The correlation between wear evolution and mechanical property degradation of wire rope in a multi-layer winding system

2022 ◽  
pp. 1-17
Author(s):  
Xiangdong Chang ◽  
Peng Yu-Xing ◽  
Deqiang Cheng ◽  
Zhencai Zhu ◽  
Dagang Wang ◽  
...  
Keyword(s):  
Mechanical Property ◽  
Residual Strength ◽  
Performance Degradation ◽  
Wire Rope ◽  
Surface Wear ◽  
Characteristic Parameters ◽  
Wear Area ◽  
Wire Ropes ◽  
Adhesion Wear ◽  
The Wire

Abstract Surface wear is one of the major causes of damage to wire ropes in multi-layer winding systems. This damage leads to performance degradation and affects the service safety of wire rope. To reveal the wear evolution and the performance degradation of wire rope in service, the correlations between the wear characteristic parameters and the residual strength were investigated. The results show that the variation in the wear parameters is affected by the wear distribution and the structure of the wire rope. The main wear mechanisms between wire ropes are adhesion wear and abrasive wear. Different wear parameters should be combined to evaluate the wear state of the wire rope. The tensile temperature rise could accurately reflect the wear evolution of the in-service wire rope under the condition of a large wear degree. The negative correlation between the residual strength and the wear area of the damaged rope samples is the strongest.

Arrangement Characteristics and Wear Distribution of Wire Rope in Parallel Grooved Multi-Layer Winding

2013 ◽  
Vol 423-426 ◽  
pp. 842-845 ◽  
Author(s):  
Zhi Hui Hu ◽  
Yong Hu ◽  
Ji Quan Hu
Keyword(s):  
Experimental Study ◽  
Wire Rope ◽  
Wire Ropes ◽  
The Wire ◽  
Wear Damage

Based on the analysis of multi-layer winding arrangement characteristic of the wire rope in Lebus drum, the experimental study is carried on wear distribution of the wire rope in parallel grooved multi-layer winding. The result shows that, the wire rope is arranged regularly in each drum area in parallel grooved multi-layer winding; the wear of wire ropes in crossover zone is more serious than that of the parallel zone; in the same-layer wire rope winding in crossover zone, the wear damage during the wire rope winding in crossover zone at the end of each-layer drum is the most serious.

scholarly journals Design and analysis of elevator wire ropes

2021 ◽  
Vol 12 ◽  
pp. 20
Author(s):  
Anil Babu Seelam ◽  
Mohammad Saif Jawed ◽  
Sachidananda Hassan Krishanmurthy
Keyword(s):  
Best Practices ◽  
Research Paper ◽  
Wire Rope ◽  
New Materials ◽  
Wire Ropes ◽  
Mechanical Handling ◽  
The Wire ◽  
Design Calculations

In this research paper design and analysis of wire ropes used in elevator have been presented. The main objective of this study is to find the best practices on handling wire ropes for safety and to reduce the downtime of elevators due to wire rope failures. Design calculations have been done to calculate the apt dimensions and design is constructed on Auto Desk inventor software and the analysis have been performed using Ansys. Two configurations of the wire ropes have been studied and from this result it can be concluded that the design of wire rope is possible to relieve mechanical handling and to improve the design of wire ropes making it more durable by possible inclusion of new materials which in turn increases the efficiency and life of wire ropes without compromising safety.

scholarly journals Failure Analysis of Wire Ropes Used in Multi-Wire Machines for Cutting Blocks of Stone

2021 ◽  
Vol 18 (3) ◽  
pp. 278-284
Author(s):  
Sergio Baragetti
Keyword(s):  
Service Life ◽  
Failure Analysis ◽  
Cutting Tools ◽  
Contact Fatigue ◽  
Wire Rope ◽  
Damage Mechanisms ◽  
Wire Ropes ◽  
Increase Service Life ◽  
The Wire ◽  
Fatigue Corrosion

ABSTRACT: This paper reports the analyses carried out with the company Pedrini SpA ad unico socio, located in Carobbio degli Angeli, Bergamo (IT). Wire ropes with diamond beads, used as cutting tools in multi-wire machines for cutting blocks of stone, were considered and a failure analysis of the wire ropes was carried out. The aim of the paper is to highlight the damage mechanisms of the wire ropes to increase service life of these cutting tools. Microscope observations and the penetrating liquids method were used to analyze the damaged wire ropes. Fatigue, corrosion and contact fatigue problems were observed and the effect of the centering of the beads on the wire rope was studied.

scholarly journals RESEARCH OF BROKEN WIRE ON THE ROPE SURFACE USING DYNAMIC METHOD / LYNO IŠORINIAME SLUOKSNYJE NUTRŪKUSIŲ VIELŲ TYRIMAS, TAIKANT DINAMINĮ METODĄ

2013 ◽  
Vol 5 (6) ◽  
pp. 629-632
Author(s):  
Ernestas Šutinys ◽  
Vytautas Bučinskas
Keyword(s):  
Experimental Test ◽  
Dynamic Method ◽  
Dynamic Properties ◽  
Excitation Frequency ◽  
Wire Rope ◽  
Wire Ropes ◽  
The Wire

