不銹鋼(gang)瓦(wa)楞(leng)形板(ban)是不銹鋼(gang)寬幅型鋼(gang)的一種,由于其形狀如同(tong)頂上用瓦(wa)片鋪成的行列隆起部(bu)分,故稱為在線亞洲日產一區二區:不銹鋼瓦楞形板,如圖5-37所示。


圖 37.jpg


 人們過去(qu)常見的(de)(de)(de)“瓦楞(形(xing)(xing))板(ban)”大都是用(yong)普通低碳鋼,也就是非(fei)合金(jin)鋼材(cai)(cai)料(liao)(liao)制成的(de)(de)(de)(見圖5-38),還(huan)有用(yong)非(fei)金(jin)屬材(cai)(cai)料(liao)(liao)如石棉(mian)、塑(su)料(liao)(liao)、紙板(ban)等制成的(de)(de)(de)瓦楞形(xing)(xing)板(ban)。這(zhe)些(xie)瓦楞形(xing)(xing)板(ban)主要用(yong)于建筑領域的(de)(de)(de)屋頂(ding)材(cai)(cai)料(liao)(liao)、外墻材(cai)(cai)料(liao)(liao)和(he)(he)各種包(bao)裝箱體的(de)(de)(de)外形(xing)(xing)材(cai)(cai)料(liao)(liao)和(he)(he)產品包(bao)裝箱、盒等,之所(suo)以做(zuo)成瓦楞形(xing)(xing)狀(zhuang),主要目的(de)(de)(de)是增(zeng)加結構剛度和(he)(he)穩定性。因此(ci),其(qi)尺寸精度和(he)(he)表面(mian)質量要求及材(cai)(cai)質要求都不(bu)是很高。


圖 38.jpg


 此處介紹的(de)不銹鋼瓦楞(leng)形(xing)板(ban)(ban)(ban)(ban)(ban)與(yu)普(pu)通的(de)“瓦楞(leng)(形(xing))板(ban)(ban)(ban)(ban)(ban)”有(you)(you)著本質的(de)不同,首先材料是不銹鋼,無疑(yi)要(yao)(yao)比普(pu)通的(de)“瓦楞(leng)(形(xing))板(ban)(ban)(ban)(ban)(ban)”具(ju)有(you)(you)更高的(de)強度、良(liang)好的(de)耐(nai)腐(fu)蝕性(xing)能(neng)(neng)(neng)和極好的(de)裝飾效果,另(ling)外在結(jie)構上也大不相同。這些都賦予了(le)不銹鋼瓦楞(leng)形(xing)板(ban)(ban)(ban)(ban)(ban)不僅(jin)具(ju)有(you)(you)普(pu)通“瓦楞(leng)形(xing)板(ban)(ban)(ban)(ban)(ban)”的(de)各種(zhong)功能(neng)(neng)(neng)與(yu)作(zuo)用(yong)(yong),而(er)且(qie)具(ju)有(you)(you)普(pu)通“瓦楞(leng)(形(xing))板(ban)(ban)(ban)(ban)(ban)”沒(mei)有(you)(you)的(de)功能(neng)(neng)(neng),即不銹鋼瓦楞(leng)形(xing)板(ban)(ban)(ban)(ban)(ban)可以(yi)作(zuo)為傳熱元件使用(yong)(yong)。作(zuo)為傳熱元件,對(dui)其(qi)各方(fang)面的(de)要(yao)(yao)求(qiu)就比普(pu)通“瓦楞(leng)(形(xing))板(ban)(ban)(ban)(ban)(ban)”高得多(duo),特別是對(dui)瓦楞(leng)形(xing)板(ban)(ban)(ban)(ban)(ban)表(biao)(biao)觀(guan)(guan)的(de)要(yao)(yao)求(qiu)。對(dui)瓦楞(leng)形(xing)板(ban)(ban)(ban)(ban)(ban)表(biao)(biao)觀(guan)(guan)的(de)要(yao)(yao)求(qiu)主(zhu)要(yao)(yao)體現在對(dui)外形(xing)尺寸和表(biao)(biao)面質量(liang)的(de)要(yao)(yao)求(qiu)上。因此,采用(yong)(yong)何種(zhong)方(fang)式、何種(zhong)工(gong)藝加工(gong)生產不銹鋼瓦楞(leng)形(xing)板(ban)(ban)(ban)(ban)(ban)就成為保(bao)證其(qi)外形(xing)尺寸和質量(liang)的(de)關鍵。其(qi)他性(xing)能(neng)(neng)(neng)(機械性(xing)能(neng)(neng)(neng)、耐(nai)腐(fu)蝕性(xing)能(neng)(neng)(neng)和焊接(jie)性(xing)能(neng)(neng)(neng))主(zhu)要(yao)(yao)取決(jue)于所選用(yong)(yong)的(de)材料。



