Pure-Bend and Over-Bend Straightening Theory for In-Plane Curved Beams with Symmetrical Section and Straightening Mechanism Analysis

Straightening is an important process in the production and application of shafts, tubes, and various profiles. According to the springback theory of small curvature plane bending, the pure bending process and springback of in-plane curved beam with symmetrical section were analyzed, and the over-bend straightening theory was established. Based on this, the straightening mechanism of the existing over-bend straightening process was revealed; that is, a zigzag straightening moment was applied in the three-point multi-step straightening process to approximate the smooth curve of theoretical moment, while the multi-point one-time straightening technology was to discretize the theoretical curve using the broken line, so both of them needed a load correction coefficient to compensate the error between the actual load and theoretical calculation. In order to realize the complete loading of theoretical curve, a new technology of three-roll continuous straightening was further proposed and the experimental equipment for shafts and tubes was built. In order to match the characteristics of a pipe section, an accurate moment calculation equation was established. Three-roll continuous straightening experiments of the tube showed that the straightness of the straightened workpiece could be controlled within 1.5 parts per thousand, which meets the standard requirements. Therefore, it is suggested that the over-bend straightening theory can predict the load required for straightening in-plane curved parts with any symmetrical cross-section, and the three-roller continuous straightening process is an efficient and highly accurate straightening technique.