This paper is intended to reveal possibilities to research of brokenwire on the wire ropes using dynamic properties of tensedwire rope and research properties of broken wire in piece ofwire rope when it is affixed on the wire rope in special testrig. During experimental test wire rope and broken wire on thetensed wire rope dynamic properties was estimated dependingon excitation frequency, also including affixed weight on thetensed wire rope dynamic properties. Finally, results are givenand conclusions are made. Santrauka Straipsnis skirtas mokslinių tyrimų galimybėms atskleisti. Naudojant dinamines savybes, bandyta aptikti nutrūkusias vielas ant įtempto plieninio lyno ir ant plieninio lyno gabaliuko rasti nutrūkusią vielą, kai šis lyno gabaliukas mechaniškai tvirtinamas ant plieninio lyno specialiame bandymų stende. Eksperimentinių tyrimų metų buvo išmatuotos plieninio lyno ir ant įtempto plieninio lyno nutrūkusios vielos dinaminės savybės priklausomai nuo lyno žadinimo dažnio, taip pat įvertinant įtempto plieninio lyno dinamines savybes, pritvirtinus ant jo papildomą svorį. Pateikiami tyrimų rezultatai ir išvados.

scholarly journals A Sensor for Broken Wire Detection of Steel Wire Ropes Based on the Magnetic Concentrating Principle

Sensors ◽  
2019 ◽  
Vol 19 (17) ◽  
pp. 3763 ◽  
Author(s):  
Zhang ◽  
Jing ◽  
Xu ◽  
Zhan ◽  
Tan
Keyword(s):  
Permanent Magnet ◽  
Structural Parameters ◽  
Steel Wire ◽  
Sensor Arrays ◽  
Wire Rope ◽  
Hall Sensor ◽  
Wire Ropes ◽  
Depth Analysis ◽  
The Wire ◽  
Lift Off

Electromagnetic testing is the most widely used technique for the inspection of steel wire ropes. As one of the electromagnetic detecting approaches, the magnetic flux leakage (MFL) method has the best effect for the detection of broken wires. However, existing sensors based on MFL method still have some problems. (1) The size of the permanent magnet exciter is usually designed according to experience or rough calculation, and there is not enough depth analysis for its excitation performance; (2) Since the detectable angular range for a single Hall component is limited, Hall sensor arrays are often employed in the design of MFL sensors, which will increase the complexity of the subsequent signal processing due to the extensive use of Hall components; (3) Although the new magneto-resistance sensor has higher sensitivity, it is difficult to be applied in practice because of the requirement of the micron-level lift-off. To solve these problems, a sensor for the detection of broken wires of steel wire ropes based on the principle of magnetic concentration is developed. A circumferential multi-circuit permanent magnet exciter (CMPME) is employed to magnetize the wire rope to saturation. The traditional Hall sensor array is replaced by a magnetic concentrator to collect MFL. The structural parameters of the CMPME are optimized and the performance of the magnetic concentrator is analyzed by the finite element method. Finally, the effectiveness of the designed sensor is verified by wire breaking experiment. 1–5 external broken wires, handcrafted on the wire rope with a diameter of 24 mm, can be clearly identified, which shows great potential for the inspection of steel wire ropes.

Studies on friction and wear characteristics of wire rope used in multi-layer winding hoist during inter-circle transition under dry friction

2021 ◽  
pp. 135065012110094
Author(s):  
Qing Zhang ◽  
Yuxing Peng ◽  
Zhencai Zhu ◽  
Wei Tang ◽  
Guoan Chen ◽  
...  
Keyword(s):  
Coefficient Of Friction ◽  
Growth Phase ◽  
Dry Friction ◽  
Friction And Wear ◽  
Wire Rope ◽  
Maximum Temperature ◽  
Stable Phase ◽  
Test Rig ◽  
Wire Ropes ◽  
The Wire

A winding hoist is a key equipment for ultra-deep mine hoisting. The inter-circle transition in the winding process of the hoisting wire rope causes vibration, impact, extrusion, wear, and other negative phenomena, which seriously affect the service life of the rope. In order to explore the effect of inter-circle transition on the friction and wear performance of wire ropes, the present study adopts the principle of equal ratio scaling to build a test rig for an inter-circle transition of wire ropes, and the evolutions of coefficient of friction and maximum friction temperature with increasing the tensioning force and rope speed under dry friction were investigated by the test rig, and the major wear mechanisms under different working conditions were investigated in combination with the wear morphologies. The results show that the coefficient of friction decreases first and then increases with an increase in the tensioning force, and decreases linearly with increasing the rope speed. The evolution of maximum temperature over time under different tensioning forces and rope speeds are all mainly divided into three stages: The rapid growth phase, the slow growth phase, and the stable phase. The influence of the rope speed on the temperature of the wire rope is greater than that of the tensioning force. Moreover, in the process of inter-circle transition, the major wear mechanism is abrasive wear. Furthermore, larger tensioning force and rope speed may cause the steel wires on the contact surface of the wire rope to break.