1. 不銹鋼(gang)瓦楞形板外形尺寸(cun)


 從圖5-37和(he)圖5-39可以看出不銹鋼(gang)瓦楞形(xing)(xing)板(ban)的外表形(xing)(xing)狀是(shi)有規(gui)律(lv)、周(zhou)期性變(bian)化(hua)的,而且(qie)彎曲深度較(jiao)小、形(xing)(xing)狀單一,不僅(jin)有橫(heng)向波(bo)(bo)紋(wen)(wen),而且(qie)還(huan)有縱向波(bo)(bo)紋(wen)(wen)。所以說,其形(xing)(xing)狀既簡單又復雜,簡單是(shi)指形(xing)(xing)狀單一,有規(gui)律(lv);復雜是(shi)指不僅(jin)有橫(heng)向波(bo)(bo)紋(wen)(wen),而且(qie)還(huan)有縱向波(bo)(bo)紋(wen)(wen)。這(zhe)就給不銹鋼(gang)瓦楞形(xing)(xing)板(ban)的成型(xing)帶(dai)來不小的難度,在成型(xing)工藝上必須采取相應的工藝措施和(he)手段,方能保證獲得要(yao)求的外形(xing)(xing)尺寸和(he)成型(xing)質量。


圖 39.jpg


 圖(tu)(tu)5-39是不(bu)銹鋼瓦楞(leng)形板(ban)的(de)實(shi)物照片(pian),從圖(tu)(tu)片(pian)可以看出,不(bu)銹鋼瓦楞(leng)形板(ban)的(de)外表(biao)和形狀是非(fei)常美觀、漂(piao)亮的(de),具有較高的(de)觀賞性(xing),如同工藝(yi)品、裝飾(shi)品。


 圖(tu)5-39不銹(xiu)鋼(gang)瓦楞形板A-A截(jie)面(mian)(mian)尺寸(cun),見圖(tu)5-40,B-B截(jie)面(mian)(mian)尺寸(cun),見圖(tu)5-41。


圖 40.jpg


 不(bu)銹鋼瓦楞(leng)形板成品實物斷面圖(tu)片,見圖(tu)5-40(b)和(he)圖(tu)5-41(b)。


 從圖5-40和圖5-41可以看出,不(bu)銹鋼瓦楞形板(ban)的斷面變(bian)化的規律(lv)是周期性的,斷面形狀(zhuang)是關于縱向中心線為對(dui)稱的型(xing)鋼,彎曲深度較淺(qian),深度僅有(you)7mm。


 不銹鋼瓦(wa)楞形板外形尺寸精度(du):截面最(zui)大邊長(chang)誤差≤0.3mm;圓角最(zui)大直徑:≤2.0mm;縱向(xiang)、橫向(xiang)彎曲度(du):每(mei)米≤1mm; 扭轉:每(mei)米≤1°。



