Abstract
The cross-sectional shape of a linear guideway has been processed before the straightening process. The cross-section features influence not only the position of the neutral axis, but also the applied and residual stresses along the longitudinal direction, especially in a multi-step straightening process. This paper aims to present an analytical model based on elasto-plastic theory and three-point reverse bending theory to predict straightening stroke and longitudinal stress distribution during the multi-step straightening process of linear guideways. The deviation of the neutral axis is first analyzed considering the asymmetrical features of the cross-section. Owing to the cyclic loading during the multi-step straightening process, the longitudinal stress curves are then calculated using the linear superposition of stresses. Based on the cross-section features and the superposition of stresses, the bending moment is corrected to improve the predictive accuracy of the multi-step straightening process. Finite element analysis, as well as straightening experiments, have been performed to verify the applicability of the analytical model. The proposed approach can be implemented in the multi-step straightening process of linear guideways with similar cross-sectional shape to improve the straightening accuracy.
Highlights
With the rapid development of the automation industry, linear transmission parts will increasingly focus on the growing demands for straightness accuracy
The simulation and experimental results show the asymmetry of stresses in tensile and compressive regions was caused by the deviation of neutral axis
Taking the asymmetrical cross-section features into account, the position of the neutral axis and and surface is varying during the straightening process, thereby influencing the longitudinal stresssurface is varying during the straightening process, thereby influencing the longitudinal stress-strain distributions
Summary
With the rapid development of the automation industry, linear transmission parts will increasingly focus on the growing demands for straightness accuracy. The cold-straightening process for rolling bars has a wide range of applications including linear transmission automation, steel structure industry, and military industry. It mainly consists of rough and precise straightening processes according to various stages in the whole machining process. In the existing research of precise straightening, predictive models are mainly focused on the single straightening process, which is based on the assumption that the straightness of a workpiece can meet the requirement through a one-step straightening process [1,2,3,4]. The theories of predictive models are comprehensive and relatively mature, but the complex interaction between different procedures has not been considered in multi-step
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