Linear Guide Rail Nitriding and Micro-Lubrication
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Solution Overview
Problem
The manufacturing process of linear guide rails is labor-intensive and costly due to numerous machining operations required to achieve straightness and surface hardness, which also affects the mechanical characteristics and corrosion resistance.
Innovation Solution
A method involving the use of drawn steel with nitriding and post-oxidation treatments, combined with micro-lubrication, to enhance surface hardness and corrosion resistance, while minimizing the need for extensive straightening and machining steps, utilizing a C-shaped or L-shaped cross-section for the guide rail and slider configuration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If surface tempering by induction is used to harden the raceways, then surface hardness is improved, but the guide rails become bent, warped and twisted
Solution Approach 1:
The guide rails are pre-straightened after the tempering operation, before subsequent machining operations. This preliminary straightening action prevents the accumulation of deformations and eliminates the need for multiple straightening operations later in the manufacturing process, thereby resolving the contradiction between achieving surface hardness and maintaining straightness
Solution Approach 2:
The patent modifies the tempering parameters and introduces a controlled straightening process that adjusts the geometric parameters of the guide rail back to specification. By changing the process parameters and introducing corrective actions, the patent simultaneously achieves both surface hardness improvement and shape maintenance
2Manufacturing precision
If multiple machining operations are performed to achieve straightness and surface hardness, then manufacturing precision is improved, but the amount of work and time required increases
Solution Approach 1:
The patent combines multiple machining operations into a more streamlined sequence by performing straightening operations at strategically chosen points in the process flow. Instead of treating straightening and hardening as separate, iterative operations, they are merged into an integrated process sequence that reduces total manufacturing time while maintaining precision requirements
Solution Approach 2:
Straightening operations are performed preliminarily after tempering, before subsequent machining steps. This preliminary action ensures that the guide rail is properly aligned before further processing, preventing the need for re-work and reducing total manufacturing time while maintaining high precision standards
3Shape
If manual straightening operations are performed by specialized personnel, then shape accuracy is improved, but manufacturing cost increases
Solution Approach 1:
The patent implements a self-service approach where the guide rail itself is used as part of the straightening apparatus. By utilizing the guide rail's own structure and properties in the straightening process, manual intervention by specialized personnel is minimized, thereby reducing labor costs while maintaining shape accuracy
Solution Approach 2:
The straightening process is designed to be multi-functional, serving both as a shaping operation and as a preparation step for subsequent machining. This universal approach eliminates the need for dedicated manual straightening operations by specialized personnel, reducing manufacturing costs while achieving the required straightness
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach reduces manufacturing costs and time while maintaining or improving mechanical characteristics, achieving superior corrosion resistance and wear performance, with a significant reduction in the number of machining operations needed.
Implementation Method 1
A method involving the use of drawn steel with nitriding and post-oxidation treatments
Implementation Method 2
nitriding and post-oxidation treatments
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
The present invention relates to a linear guide rail (10) suitable for co-operating with a slider (12). The contact between the linear guide rail and the slider is obtained by means of rolling elements (14). The guide rail is made of drawn steel and comprises holes (18) for operational assembly, and raceways (16) suitable for making contact with the rolling elements. The surface of the raceways is smoothed by means of abrasive tools. The surface of the guide is treated using nitriding, post-oxidation and micro-lubrication processes.