ME 463- MACHINE

DESIGN 2
Instructor: Engr. Danielle D. Cabana, MEng
Department of Mechanical Engineering
Cebu Institute of Technology - University

Reference:
A textbook of Machine Design (SI Units) by R.S. Khurmi,
J.K. Gupta
Design of Machine Elements 4th Edition by Virgil Moring
Faires
WIRE ROPE TRANSMISSION DRIVE
Wire
Ropes

When a large amount of power is to be transmitted over long distances from one
pulley to another (i.e. when the pulleys are up to 150 metres apart), then wire
ropes are used. The wire ropes are widely used in elevators, mine hoists,
cranes, conveyors, hauling devices and suspension bridges. The wire ropes run
on grooved pulleys but they rest on the bottom of the grooves and are not
wedged between the sides of the grooves.
Advantages of Wire
ropes
1. These are lighter in weight,
2. These offer silent operation,
3. These can withstand shock loads;
4. These are more reliable,
5. These are more durable,
6. They do not fail suddenly,
7. The efficiency is high, and
8. The cost is low.
Construction of wire ropes
Classification of wire ropes
• Cross or regular lay ropes. In these types of ropes, the
direction of twist of wires in the strands is opposite to the
direction of twist of the stands.
• Parallel or lang lay ropes. In these type of ropes, the direction
of twist of the wires in the strands is same as that of strands in
the rope.
• Composite or reverse laid ropes. In these types of ropes, the
wires in the two adjacent
• strands are twisted in the opposite direction
Cross-sections and standard designation of Wire Ropes
Designation of wire ropes
Cross-sections and standard designation of Wire
Ropes, (Khurmi)
Standard Designation of Wire Ropes
Standard Designation of Wire Ropes
Standard Designation of Wire Ropes
Nomenclature for wire ropes (Khurmi)
W = Load lifted, N or kN
w = Weight of the rope, N/m
A = Net cross-sectional area of the rope
𝐸𝑟 = Modulus of elasticity of the wire rope
𝑑𝑤 = Diameter of the wire
D = Diameter of the sheave or drum
a = Acceleration of the rope and load
g = Acceleration due to gravity
h = Slackness in the rope
l = Length of the rope
Design calculations for Wire ropes

Stresses in wire ropes

Direct stress,
𝑊+𝑤
𝜎𝑑 =
𝐴
Bending stress when the rope winds round the sheave or
drum,
𝐸𝑟 × 𝑑𝑤
𝜎𝑏 =
𝐷
Design calculations for Wire ropes

Equivalent bending load,

𝐸𝑟 × 𝑑𝑤 × 𝐴
𝑊𝑏 = 𝜎𝑏 × 𝐴 =
𝐷
Stresses during starting and stopping,
𝑊+𝑤
𝜎𝑎 = ×𝑎
𝑔
Additional load in the rope,
𝑊+𝑤 𝑎
𝑊𝑎 = ×
𝑔 𝐴
Design calculations for Wire ropes
Impact load on starting (considering the slackness of the rope),
2𝑎 × ℎ × 𝐸𝑟
𝑊𝑠𝑡 = 𝑊 + 𝑤 1 + 1 +
𝜎𝑑 × 𝑙 × 𝑔

When there is no slackness in the rope,

𝑊𝑠𝑡 = 2 𝑊 + 𝑤

2 𝑊+𝑤
𝜎𝑠𝑡 =
𝐴
Design calculations for Wire ropes
Effective stress,
rope during normal working
= 𝜎𝑑 + 𝜎𝑏
rope during starting
= 𝜎𝑠𝑡 + 𝜎𝑏
rope during acceleration of the load
= 𝜎𝑑 + 𝜎𝑏 + 𝜎𝑎
Procedure for designing a wire rope, (Khurmi)
1. First of all, select a suitable type of rope from Tables 20.6, 20.7, 20.8 and
20.9 for the given application.
2. Find the design load by assuming a factor of safety 2 to 2.5 times the factor
of safety given in Table 20.11.
3. Find the diameter of wire rope (d) by equating the tensile strength of the
rope selected to the design load.
4. Find the diameter of the wire (𝑑𝑤 ) and area of the rope (A) from Table
20.10.
5. Find the various stresses (or loads) in the rope as discussed in Art. 20.22.
6. Find the effective stresses (or loads) during normal working, during
starting and during acceleration of the load.
7. Now find the actual factor of safety and compare with the factor of safety
given in Table 20.11. If the actual factor of safety is within permissible
limits, then the design is safe.
Example:
Select a wire rope for a vertical mine hoist to lift a load
of 55 kN from a depth 300 metres. A rope speed of 500
metres / min is to be attained in 10 seconds.
Example:
Select a wire rope for a vertical
mine hoist to lift a load of 55 kN
from a depth 300 metres. A rope
speed of 500 metres / min is to be 1. From Table 20.6, we find that the wire ropes for haulage purposes in mines are
attained in 10 seconds.
of two types, i.e. 6 × 7 and 6 × 19. Let us take a rope of type 6 × 19.

2. From Table 20.11, we find that the factor of safety for mine hoists from
300 to 600 m depth is 7. Since the design load is calculated by taking a
factor of safety 2 to 2.5 times the factor of safety given in Table 20.11,
therefore let us take the factor of safety as 15.

