FLEXIBLE POWER TRANSMITTING ELEMENTS D. WIRE ROPES WIRE ROPE DRIVE! Reference DME by Faires ‘Useful Table and Chart AT 28: Wire rope properties Fig 17.30: Pressure ratio vs. cycles to failure Note: Caleulations involved in the preceding discussion about wire ropes are based on the wire rope properties taken from Design of Machine Elements by Faires. Such properties may differ slightly when compared to newer designs and constructions of wire ropes from modem manufacturers, However, the principles involved in the manner of selecting or evaluating the performance of a wire rope drive are still the same, ENTER ‘STRAND oe WIRE Ke D, oar Pgs = rope diameter Dy = wire dimotr Two oommon lays of wie rope Wire Rope Specifications Example: Rope specified as 1-6 x 19- MPS Wire rope material Number of wires per strand Number of Wire rope diameter Description’ 1° 6x 19 MPS — a wire rope made of a mild plow steel (MPS) with a rope diameter D; = 1”, consisting of 6 strands with 19 wires per strand $ Machine Design 2_1Sem2023-2024 _HASAEN.RV_ $ Db, b, sheave with ound groove rope diameter pitch diameter ofthe sheave = total tensile load of the rope Wire Rope Cross Sections: The following most widely used sections are described by the reference material mentioned above 6x7 = extra strong wire rope (most resistant 10 abrasion and wear) - used for guard rails, rigging, guy wires, ete 6x19 = general purpose rope - used for hoisting, draglines, haulages, etc. extra flexible — used for overhead cranes, winch lines, hoists, ete Other eross sections include the followii 8x19, 8x25, 19X19, ete., which are design applications. TXT, 7x19, for special + Regular Lay vs. Lang Lay Regular lay ~ wires and strands are twisted inthe ‘opposite directions (standard US rope construction) Langley - wires and strands are twisted inthe same direction (harder to splice and twists more easily when foaded, but rope has better wearing surface) ¢ Wire Rope Loads a) Total Tensile Load, F, This includes the effect of acceleration of the load (inertia force) K w 26= mal: from Newton's law F— W.-W, = (m, +m,)a Fe—w,—w, = hy Mg WL We ES @ F, i+w (1+2) Where Wi. = weight of load being supported W. = ropes own weit a. = acceleration ofthe load & = gravitational acceleration Note: The worst loading condition of rope is when the load is at its lowest position and is accelerating, upward. b) Equivalent Bending Load, F, ‘This represents the equivalent loading of the rope due to bending around the sheave. staight rope: rope is bent around Dy meio From the moment vs, radius of curvature equation in Mechanics of Deformable Box Ds where p = And, from the bending stress equation, HL Me_ pO _ ke an er) S= Considering a bent steel wire of diameter Dy as basis, then ¢ = Dy /2. ‘Thus, Then from, sos to relate it to the equivalent bending load. Mochine Design 2 1Sem2023-2024 _BASAENRV_ $ EDy _ Fy De An Then, EDw De (An) metallic cross-sectional area of the rope E = modulus of elasticity of the wires (E= 30x 10° psi for steel wires) D, = sheave’s pitch diameter Dy = wire diameter Note From the properties of wire ropes, the following parameters are specified: Ay, Dy, DE, Bi, w, and breaking sirengih F, of different cross sections, sizes and rope materials Factor of Safety of Rope a. Static Approach Unless otherwise specified, the rope’s factor of safety is defined as net strength after bending on the sheave ‘otal tensile load FuaFe i Fy Where Fy = breaking strength ofthe rope (AT28) Note Other reference materials have different description about the rope's static factor of safety From Handbooks: N Be contort From MD by Black and Adams and DMM by Doughtie: Fu il Fo+ Fy From DME by Faires, as used in this discussion 4. Fatigue Approach ‘This factor of safety is based on the contact, or bearing pressure between the rope and the sheave. 27D, “Gta rca, P Ay = DD, RB R Practical Derivation Considering that each end of the rope is loaded with the total tensile load F,. The bearing pressure p is then F_2F pD,D, A Dds OR For safety, the left side ofthe equation should be greater than unity (N > 1). Thus, pD,Ds ars Then, considering the ultimate strength of the rope material, S. Ny (P/Su)D/Ds(Su) 2F, Where P/Sq_ ratio of bearing pressure on rope to ultimate strength of rope material Note This is a well-defined property of rope, as tested. For indefinite life, this ratio should not exceed 0,0015 P/Sy < 0.0015 Thus, if plSu is set as 0.0015 and[N]jerigue > 1, the rope is expected to withstand indefinite number of flexings, but iN < 1, the rope's life is ited. Estimation for Rope’s Li Years (ny, No.of bendings to failure) aoe ‘Usage, bendings/year Where ny = value resulting from Fig, 17.30 of Faires . . % Machine Design 2 Sem 2003-2024 _BASAEN.RY_ To determine the approximate rope's life, evaluate ns ~ From the fatigue approach factor of safety formula, set N= 1 and solve for p/S, (expected to be greater than 0.0015). ~ Then from Figure 17.30, estimate mp, cove forthe \ce (ee 6x19) ‘sno. oF bends to failure Thus, if the actual usage per year is known, the rope’s life can be estimated from the above equation, Rope’s Deformation Due to a Load F From the deformation formula in MDB, the rope elongates by ABjype due to an axial load F lene Bene Flrope AmEr rope = ¥ Lope = Ienath of the rope being deformed by load F (deformable length) ‘metallic cross-sectional area of rope (AT28) ‘modulus of elasticity of the rope, taken as.a single body consisting of strands of wire (E- 180° ‘The required number of wraps is given by’ Fi = Fr dace (1 — Fa)evaitabte fricton no.of wraps >@) % Machine Design? 1*Sem 2023-2024 HASAENARY 2Useful Google Images about Wire Ropes: ‘% Mochine Desgn2'Sem2003-2024 _BASAENARY_ 4