Sheave Design Manual “Partners to the Crane Industry”The Nycast Advantage Nycast Custom Cast sheaves offer some very important advantages to the equipment designer searching for ways to recuce component waights, improve service life, and provide protec- tion against corrosive environments at a cost which is competitive with other sheave materials. Nycast sheaves are custom formulated and cast from anionically polymerized Nylon Type 6, yielding a technologically advanced part, ire from localized stresses which occur in most other plastics processing methods. In addition, Nycast sheaves can be specifically formulated with modifiers and internal lubricant packages appropriate to the end use which further en- hance performance. Advantage #1- Reduced Component Weight Nycast nylon castings are approximately one- seventh the weight of cast steel sheaves of the same dimension, and approximately one-half the weight of aluminum sheaves. The use of Nycast sheaves results in reduced dead weight at the end of a boom and thus increased working capacity, and lower inertial loads in operation. Component weight reductions in the crane trans- late to lower gross vehicle weights. an important consideration in mobile crane design. Further: more, reduced woight Nycast sheaves aro oasior to handle during installation and replacement than their metallic counterparts. Advantage #2- Improved Service Life Nycast Nylon Type 6 custom cast sheaves not only provide exceptional durability and perfor- mance in demanding applications, their unique combination of physical properties significantly improve wire rope lite in operation. In addition to high tensile and compressive strength, Nycast sheaves possess oxcellent toughness and high elongation properties normally associated with (One steot sheave weighs as mucti 2a soven Nyeast Nylon sheaves. less-rigid, elastomeric materials. This provides a cushioning effect in the groove areas which contact the rope strands, which has proven to significantly extend wire rope life. Due to the ability of Nycast nylon to undergo a reversible, non-permanent deformation around the indi- vidual rope strands making contact with the groove surface, contact pressures at the rope- groove interface are almost 12 times less than a steel sheave of the same configuration. Nycast nylon sheaves provide a cushioned bedding area for the wire rope which translates into improved field performance, increased safety in ‘operation, and reduced expense associated with wire rope replacement Advantage #3- Corrosion Protection Nycast nylon sheaves are impervious to rust and salt water corrosion. This corrosion resistance is a property of the material itself, and does not rely on the integrity of a paint or similar thin coating applied to the sheave to maintain protection,In addition, Nycast sheaves are resistant to attack from most organic chemicals including solvents, degreasers, and clean-up solvents Advantage #4- Custom Engineered All Nycast sheaves are produced in molds custom engineered to the application. This optimal design for service and production re- sults in components which outperform their metallic counterparts at a competitive cost. Custom designed molds reduce material waste in production, and Nycast sheaves require minimal machining after casting to arrive at the finished part. Proper mold design also ensures that material properties are optimized and casting stresses are eliminated, resulting ina superior component. Nycast Custom Sheave design begins with an analysis of some basic key dimensions and load requirements. These are detailed below and on the Sheave Design Worksheet. Cast Nylons Ltd. provides an experienced Engineer- ing Staff in place to assist in the design of Custom Cast Sheaves and Components. Groove Configuration A correct groove angle and groove radius are required to provide maximum support to the wire rope and minimize wear on both the rope and the sheave. Experience has shown that Nycast nylon sheaves with an included groove angle of 20 deg. provide optimum rope support. The depth of the rope groove is generally speci- fied to be a minimum of 1.75 times the rope diameter. American and European standards recommend a groove diameter approximately 5% larger than the wire rope itself to accornmo- date rope tolerances and stil provide adequate ‘spport. Nycast nylon Custom Cast Sheaves “ate designed with these guidelines in mind. Recommended groove radius based on rope