High-precision rapid prototyping technology for manufacturing linear guides

A rapid prototyping and high-precision technology for manufacturing a linear motion (LM) guideway is proposed in this paper. In this technology, a trough is laid on the die, and a ram is used to press the billet before extrusion to produce high hydrostatic stress on the cutting edge of the die. The punch diameter is designed to be larger than the die hole but smaller than the die diameter. Hence, the action of the punch traveling downward to extrude the billet can increase the hydrostatic pressure around the cutting edge of the punch and die, thereby eliminating product fracture. LM rails of linear guides were formed using an experimental test, in which all the product processes were completed in only a few minutes. The results indicated that this approach can extrude a part of the linear guide with an excellent burnished surface. The test range for the roughness of the burnished surface was Ra = 0.03–0.21 μm, and the tolerance band for the width and thickness ranged from IT1 to IT4. This novel approach provides a more rapid prototyping technology as well as precise sizes higher than those obtained using traditional manufacturing methods.