2. 瓦楞(leng)形板橫向波紋(wen)的成型


 不(bu)銹鋼(gang)瓦楞形(xing)(xing)板(ban)輥式冷彎成(cheng)型時,首先(xian)將不(bu)銹鋼(gang)冷軋平板(ban)預彎曲(qu)鐓壓(ya)(ya)成(cheng)弧(hu)形(xing)(xing)波紋,如圖5-42所(suo)示(shi)的(de)(de)(de)(de)第一(yi)架成(cheng)型輥孔形(xing)(xing)的(de)(de)(de)(de)形(xing)(xing)狀。輥形(xing)(xing)的(de)(de)(de)(de)形(xing)(xing)狀為(wei)(wei)(wei),向下彎曲(qu)的(de)(de)(de)(de)弧(hu)形(xing)(xing)直(zhi)徑(jing)為(wei)(wei)(wei)Φ=265mm,向上彎曲(qu)的(de)(de)(de)(de)弧(hu)形(xing)(xing)直(zhi)徑(jing)為(wei)(wei)(wei)Φ=164mm,帶鋼(gang)進入并通過(guo)如此輥型是(shi)毫不(bu)困難(nan)的(de)(de)(de)(de),一(yi)個(ge)(ge)波長(周(zhou)期)為(wei)(wei)(wei)83.40mm,弧(hu)深度(du)(垂直(zhi)位(wei)(wei)移(yi))為(wei)(wei)(wei)4.12mm,這(zhe)個(ge)(ge)成(cheng)型形(xing)(xing)狀無論(lun)是(shi)在變形(xing)(xing)寬(kuan)度(du)上,還是(shi)變形(xing)(xing)深度(du)上都是(shi)可(ke)行的(de)(de)(de)(de)和符合要求的(de)(de)(de)(de)。一(yi)個(ge)(ge)波長(周(zhou)期)橫向位(wei)(wei)移(yi)(減寬(kuan)量)為(wei)(wei)(wei)0.60mm,相對減寬(kuan)率(lv)(橫向位(wei)(wei)移(yi))為(wei)(wei)(wei)0.71%,見圖5-42,如此的(de)(de)(de)(de)位(wei)(wei)移(yi)(減寬(kuan)量)不(bu)會對鐓壓(ya)(ya)成(cheng)型造成(cheng)困難(nan)和產生成(cheng)型缺陷,這(zhe)些都為(wei)(wei)(wei)第二架成(cheng)型輥再鐓壓(ya)(ya)創造了條件。


