了(le)限制(zhi)。
因此，當使用(yong)加(jia)(jia)工(gong)(gong)(gong)油(you)(you)(you)時，要考慮到洗凈和(he)存放問題(ti)。在加(jia)(jia)工(gong)(gong)(gong)油(you)(you)(you)選(xuan)定(ding)方面，從前認為由于不(bu)銹鋼硬(ying)度(du)比(bi)普(pu)(pu)通(tong)鋼要高(gao)，加(jia)(jia)工(gong)(gong)(gong)不(bu)銹鋼比(bi)普(pu)(pu)通(tong)鋼困難(nan)，所以(yi)要選(xuan)用(yong)有(you)黏性的(de)加(jia)(jia)工(gong)(gong)(gong)油(you)(you)(you)。具有(you)黏性的(de)加(jia)(jia)工(gong)(gong)(gong)油(you)(you)(you)往往是黏糊糊的(de)，在加(jia)(jia)工(gong)(gong)(gong)過(guo)程中不(bu)但(dan)變黑而(er)且難(nan)以(yi)清(qing)洗。另外，其(qi)中多數(shu)情況下加(jia)(jia)入氯系列添(tian)加(jia)(jia)劑。因此，更(geng)有(you)必要進行(xing)充分(fen)地清(qing)洗。近年來，開發了(le)許多水溶性加(jia)(jia)工(gong)(gong)(gong)油(you)(you)(you)，在深拉深等加(jia)(jia)工(gong)(gong)(gong)中，其(qi)潤(run)滑性堪比(bi)原用(yong)油(you)(you)(you)性的(de)加(jia)(jia)工(gong)(gong)(gong)油(you)(you)(you)。水溶性加(jia)(jia)工(gong)(gong)(gong)油(you)(you)(you)比(bi)較容易清(qing)洗，應用(yong)效(xiao)果很好。作為新技術，雖然加(jia)(jia)工(gong)(gong)(gong)條件受到某種程度(du)的(de)限制，免清(qing)洗的(de)揮發型加(jia)(jia)工(gong)(gong)(gong)油(you)(you)(you)仍得到推(tui)廣。
在揮發性(xing)加(jia)工油(you)中(zhong)，有完(wan)全(quan)揮發型(xing)和部分殘(can)留型(xing)等(deng)產品。需根據(ju)加(jia)工條件(jian)選擇，使(shi)用完(wan)全(quan)揮發型(xing)的可以(yi)省掉(diao)加(jia)工后的清洗(xi)。在家電生產廠中(zhong)，沖制(zhi)全(quan)自動(dong)洗(xi)衣機不銹鋼(gang)洗(xi)衣桶時就是(shi)采用完(wan)全(quan)揮發型(xing)加(jia)工油(you)。在其他領(ling)域中(zhong)，完(wan)全(quan)揮發型(xing)加(jia)工油(you)已實(shi)際運用到沖孔、內緣翻(fan)邊、壓制(zhi)筋板、彎曲(qu)和卷邊等(deng)沖壓工藝(yi)中(zhong)。
由于使(shi)用(yong)揮(hui)發性加工(gong)(gong)(gong)(gong)油可(ke)(ke)(ke)以省掉清洗工(gong)(gong)(gong)(gong)序(xu)，在流(liu)水加工(gong)(gong)(gong)(gong)作業(ye)線上使(shi)用(yong)，可(ke)(ke)(ke)以降低成本(ben)。主要生產廠家(jia)的(de)(de)揮(hui)發性加工(gong)(gong)(gong)(gong)油產品如表(biao)6-3所示(shi)。如將揮(hui)發性加工(gong)(gong)(gong)(gong)油的(de)(de)涂(tu)敷方(fang)式(shi)和加工(gong)(gong)(gong)(gong)條件進行(xing)改進時，即可(ke)(ke)(ke)以完全省掉清洗工(gong)(gong)(gong)(gong)作。