diameter is presented in Table Table | ] Rope Diameter and Groove Radius for Nycast Custom Sheaves. Wire Rope Diameter heave Groove Radius. vaio, ost in ae ist 76 set v2 iret ane ttt 38 206 34 236 cn iss fi rd Bore Configuration Needle type roller bearings are recommended for heavy duty applications involving heavy loads. It press fit is the method of bearing retention, ‘sufficient stock must be left in the bore to main- tain an acceptable press {it and eliminate bearing movement within the bore. Press fit allowance can be determined by the relationship: PF = .009 VBearing OD The press fit allowance is subtracted from the bearing OD to obtain the required bore diameter. This relationship takes into consideration the thermal expansion of Nycast nylon from -10 to 140°F operating temperatures. If temperatures outside this range are to be encountered, consult Cast Nylons Ltd. for the proper press fit allowance. Steel sleeves can be utilized in conjunetion with bearings to increase load handling capacity in heavy duty applications due to the resultant increase in bore diameter. Bronze bushings are not recommended for applications involving higher than moderate loads as an alternative to bearings. In lightly loaded applications, it is possible to take advantage of Nycast nylons inherent bearing properties; the bore may be machined to provide the bearing surface. The PV limits of the material selected must notbe exceeded, and the proper running clearances must be taken into account. Table II below indi- cates recommended shaft running clearances. Table Il Shaft Diameters and Recommended Running Clearances, Plain Bored Nycast Sheaves Shaft bi Funning Clearance n o.g0sin o.008 002 Boia 00:7 010 S021 024 Bore surface finishes of 32 RMS or better are recommended in plain bored sheave applications. All bore machined tolerances are +/- 0.002" Bearing Retention Bearings can be retained on the circummterence through press fit directly into the bore of a Nycast sheave. By following the formula shown under the Bore Configuration section, suffucient inter- ference can be achieved between the bearing and the bore to hold the bearing in place. Instal- lation can be achieved with a hydraulic press, or through the use of heat to expand the bore at 180-200. Side retention of bearings is required to restrict movement which may result trom side forces in operation, Thrust plates or washers can be placed on either side of the hub to restrict move- ment. Internal enap rings which lock into grooves machined into the bore of the hub have also been utilized successfully in Nycast sheaves Bearing olained in sheave bore with nap rings Idler sheaves fitted with bronze bearings, which are allowed to move freely from side to side on the shaft, and two-row, doublo-cup bearings require different methods of bearing retention Bronze idler bearings can be retained through the use of external snap rings placed outboard of the sheave hub. Similarly, a steel sleeve insert can be retained with external snap rings to accommodate two row double cup bearings which are pressed into the sleeve. Basic Sheave DimensionsLoad Capacity of Sheaves Industry standards identity the sheave pitch to rope diameter ratio (Dp/Dr) and the cesign factor (Fd) as important variables in the safe design of load bearing crane sheave applications. ANSI standarcs specify a minimum Dp/Dr of 18:1, and a minimum Fd of 8.5 for live or running wire ropes. The user should determine the values of these important design criteria based on the demands of the specific application as the initial step in custom sheave design. Sheaves with Bearings The load capacity of Nycast sheaves, which incorporate a bearing in the hub, is limited to the maximum allowable groove pressure and bore pressure of 3500 psi, The maximum load capac- ity of a sheave (Lmax) would be the lower of these two values as calculated below. 9500 pai x D, xD, $600 psi x D, x W, Loa where: D, = Rope diameter in.) D, = Tread diameter (in. D,-D, D, =Pitsh diameter fin.) Dy, = Bore diametar (in.) 1W, = Bore width in contact with bearing (Pet Fg. 1) Lax is chesan as the smaller of Loe 84 Looe, ‘The actual groove pressure (P,) may be calculated as foliows: P.