Machine Design-2

Lecture [5]

Wire Ropes

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 what is the wire rope ?
Wire rope is a complex piece of mechanical machinery
with a number of different specifications and properties that
can affect its performance and service life. It has many moving
parts, all working in tandem to help support and move an
object or load.
Flexible Load Handling Attachment: Steel Wire rope
Advantages over chains:
Lighter weight
Less susceptibility to damage from jerks
Silent operation even at high working speeds
Greater reliability in operation

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 Wire Ropes
Wire rope consists of multiple wires or strands, helically wound or
laid about an axis.
Wires, strands and cores are independent- that interact with each
other during service.
dw

Strand

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 Wire Ropes
Wire ropes are designed in different
steel grades, finishes and a variety of
constructions to attain the best
balance of strength, abrasion
resistance, crush resistance, bending
fatigue resistance and corrosion
resistance for each application.

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 Wire rope classification:
▪ Wires are the basic building blocks of a wire rope. They lay around a
“center” in a specified pattern in one or more layers to form a strand.
The strands are helically laid together around a center, typically some
type of core, to form a wire rope.
▪ The strands provide all the tensile strength of a fiber core rope and
over 90% of the strength of a typical 6-strand wire rope with an
independent wire rope core.
▪ Properties like fatigue resistance and resistance to abrasion are
directly affected by the design of strands

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 Wire rope classification:
Types of Strand
SINGLE LAYER

The most common example of the single layer construction is a 7

wire strand. It has a single-wire center with six wires of the same
diameter around it.

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 Wire rope classification:
SEALE

This construction has two layers of wires around a center with the
same number of wires in each layer. All wires in each layer are the
same diameter. The strand is designed so that the large outer
wires rest in the valleys between the smaller inner wires.
Example: 19 Seale (1-9-9) strand
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 Wire rope classification:
FILLER WIRE

This construction has two layers of uniform-size wire around a center

with the inner layer having half the number of wires as the outer layer.
Small filler wires, equal in number to the inner layer, are laid in valleys
of the inner layer. Example:25 Filler Wire(1-6-6f -12)strand.
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 Wire rope classification:
WARRINGTON

This construction has two layers of wires around a center with one
diameter of wire in the inner layer, and two diameters of wire
alternating large and small in the outer layer.
The larger outer layer wires rest in the valleys, and the smaller ones on
the crowns, of the inner layer. Example: 19 Warrington [1+6(6+6)]
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 Wire rope classification:
COMBINED PATTERNS

When a strand is formed in a single operation using two or more of the

above constructions, it is referred to as a “combined pattern.” This
example is a Seale construction in its first two layers. The third layer
utilizes the Warrington construction, and the outer layer is a Seale
construction. It’s described as: 49 Seale WarringtonSeale [1-8-8-(8+8)-16].
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 Wire ropes cores:
Wire rope consists of multi strand metal wires wrapped around a
suitable core material. Wire-rope cores are carefully designed and
must be precisely manufactured to close tolerances to ensure a perfect
fit in the rope. The most common types of cores include the following .

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 Wire ropes cores:

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 Lays of wire ropes

Lang lay is recommended

for excavating,
construction, and mining
applications including
draglines, hoist lines.
This is because of the
Lang lay ropes are more
flexible than regular lay
ropes. They also have
greater wearing surface
per wire than regular lay
ropes

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 Characteristics of a wire ropes:
(1) Strength (2) Flexibility (3) Robustness
Strength can be increased by:
• increasing the diameter of the wire rope
• increasing the tensile strength of the individual wires 30 mm
• decreasing the air voids between the wires 6*9
• using a steel core construction.

Flexibility can be increased by:

• using more wires of a smaller diameter
30 mm
• decreasing the tensile strength of the individual wires 6*19
• using a fiber core.

Robustness, or resistance to physical damage:

•increased by using fewer wires of a larger diameter
•using a steel core
•Coatings can be applied to protect against corrosion.

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 Wire Rope Size Measurement

Designation of a wire rope: 20 mm 6*19 (12/6/1) wire

Nominal diameter of wire rope : 20 mm

No. of strands: 6
No. of wires in each strand :19.
(may be formed by 12 wires over 6 wires with 01 core wire)

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 Fleet angle in wire rope:

Range of Fleet angle for maximum efficiency and service:

< 1.5o for smooth drum
< 2o for grooved drum
Large fleet angle: results in excessive rubbing of the rope against the
flanges of the drum and the sheave groove, or crushing and abrasion
of the rope on the drum.
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 Fleet angle in wire rope:

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 Fleet angle in wire rope:

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 Factors Affecting Rope Performance:
•Multi-coiling
•Bad coiling
•Small diameter sheaves
•Oversize grooves
•Undersize grooves
•Excessive angle of fleet

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 Selection of drum and sheave diameter

For faster operation of ropes in cranes:

D/d=30

For fast un-loaders:

D/d= 36
Where,
D= sheave diameter or drum diameter, centre to centre of wire rope,
d= wire rope diameter.