 第(di)(di)(di)二(er)架成(cheng)(cheng)(cheng)(cheng)(cheng)(cheng)(cheng)型(xing)(xing)輥(gun)(gun)在(zai)第(di)(di)(di)一(yi)(yi)架成(cheng)(cheng)(cheng)(cheng)(cheng)(cheng)(cheng)型(xing)(xing)輥(gun)(gun)的(de)鐓(dui)(dui)壓(ya)(ya)(ya)(ya)基礎(chu)上,再次鐓(dui)(dui)壓(ya)(ya)(ya)(ya),使(shi)其(qi)達(da)到如圖5-42所示(shi)(shi)的(de)孔(kong)形(xing)(xing)(xing)(xing)形(xing)(xing)(xing)(xing)狀,弧度(du)直徑分別為(wei)(wei)(wei)(wei)Φ=133mm和(he)p=82mm,一(yi)(yi)個波(bo)(bo)長(chang)(周(zhou)期(qi)(qi))為(wei)(wei)(wei)(wei)81.70mm、弧深度(du)為(wei)(wei)(wei)(wei)8.18mm,這(zhe)(zhe)就是(shi)說(shuo)寬(kuan)度(du)和(he)深度(du)更接近于成(cheng)(cheng)(cheng)(cheng)(cheng)(cheng)(cheng)品(pin)形(xing)(xing)(xing)(xing)狀,而相對(dui)減(jian)(jian)寬(kuan)量(liang)(liang)(水(shui)平(ping)位移)僅為(wei)(wei)(wei)(wei)1.42mm,相對(dui)減(jian)(jian)寬(kuan)率(水(shui)平(ping)方向(xiang))為(wei)(wei)(wei)(wei)1.7%,要(yao)比第(di)(di)(di)一(yi)(yi)道次大(da)了許(xu)多,這(zhe)(zhe)是(shi)符合開始小一(yi)(yi)些、中間大(da)一(yi)(yi)些的(de)成(cheng)(cheng)(cheng)(cheng)(cheng)(cheng)(cheng)型(xing)(xing)規律要(yao)求的(de),見第(di)(di)(di)三架成(cheng)(cheng)(cheng)(cheng)(cheng)(cheng)(cheng)型(xing)(xing)輥(gun)(gun)在(zai)第(di)(di)(di)二(er)架成(cheng)(cheng)(cheng)(cheng)(cheng)(cheng)(cheng)型(xing)(xing)輥(gun)(gun)的(de)鐓(dui)(dui)壓(ya)(ya)(ya)(ya)基礎(chu)上,再鐓(dui)(dui)壓(ya)(ya)(ya)(ya),使(shi)其(qi)達(da)到如圖5-42所示(shi)(shi)的(de)孔(kong)形(xing)(xing)(xing)(xing)形(xing)(xing)(xing)(xing)狀,這(zhe)(zhe)時將(jiang)已(yi)經成(cheng)(cheng)(cheng)(cheng)(cheng)(cheng)(cheng)型(xing)(xing)的(de)弧形(xing)(xing)(xing)(xing)瓦(wa)楞(leng)形(xing)(xing)(xing)(xing)鐓(dui)(dui)壓(ya)(ya)(ya)(ya)成(cheng)(cheng)(cheng)(cheng)(cheng)(cheng)(cheng)梯形(xing)(xing)(xing)(xing)狀瓦(wa)楞(leng)形(xing)(xing)(xing)(xing),而一(yi)(yi)個波(bo)(bo)長(chang)(周(zhou)期(qi)(qi))為(wei)(wei)(wei)(wei)80mm,相對(dui)減(jian)(jian)寬(kuan)量(liang)(liang)(水(shui)平(ping)位移)僅為(wei)(wei)(wei)(wei)2.28mm,一(yi)(yi)個波(bo)(bo)長(chang)(周(zhou)期(qi)(qi))相對(dui)減(jian)(jian)寬(kuan)率(水(shui)平(ping)方向(xiang))為(wei)(wei)(wei)(wei)2.79%.通過鐓(dui)(dui)壓(ya)(ya)(ya)(ya)使(shi)弧深由8.18mm減(jian)(jian)小為(wei)(wei)(wei)(wei)7.00mm,這(zhe)(zhe)樣可使(shi)梯形(xing)(xing)(xing)(xing)成(cheng)(cheng)(cheng)(cheng)(cheng)(cheng)(cheng)型(xing)(xing)更加精確到位,為(wei)(wei)(wei)(wei)最(zui)后沖壓(ya)(ya)(ya)(ya)成(cheng)(cheng)(cheng)(cheng)(cheng)(cheng)(cheng)型(xing)(xing)達(da)到成(cheng)(cheng)(cheng)(cheng)(cheng)(cheng)(cheng)品(pin)形(xing)(xing)(xing)(xing)狀及尺寸奠定良(liang)好的(de)基礎(chu),此時,橫向(xiang)鐓(dui)(dui)壓(ya)(ya)(ya)(ya)成(cheng)(cheng)(cheng)(cheng)(cheng)(cheng)(cheng)型(xing)(xing)已(yi)全部(bu)完成(cheng)(cheng)(cheng)(cheng)(cheng)(cheng)(cheng),隨后將(jiang)采用沖壓(ya)(ya)(ya)(ya)成(cheng)(cheng)(cheng)(cheng)(cheng)(cheng)(cheng)型(xing)(xing)輥(gun)(gun)在(zai)已(yi)成(cheng)(cheng)(cheng)(cheng)(cheng)(cheng)(cheng)型(xing)(xing)橫向(xiang)波(bo)(bo)紋上完成(cheng)(cheng)(cheng)(cheng)(cheng)(cheng)(cheng)最(zui)終(zhong)成(cheng)(cheng)(cheng)(cheng)(cheng)(cheng)(cheng)型(xing)(xing)。