=2(UIF) DxD, where: U = Breaking strength of wire 196 (Ib.) and —UIF, = Maximum single line pull (b.) The actual bore pressure (P,) may be caleulated as folows: Pe2WiFy Ox Ww, The load capacity limits recommended above are based on intermittent cyclic loading at 70°F. If the application involves continuous loading or cy- cling, heavy impact forces, high speeds and acceleration, or operation at temperatures signifi- cantly higher or lower than ambient, the applica- tion should be evaluated thoroughly and the limits should be reduced. Consult Cast Nylons Lig, for Engineering asistance in these cases. Sheaves without Bearings \n applications involving sheaves without the use of bearings, the load capacity of a Nycast sheave is limited by the ability of the bore to act asa bearing. This limit is established by the maximum recommended pressure (P) loading and velocity (V) at the bore surface, and the product of the two, the limiting PV of the material PV =Design Load lbs) X V D,xW, The calculated PV must not exceed the limiting PV licted in the Physical Properties table. To determine load capacity, first obtain the limitng PV of the material. Calculate the bore suriace velocity (V): V=.262 x RPMxD, where D, = Bore diameter (in) The velue of V should not exceed 400 fpm. Next, deter: mine the bare pressure P, P, = Limiting PV V ‘The maximum recommended bore pressure loading is 1,000 psi. Use the calcuated Pb or 1,000 psi, whichever Is less, to determine load capacity as follows: Lmax =P, xD, x1, whore: Lma W, Load capacity (Ibs.) jore width in contact with shaft (in) Excessive loads or speeds above the recommended limits may cause accelerated wear and increased bore clearance.Nycast Sheave Design Worksheet In reference to the drawing above, the following need to be determined to calculate load capacities: (assume a bearing is to be used) D, = Rope diameter = in D,=D,+D,=___in. D,=Treaddiameter=____in. Check: Is D,/ D, equal to or greater than 18? If not, change D, or D, to achieve this ratio. © e D, = Bore diameter = in, W, = Bore wicth = in, Maximum load capacities are then: MAX Lggie~ 3500 x D, x D, Ibs. MAX Ly. = 3500 x D, x WY, Ibs. Choose maximum load to be the smaller of the two quantities above. This is the Maxi- mum Load in pounds the sheave can carry. To optimize the choice of rope and sheave dimensions, use the actual groove and bore pressure equations and choose values that maximize the P, and P, at or near 3500 psi U=Broaking strongth of rope —_F, = Safety factor = 3.5, size chosen (Ibs.) P, MAX = 8500 psi. P, MAX = 3500 psi. D, /D, = 18 (minimum recommended) Substituting and simplitying: Minimum D,= V .0028_x U and Minimum W, = 1.47 x 104 x U Ds ‘The remaining items shown in the drawing above are required for an accurate quote of the part cost. (aaEEERniiieeemmmeemmememmmeinieinnmmmmmenseeneesaeeeneee ed———$——]$—_[_{[{[{[{ Material Properties ASTMTEST | NYCASTSPA PROPERTY UNITS —NETHOD-—_NYCAST6FA-COLORS" NYCASTEPA-MoS2 NYCASTNYLOIL HYCASTXHA Sresie Geaniy : one 416447 1184.47 1aets 1151.17 Tensile Strength pst ese +2,000-13600 apo0r3.sco —@an0-9.600 12000-13500 Tensile Elongation % ese 2045, 2500 4558 20.00 “Tenste teats ps fd 485-550.000 s20-80.000 390-409,009 _485-580,000 Comprossve Stiengh psi 606 16-1800 16-1800 : (@ 1% ote) Floral Sanath ps 0730 15,600-17,500 15500-17500 130043,500 _15.000-15,000, Floral ods pa 700 0.440.000 420-840 000 so-86n,000 420.140 000 Shear Srength pa ore +10,000-1,000 10000-11,900 0005.60 70,000-11,000 Netchee io pec —tebsin 286 m8 a9 1418 ne Hardness, Rockwell FL vas 115-120 115-120 40518 110-115 Hovdnose, Shere DD bere 7081 e199 878 7678 Meting Port * o7ee 450-4410 eso se0 4504/10 460-410 Coe efLiearThemal —intinsF D696, Bx to ex 108 36x10" 45x10 Expansion Doemaen UndeLead — % vezi 102s sta oe a0 Detection Temp, ‘204 ps * bese ss0-anu 330-400 30-409 330-400 pei * pee 400.430 00-420 400499 400-430 Coninuous Serco Temp. 230 290 230 250 Intent Soni Tero. °F 390 30 0 330 Flarmaiity : ves Soltexing Satanting Sotexirg Settting Water Abeomton 24 Hous rs ps0 ae a4 a4 ad Saturation % bore 9080 20-80 2025 5060 Limiting PY Unturieared pstumin = 3600 3.600 16,000 3.609 Lutricatod peittnin 44,000 +4000 318,009 14000 This informations presented 2s a quie for material comparison only. No cuarante® is mace of hei accuracy, however rl the products are sold without warranty express or pied, anc upon the condions that purchasers shall conduct ther dn teas to termine suitably for thai intended use Available in raiual, blue, black, re6, orange, ard yellow. Call fr olor samples. a NEYour Complete Source For Nylon Crane Components. 4300 Hamann Pkwy + Willoughby, Ohio 44094. 216-269-2300 © 1-800-543-3619