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 Dimension of grooves on drums and in sheaves:

Drum

Sheave

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 Stresses and Load Calculation.
The wire diameter is given by the approximate relation :
𝑑
𝑑𝑤 =
1.5 𝑛
The metallic area of the rope is approximately given by
𝜋 2
𝐴𝑚 = 𝑑𝑤 ∗ 𝑛
4
𝐴𝑚 = 0.35 𝑑 2
Where,
d= wire rope diameter.
n = the total number of wires
𝑑𝑤 = the wire diameter.
𝐷 𝐷
> 400 = 800 ∶ 1000 𝑓𝑜𝑟 𝑒𝑙𝑒𝑣𝑎𝑡𝑜𝑟𝑠 𝑎𝑛𝑑 𝑚𝑖𝑛𝑒 ℎ𝑜𝑠𝑖𝑡𝑠
𝑑𝑤 𝑑𝑤

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 Stresses and Load Calculation.
The bending force

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 Stresses and Load Calculation.
As the rope passes around a sheave. The bending force produced in the
rope equal to.
𝐴𝑚 𝐸𝑑𝑤
𝐹𝑏 = 𝐾
𝐷
The metallic area of the rope is approximately given by
𝜋 2
𝐴𝑚 = 𝑑𝑤 ∗ 𝑛 𝐴𝑚 = 0.35 𝑑 2
4
Where,
K = 1 for elevator and k = 3/8 for any application
d= wire rope diameter.
n = the total number of wires
𝑑𝑤 = the wire diameter.
𝐷 𝐷
> 400 = 800 ∶ 1000 𝑓𝑜𝑟 𝑒𝑙𝑒𝑣𝑎𝑡𝑜𝑟𝑠 𝑎𝑛𝑑 𝑚𝑖𝑛𝑒 ℎ𝑜𝑠𝑖𝑡𝑠
𝑑𝑤 𝑑𝑤

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 Stresses and Load Calculation.
The Static Force

𝐹𝑠
𝑇𝑜𝑡𝑎𝑙 𝑤𝑒𝑖𝑔ℎ𝑡(𝑘𝑔) ∗ 9.8
=
𝑁𝑂. 𝑜𝑓 𝑤𝑖𝑟𝑒 𝑟𝑜𝑝𝑒𝑠
+ 𝑤𝑒𝑖𝑔ℎ𝑡 𝑜𝑓 𝑒𝑎𝑐ℎ 𝑟𝑜𝑝𝑒( N )
The Dynamic Force
𝐹𝑑 = 𝑚. 𝑎 𝑎
𝐹𝑑 = 𝐹𝑠
𝑔
Where,
a = Acceleration (m/s2)

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 Stresses and Load Calculation.
𝜋
𝑠𝑡𝑟𝑒𝑛𝑔𝑡ℎ ∗ ( ∗ 𝑑2 )
𝐹𝑇 = 𝐹𝑠 +𝐹𝑑 +𝐹𝑏 = 4
𝑓. 𝑜. 𝑠

Experiments have shown that the rope is not likely to fail by fatigue if
2000 𝐹
𝑆𝑢 ≥
𝐷𝑑
𝐹 = 𝐹𝑇 − 𝐹𝑏 = 𝐹𝑠 +𝐹𝑑

𝑆𝑢 = 1100 – 1300 MPa for Plow Steel

= 1400 – 1600 Mpa for Monitor Steel

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 Hoisting Tackle

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 Hoisting Tackle
A hoisting tackle is an arrangement of rope
(or chain ) and pulleys which provides a
“Mechanical Advantage”.
“ A small force or torque input to a
mechanism results in large force or
torque output.

velocity of point at the input force is applied

M. A =
velocity of the output load

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 Hoisting Tackle

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 Hoisting Tackle
For ideal system, in the absence of friction
the force (F) equal to load (W).
For normal system with friction
At Raising the load
F>W F = c.W
At Lowering the load
F<W W = c.F
Where
C = pulley friction constant F
>1
c ~ 1.1
W
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 Hoisting Tackle
At Raising the load
𝐹
𝐹 = 𝑐. 𝑇4 𝑇4 =
𝑐
𝑇4 𝐹
𝑇4 = 𝑐. 𝑇3 𝑇3 = = 2
𝑐 𝑐 𝑻𝟒 𝑻𝟏
𝑇3 𝐹 𝑻𝟑 𝑻𝟐
𝑇3 = 𝑐. 𝑇2 𝑇2 = = 3
𝑐 𝑐
𝑇2 𝐹
𝑇2 = 𝑐. 𝑇1 𝑇1 = = 4
𝑐 𝑐
W= 𝑇1 +𝑇2 +𝑇3 +𝑇4
1 1 1 1
W= 𝐹 + + +
𝑐4 𝑐3 𝑐2 𝑐

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 Hoisting Tackle
At Lowering the load

. 𝑇4 = 𝑐. 𝐹

𝑇3 = 𝑐. 𝑇4 𝑇3 = 𝑐 2 . 𝐹
𝑻𝟒 𝑻𝟏
𝑻𝟑 𝑻𝟐
𝑇2 = 𝑐. 𝑇3 𝑇2 = 𝑐3 .𝐹

𝑇1 = 𝑐. 𝑇2 𝑇1 = 𝑐 4 . 𝐹

W= 𝑇1 +𝑇2 +𝑇3 +𝑇4

W= 𝐹 𝑐 4 + 𝑐 3 + 𝑐 2 + 𝑐

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 Hoisting Tackle
At Raising the load 𝐹 + 𝑇3 𝑇1 + 𝑇2
𝐹
𝐹 = 𝑐. 𝑇3 𝑇3 =
𝑐
𝑇3 𝐹 𝐹 𝑇3 𝑇2 𝑇1
𝑇3 = 𝑐. 𝑇2 𝑇2 = = 2
𝑐 𝑐
𝑇2 𝐹
𝑇2 = 𝑐. 𝑇1 𝑇1 = = 3
𝑐 𝑐
W= 𝑇1 +𝑇2 +𝑇3
1 + 𝑐 + 𝑐 2
1 1 1 W=𝐹
W= 𝐹 3 + 2 + 𝑐 3
𝑐 𝑐 𝑐
𝑐3
𝐹 = 𝑊.
1 + 𝑐 + 𝑐2
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 Hoisting Tackle
𝑀. 𝐴 = 5
𝐹0 = 20 𝐾𝑔
𝐶 = 1.1 𝑇4 𝑇5 𝑇3 𝑇2 𝑇1

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