Straightening processing is one of the most important processes to improve straightness of linear motion components. The most urgent problem to be solved by the precision straightening process is the residual deflection caused by elastic rebound and obtaining accurate straightening stroke. Stroke-deflection model is a major critical factor that decides the precision and efficiency of straightening process. In this paper, a novel way to establish and simulate the stroke-deflection model is proposed based on mathematical method, bending experiment and online real-time measurement method. The online real-time technology, as well as online measurement experiment and data processing, improves the accuracy of stroke-deflection model. It is demonstrated that the stroke-deflection model adjusted by the online measurement model is more accurate than that of the theory model and bending experiment model. The stroke-deflection model based on online measurement can compensate the errors caused by various reasons and be more compatible with the actual straightening process.

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