This paper studies systematically the straightening process of a bar in a t
wo cross-roll straightener. A mathematical model on the precision of the st
raightened bars is developed. It considers the straightening process to be
a continuous alternating bending and reverse bending process. The solution
for the residual curvature of the straightened bars involved is an iterativ
e function in the mathematical treatment. The precision form of the bar is
to be virtually produced to its final shape after it has been straightening
severely, using a self-developed prediction model. The developed quantitat
ive model is found to coincide excellently with the experimental results an
d is proven to be effective after successful applications in industrial des
igns, (C) 2000 Elsevier Science S.A. All rights reserved.