Analytical Model of a Multi-Step Straightening Process for Linear Guideways Considering Neutral Axis Deviation

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.