 圖(tu)5-42是(shi)各(ge)架(jia)次成型輥輥形尺寸圖(tu)。


圖 42.jpg


 第三架成(cheng)型(xing)(xing)輥輥形(xing)圖和孔形(xing)圖,見(jian)(jian)圖5-43.第三架成(cheng)型(xing)(xing)輥應(ying)是(shi)由多(duo)片輥片疊加組合(he)而(er)成(cheng)的(de)(de)組合(he)輥,輥片的(de)(de)水平段和圓(yuan)弧(hu)段采(cai)取與(yu)板(ban)(ban)材接觸(chu)的(de)(de)方式,而(er)傾(qing)斜段則采(cai)取與(yu)板(ban)(ban)材不接觸(chu)的(de)(de)方式,為的(de)(de)是(shi)減少成(cheng)型(xing)(xing)表(biao)面的(de)(de)擦劃傷,此(ci)外,如此(ci)結構也將便于(yu)成(cheng)型(xing)(xing)輥的(de)(de)加工和隨后的(de)(de)使(shi)用(yong)與(yu)維護等。上、下輥斜角(jiao)采(cai)取圓(yuan)弧(hu)過渡(du),一般(ban)情況下,圓(yuan)弧(hu)的(de)(de)直(zhi)徑應(ying)大(da)于(yu)板(ban)(ban)厚,所(suo)以圖5-43所(suo)示的(de)(de)第三架上、下輥斜角(jiao)的(de)(de)圓(yuan)弧(hu)過渡(du)直(zhi)徑為2.0mm,見(jian)(jian)圖5-43局部放(fang)大(da)圖。


圖 43.jpg


3. 縱向波紋的成型


 縱(zong)向(xiang)波(bo)紋的成(cheng)型是在橫(heng)(heng)向(xiang)波(bo)紋成(cheng)型之后(hou)的橫(heng)(heng)向(xiang)波(bo)紋上(shang)(shang)成(cheng)型的。所以在已成(cheng)型的波(bo)紋上(shang)(shang)再成(cheng)型縱(zong)向(xiang)波(bo)紋是有難度的。其難度主要表現(xian)為(wei)(wei),可(ke)能破壞已成(cheng)型的橫(heng)(heng)向(xiang)波(bo)紋,而且縱(zong)向(xiang)波(bo)紋也成(cheng)型不好(hao)。選用(yong)何種方式(shi)成(cheng)型就成(cheng)為(wei)(wei)縱(zong)向(xiang)波(bo)紋成(cheng)型的關(guan)鍵。


