Wire Rope

ENTC 463 Mechanical Design Application II

Hoisting Elevator Ski lift, etc.

wire diameter, dw strand rope diameter, d pulley diameter, D Designation example : 1 x 6 x 19 d = 1.5 6 strands/rope 19 wires/strand

Wire rope lays

Regular Lay: wires twist in one direction and strands twist in another direction Lang Lay: wire and strand twist in the same direction; more resistance to abrasive wear and bending fatigue; easier to kink and untwist, more difficult to handle

Wire Rope Lays

Rope 6 x 7 Haulage

Weight per height, lb/f t 1.50d 2

Minimu m sheave diameter, in. 42 d

Rope diameter, d, in. Material 1/4 - 1 1/2

14 x 10 6 100 x 103 Monitor steel 6 14 x 10 88 x 10 3 Plow steel Mild plow steel 14 x 10 6 76 x 10 3 1.60d 2 12 x 10 6 106 x 103 6 x 19 26 d-34d 1/4 - 2 3/4 Monitor steel 6 Standard Plow steel 12 x 10 93 x 10 3 hoisting Mild plow steel 12 x 10 6 80 x 10 3 Monitor steel 1.55d 2 11 x 10 6 100 x 103 18 d 1/4 - 3 1/2 6 6 x 37 Special Plow steel 11 x 10 88 x 10 3 flexible Monitor steel 1.45d 2 10 x 10 6 92 x 10 3 21 d-26d 1/4 - 1 1/2 8 x 19 Extra Plow steel 10 x 10 6 80 x 10 3 flexible Corrosion1.70d 2 124 x 103 1/16 - 3/8 7 x 7 Aircraft resistant steel Carbon steel 124 x 103 Corrosion1.75d 2 135 x 103 1/8 - 1 3/8 7 x 9 Aircraft resistant steel Carbon steel 143 x 103 Corrosion2.15d 2 165 x 103 1/32 - 5/16 resistant steel 19-Wire Carbon steel 165 x 103 aircraft a The modulus of elasticity is only approximate; it is affected by the loads on the rope and, in general, increases with the life of the rope. b The strength is based on the nominal area ofthe rope. The figures given are only approximate and are based on 1in. rope sizes and 1/4 in. aircraft cable sizes.

Size of outer wires d /9 d /9 d /9 d /13-d /16 d /13-d /16 d /13-d /16 d /22 d /22 d /15-d /19 d /15-d /19 -

Modulus of elasticitya psi

Strengthb psi

Table 18.7 Wire rope data [From Shigley and Mitchell (1983)]

Wire Rope Design Considerations

Tensile Bending Fatigue Bearing pressure (sheaves)

Tensile Stress

Ftotal = Fweight + Frope + Facc

Fweight: dead weight being supported Frope: rope weight Facc: force due to acceleration

Tensile stress
tensile
Ftotal = Ametal
Ametal =

d 2 ) 16 6 19 = 0.35d 2 4

Tensile Stress

Safety Factor
N= Strength

tensile

Application Track cables Guys Mine shafts, ft Up to 500 1000-2000 2000-3000 Over 3000 Hoisting Haulage Cranes and derricks Electric hoists Hand elevators Private elevators Hand dumbwaiters Grain elevators Passenger elevators, ft/min 50 300 800 1200 1500 Freight elevators, ft/min 50 300 800 1200 1500

Safety factora, n s 3.2 3.5 8.0 7.0 6.0 5.0 5.0 6.0 6.0 7.0 5.0 7.5 4.5 7.5 7.60 9.20 11.25 11.80 11.90 6.65 8.20 10.00 10.50 10.55

Bending Stress

Bending
r

1 M EI = M = r EI r I Mc = M = I c EI I Ec = = c r r

D 2 d c w 2 r

bending =

Ed w E = D D dw

E : Modulus of elasticity in Table 18.7

Bending Stress
bending
Ed w E = = bending when D d w D D dw
D > 400 dw

Safe design :

Minimum sheave diameter Fig. 18.7

Consider d = 2, dw = 0.125, For D/dw >= 400, D = 50 !!! Inspection, inspection!

Fatigue

Allowable fatigue force

Su dD Ff = 2000 Ftotal < F f

Ultimate strength
Mild plow steel: 180 ksi Plow steel: 210 ksi Improved plow steel: 240 ksi

Bearing Pressure (Sheave)

Average contact pressure

2 Ftotal P= dD

D d

Compared to maximum allowable bearing pressure in Table 18.9

Max. Allowable Bearing Pressure for Different Sheave Materials

a

Wood Rope Regular Lay 6 x7 6 x 19 6 x 37 8 x 19

Material Cast Iron Cast stee lc Chilled cast iron d Allowable be aring pressure, pall, psi
b

Manganese stee le

150 250 300 350

300 480 585 680

550 900 1075 1260

650 1100 1325 1550

1470 2400 3000 3500

Lang Lay 6 x7 165 350 600 715 6 x 19 275 550 1000 1210 6 x 37 330 660 1180 1450 a On end grain of beech, hickory or gum b For H B(min.)=125. c 30-40 carbon; H B(min.)=160. d Use only with uniform surface hardness. e For high sp eeds with balanced sheaves having ground surfaces.

1650 2750 3300

Wire Rope Design Example

Given
Weight to hoist Maximum height during operation Acceleration

Design
Specify rope type and diameter Select rope material Specify sheave diameter Specify sheave material

HW #3

Estimate the load carrying capacity of a wire rope:

x 6 x 7 haulage wire rope Plow steel Max. operating height at 30 ft No significant acceleration Cast iron sheave