scholarly journals Failure Analysis of Stainless Steel Lanyard Wire Rope

2018 ◽  
Vol 3 (3) ◽  
pp. 143-150
Author(s):  
Aginaparru Sambasiva Rao ◽  
Ashok Kumar Singh
Keyword(s):  
Stainless Steel ◽  
Fracture Surface ◽  
Failure Analysis ◽  
Wire Rope ◽  
304 Stainless Steel ◽  
Aisi 304 Stainless Steel ◽  
Humid Atmosphere ◽  
Aisi 304 ◽  
Wire Ropes ◽  
The Wire

Present work describes the failure analysis of AISI 304 stainless steel lanyard wire rope which has failed during application in humid atmosphere. The wire rope has 7´19 construction which means that it consists of seven strands and each strand having 19 wires twisted in a helical fashion. The microstructures and properties of failed wire rope have been investigated and compared with unused wire rope. Both the periphery and fracture surface of the wire rope display the presence of corrosion debris enriched with O and Cl. The fracture surfaces of the failed and unused wire ropes display intergranular and dimples, respectively. The lanyard wire rope has been exposed in corrosive atmosphere and failed in intergranular mode due to enrichment of O and Cl along the grain boundaries.

scholarly journals Deterioration Mechanisms in Dragline Wire Ropes

2008 ◽  
Vol 41-42 ◽  
pp. 199-204
Author(s):  
Daya Dayawansa ◽  
Mahinda Kuruppu ◽  
Fidelis Mashiri
Keyword(s):  
Wire Rope ◽  
Wire Ropes ◽  
Machine Operation ◽  
Service Loading ◽  
The Wire

Failures in hoist and drag ropes are studied and described based on site inspections on Marion and BE draglines. Causes of the failures are discussed. Some of the analyses of the wire rope failures centres on the wire rope accessories through which these ropes travel during machine operation. The influence of wire quality on wire rope life is also studied. Visual and metallographic examinations are both used in this study leading to a better understanding of deterioration mechanisms that lead to failure of hoist and drag ropes under service loading.

Fatigue reliability theory-based optimal design of wire ropes on test platforms for FAST actuators

2015 ◽  
Vol 11 (3) ◽  
pp. 413-423
Author(s):  
Ming Zhu ◽  
QiMing Wang ◽  
Lei Yang ◽  
Zheng Lei ◽  
Yong Wang ◽  
...  
Keyword(s):  
Reliability Theory ◽  
Wire Rope ◽  
Stress Model ◽  
Fatigue Reliability ◽  
Total Stress ◽  
Content Type ◽  
Wire Ropes ◽  
Test Platform ◽  
Optimization Function ◽  
The Wire

Purpose – Three test platforms for long-term continuous loading are adopted to test the actuator prototypes of the 500-meter aperture spherical radio telescope (FAST). However, the wire ropes that are the key components of these platforms often break during testing. The purpose of this paper is to present an effective dimension design method for these wire ropes. This method is based on fatigue reliability theory. Design/methodology/approach – Three types of stresses are introduced into the total stress model of the wire rope according to the complicated stress conditions. The fatigue strength of the ropes is also discussed in this paper. Then, the total stress model and the results of fatigue strength analysis are applied to set the optimization function for these wire ropes. Subsequently, this optimization function is used to calculate the reliability of previously developed wire ropes in relation to the actuator test platform. Findings – The wire rope is unreliable, which is a finding that corresponds to those of previous tests. Upon drawing the optimal curve from the optimization function (whose optimal objective is the wire diameter), a wire rope is optimized for the FAST actuator test platforms. Finally, this optimized rope is used on the new actuator test platform. No fracture phenomenon has been detected in tests conducted over the past six months. Originality/value – The fatigue reliability theory-based optimization function for wire ropes can be adopted for the universal dimension design of other wire ropes.

scholarly journals Research on Analysis of Eddy Current Response to Lay Length of Wire Ropes

2020 ◽  
Author(s):  
Shaoni Jiao ◽  
Xiaojuan Jia ◽  
Tengyu Li ◽  
Shukui Jin ◽  
Ziming Kou ◽  
...  
Keyword(s):  
Eddy Current ◽  
Surface Preparation ◽  
Surface Damage ◽  
Wire Rope ◽  
Current Response ◽  
Damage State ◽  
Wire Ropes ◽  
Single Side ◽  
The Wire ◽  
Easy Operation

The lay length is one of the important parameters for the wire rope and its detection can indirectly characterize its stress and surface damage state. The eddy current testing (ECT) method is advantageous because of its easy operation, single-side detection, low requirement of surface preparation, applicability in harsh environment, and other properties. Hence the lay length of the wire ropes is measured by ECT in this paper. The eddy current (EC) response to the wire rope is simulated. The EC on the surface of the strand below the pancake coil forms a vortex, and the distribution of the EC on the curved surfaces on both sides of the strand is symmetrical. The spacing between the adjacent peaks or troughs of the scanning signal is the distance between the adjacent strands, and the number of peaks or troughs of the scanning signal in a range of the lay length is related to the number of strands of the wire rope. Finally, the experimental validation is performed. The relative error of the lay length of the wire rope assessed by the EC method is less than 0.28%.

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