 沖壓成(cheng)(cheng)(cheng)(cheng)型(xing)(xing)(xing)(xing)(xing)輥(gun)(gun)就(jiu)是在(zai)(zai)一對成(cheng)(cheng)(cheng)(cheng)型(xing)(xing)(xing)(xing)(xing)輥(gun)(gun)上,按工藝(yi)和產(chan)品(pin)的(de)(de)(de)要(yao)求,在(zai)(zai)要(yao)面上間隙(xi)分布(bu)著凸起和凹陷(xian)的(de)(de)(de)部(bu)(bu)分,用(yong)(yong)于(yu)壓制成(cheng)(cheng)(cheng)(cheng)型(xing)(xing)(xing)(xing)(xing)瓦楞(leng)(leng)形(xing)(xing)板(ban)的(de)(de)(de)縱向(xiang)(xiang)(xiang)波(bo)(bo)紋(wen),同(tong)時(shi)又不能損壞已成(cheng)(cheng)(cheng)(cheng)型(xing)(xing)(xing)(xing)(xing)的(de)(de)(de)橫向(xiang)(xiang)(xiang)梯形(xing)(xing)波(bo)(bo)紋(wen),縱向(xiang)(xiang)(xiang)波(bo)(bo)紋(wen)尺寸圖及實物(wu)圖片,見圖5-40和圖5-41。之所以(yi)將沖壓成(cheng)(cheng)(cheng)(cheng)型(xing)(xing)(xing)(xing)(xing)輥(gun)(gun)置于(yu)橫向(xiang)(xiang)(xiang)波(bo)(bo)紋(wen)成(cheng)(cheng)(cheng)(cheng)型(xing)(xing)(xing)(xing)(xing)輥(gun)(gun)后、平整輥(gun)(gun)前(qian),是為(wei)了保證瓦楞(leng)(leng)形(xing)(xing)板(ban)的(de)(de)(de)成(cheng)(cheng)(cheng)(cheng)型(xing)(xing)(xing)(xing)(xing)過(guo)程的(de)(de)(de)穩(wen)定(ding)(ding)和成(cheng)(cheng)(cheng)(cheng)型(xing)(xing)(xing)(xing)(xing)質量(liang)。可以(yi)想(xiang)象,在(zai)(zai)沒有(you)橫向(xiang)(xiang)(xiang)波(bo)(bo)紋(wen)的(de)(de)(de)平板(ban)帶材(cai)上沖壓成(cheng)(cheng)(cheng)(cheng)型(xing)(xing)(xing)(xing)(xing)凸起和凹陷(xian)型(xing)(xing)(xing)(xing)(xing)材(cai),由于(yu)自由度(du)大沒有(you)約束(shu)力(li),沖壓成(cheng)(cheng)(cheng)(cheng)型(xing)(xing)(xing)(xing)(xing)會(hui)造成(cheng)(cheng)(cheng)(cheng)坯料(liao)局部(bu)(bu)收(shou)(shou)縮,產(chan)生皺折及其(qi)他缺陷(xian),影響成(cheng)(cheng)(cheng)(cheng)型(xing)(xing)(xing)(xing)(xing)質量(liang)和成(cheng)(cheng)(cheng)(cheng)品(pin)的(de)(de)(de)尺寸。另外,瓦楞(leng)(leng)形(xing)(xing)板(ban)型(xing)(xing)(xing)(xing)(xing)鋼(gang)截面受材(cai)料(liao)內部(bu)(bu)殘(can)余應力(li)作用(yong)(yong),很容易產(chan)生扭轉,這也會(hui)影響成(cheng)(cheng)(cheng)(cheng)型(xing)(xing)(xing)(xing)(xing)過(guo)程的(de)(de)(de)穩(wen)定(ding)(ding)性。但在(zai)(zai)瓦楞(leng)(leng)形(xing)(xing)板(ban)橫向(xiang)(xiang)(xiang)波(bo)(bo)紋(wen)成(cheng)(cheng)(cheng)(cheng)型(xing)(xing)(xing)(xing)(xing)輥(gun)(gun)后、平整輥(gun)(gun)前(qian),再用(yong)(yong)沖壓輥(gun)(gun)成(cheng)(cheng)(cheng)(cheng)型(xing)(xing)(xing)(xing)(xing)其(qi)縱向(xiang)(xiang)(xiang)波(bo)(bo)紋(wen),此時(shi),已成(cheng)(cheng)(cheng)(cheng)型(xing)(xing)(xing)(xing)(xing)的(de)(de)(de)橫向(xiang)(xiang)(xiang)波(bo)(bo)紋(wen)使瓦楞(leng)(leng)形(xing)(xing)板(ban)的(de)(de)(de)剛度(du)增大,同(tong)時(shi)又受到(dao)成(cheng)(cheng)(cheng)(cheng)型(xing)(xing)(xing)(xing)(xing)輥(gun)(gun)和平整輥(gun)(gun)的(de)(de)(de)約束(shu),其(qi)自由度(du)就(jiu)減小。以(yi)上這些都可以(yi)有(you)效地防止局部(bu)(bu)收(shou)(shou)縮和型(xing)(xing)(xing)(xing)(xing)鋼(gang)的(de)(de)(de)扭轉,從(cong)而對保證瓦楞(leng)(leng)形(xing)(xing)板(ban)的(de)(de)(de)成(cheng)(cheng)(cheng)(cheng)型(xing)(xing)(xing)(xing)(xing)及質量(liang)起到(dao)有(you)效的(de)(de)(de)保障作用(yong)(yong)。瓦楞(leng)(leng)形(xing)(xing)板(ban)橫向(xiang)(xiang)(xiang)波(bo)(bo)紋(wen)沖壓輥(gun)(gun)的(de)(de)(de)示(shi)意(yi)圖,見圖5-44。


圖 44.jpg


 沖壓成(cheng)型輥也應做成(cheng)組(zu)合式(shi)輥子,即由(you)多輥片疊加(jia)組(zu)合而成(cheng)。這種形式(shi)的輥子便(bian)于加(jia)工和維護,調整使用方便(bian)。