但是，揮(hui)發性加工(gong)(gong)(gong)(gong)油涂(tu)敷方(fang)式(shi)、加工(gong)(gong)(gong)(gong)條件及加工(gong)(gong)(gong)(gong)夾具(ju)的(de)(de)質量管理不(bu)善(shan)時，由于加工(gong)(gong)(gong)(gong)夾具(ju)的(de)(de)磨損(sun)等(deng)可(ke)(ke)(ke)能產生對(dui)不(bu)銹(xiu)鋼的(de)(de)鐵(tie)粉銹(xiu)蝕(shi)事故。關于鐵(tie)粉銹(xiu)蝕(shi)檢查方(fang)法，可(ke)(ke)(ke)參照(zhao)本(ben)書后部章節中的(de)(de)“使(shi)用(yong)時注(zhu)意重占日惠執(zhi)處理”由的(de)(de)說明。
先前在(zai)沖壓(ya)加(jia)(jia)工(gong)過(guo)程中(zhong)使(shi)用(yong)加(jia)(jia)工(gong)油。為了洗凈這(zhe)些加(jia)(jia)工(gong)油而使(shi)用(yong)了破壞臭(chou)氧層(ceng)的(de)三(san)氯乙烷，三(san)氯乙烯(xi)等。后來(lai)，洗凈方法(fa)改為堿性(xing)洗凈方法(fa)。在(zai)1995年，考慮到保護(hu)地球環境(jing)問題，開發了潤(run)(run)滑(hua)不銹(xiu)鋼(gang)板(ban)。在(zai)汽車、電(dian)機、燃氣器具領域(yu)中(zhong)，積極推廣了省掉(diao)清洗工(gong)序(xu)的(de)潤(run)(run)滑(hua)不銹(xiu)鋼(gang)板(ban)。特別是在(zai)汽車領域(yu)中(zhong)的(de)排(pai)氣分支(zhi)管的(de)不銹(xiu)鋼(gang)化過(guo)程中(zhong)，實踐證明，加(jia)(jia)工(gong)這(zhe)種形狀復雜的(de)工(gong)件(jian)，認為潤(run)(run)滑(hua)不銹(xiu)鋼(gang)板(ban)比以(yi)前使(shi)用(yong)潤(run)(run)滑(hua)油的(de)加(jia)(jia)工(gong)性(xing)更優(you)越。所以(yi)，潤(run)(run)滑(hua)不銹(xiu)鋼(gang)板(ban)的(de)需要量(liang)大(da)幅度增加(jia)(jia)。
潤(run)滑(hua)不(bu)(bu)銹鋼(gang)板，根據用(yong)(yong)途亦(yi)有不(bu)(bu)涂薄(bo)膜(mo)(mo)的(de)。非脫(tuo)膜(mo)(mo)型和脫(tuo)膜(mo)(mo)型兩類(lei)已經產品(pin)化了(le)。潤(run)滑(hua)不(bu)(bu)銹鋼(gang)板種類(lei)和特性如表6-4所示。在建筑(zhu)材料領域(yu)中(zhong)，使(shi)用(yong)(yong)潤(run)滑(hua)不(bu)(bu)銹鋼(gang)板做屋頂時，非脫(tuo)膜(mo)(mo)型和脫(tuo)膜(mo)(mo)型一樣，其薄(bo)膜(mo)(mo)經過1~2年(nian)的(de)紫外(wai)線照射就消失了(le)。作(zuo)為工(gong)程(cheng)實(shi)例，用(yong)(yong)于西(xi)武百貨大(da)(da)樓和福岡機場候機大(da)(da)廳。實(shi)踐證明，潤(run)滑(hua)不(bu)(bu)銹鋼(gang)板的(de)加工(gong)性比(bi)加工(gong)油還(huan)要(yao)優(you)越，見表6-5。
不(bu)銹(xiu)鋼(gang)板生產廠家的潤(run)滑(hua)不(bu)銹(xiu)鋼(gang)板產品(pin)，在(zai)透明涂裝不(bu)銹(xiu)鋼(gang)項(xiang)目中有介紹。