Design load for the wire rope = 15 × 55 = 825 kN = 825 000 N

3. From Table 20.6, we find that the tensile strength of 6 × 19 rope made of wire
with tensile strength of 1800 MPa is 595 d2 (in newton), where d is the diameter of
rope in mm. Equating this tensile strength to the design load, we get:
Continuation
4. From Table 20.10, we find that for a 6 × 19 rope,

6. We know that the effective load on the rope during normal working (i.e. during
uniform lifting or lowering of the load)

5. Now let us find out the various loads in the rope as discussed below :

Since the actual factor of safety as calculated above are safe, therefore a
wire rope of diameter 38 mm and 6 × 19 type is satisfactory. Ans.
Assignment:
An extra flexible 8 × 19 plough steel wire rope of 38 mm
diameter is used with a 2m diameter hoist drum to lift 50 kN
of load. Find the factor of safety (ratio of the breaking load to
the maximum working load) under the following conditions of
operation:
The wire rope is required to lift from a depth of 900 metres.
The maximum speed is 3 m/s and the acceleration is 1.5 m/s2,
when starting under no slack condition. The diameter of the
wire may be taken as 0.05 d, where d is the diameter of wire
rope. The breaking strength of plough steel is 1880 N/mm2 and
modulus of elasticity of the entire rope is 84 × 103 N/mm2. The
weight of the rope is 53 N/m length.
 Design Consideration for Wire ropes using Faires
Materials used for wire ropes and Minimum design factors in
their ultimate tensile strength corresponding wire ropes application

Wire Ropes material Ultimate tensile Wire ropes for Minimum

strength, 𝑠𝑢 design factors
Improved Plow Steel (IPS) 240 ksi – 280 ksi Guys 3.5
Miscellaneous hoisting 5
Mild Plow Steel (MPS) 210 ksi – 240 ksi equipment

Plow Steel (PS) 180 ksi – 210 ksi Haulage ropes, cranes, 6
and derricks
Traction 180 ksi – 190 ksi
Small hoists 7
Iron with lower carbon < 100 ksi
Hot ladle cranes 8
(0.1%)
Very-high-strength (VHS) 280 ksi – 340 ksi
 Design Consideration for Wire
ropes using Faires
Table AT 28 Properties of Wire Ropes is table where
necessary information and equations in designing
and choosing appropriate wire ropes can be found.

Figure 17.30
Pressure ratio vs.
Cycles to failure is
used to identify the
life of wire ropes by
calculating its cycles
or number of bends
to failure
Nomenclature for wire ropes (Faires)
w = Weight of the rope, lb/in
𝐴𝑚 = Net cross-sectional area of the rope, 𝑖𝑛2
E = Modulus of elasticity, (3 × 104 ksi for steel)
𝐸𝑟 = Modulus of elasticity of the wire rope, ksi
𝐷𝑤 = Diameter of the wire, in
𝐷𝑠 = Diameter of the sheave or drum, in
𝐷𝑟 = Diameter of the rope, in
a = Acceleration of the rope and load, in/𝑠 2
g = Acceleration due to gravity, (32.2 ft/𝑠 2 )
L = Length of the rope, in or ft
𝐹𝑡 = Tensile force in the rope, lb or kips
𝐹𝑢 = Breaking force or ultimate force of the wire rope, lb or kips
F = Subjected load, lb or kips
 Design Calculation using Faires
Approximate bending stress Design Factor w/out bending
in the wire, load,
𝐸𝐷𝑤 𝐹𝑢
𝑠𝑏 = , 𝑝𝑠𝑖 𝑜𝑟 𝑘𝑠𝑖 𝑁=
𝐷𝑠 𝐹𝑡
Design Factor with bending
Equivalent bending load, load,
𝐹𝑢 + 𝐹𝑏
𝐹𝑏 = 𝑠𝑏 𝐴𝑚 , 𝑙𝑏 𝑜𝑟 𝑘𝑖𝑝𝑠 𝑁=
𝐹𝑡
Considering fatigue failure
Extension of the wire rope 2𝑁𝐹𝑡
under load, 𝐷𝑟 𝐷𝑠 =
𝐹𝐿 𝑝Τ𝑠𝑢 𝑠𝑢
𝛿= , 𝑖𝑛 Note: 𝑝Τ𝑠𝑢 ≤ 0.0015 𝑓𝑜𝑟 𝑖𝑛𝑑𝑒𝑓𝑖𝑛𝑖𝑡𝑒 𝑙𝑖𝑓𝑒
𝐴𝑚 𝐸𝑟
Example:
In a coal-mine hoist, the weight of the cage and load is 20 kips;
the shaft is 400 ft. deep. The cage is accelerated from rest to
1600 fpm in 6 sec. A single 6 x 19, IPS, 1 ¾-in. rope is used,
wound on an 8-ft. drum. (a) Include the inertia force but take
the static view and compute the factor of safety with and
without allowances for the bending load. (b) If N =1.35 , based
on fatigue, what is the expected life? (c) Let the cage be at the
bottom of the shaft and ignore the effect of the rope’s weight. A
load of 14 kips is gradually applied on the 6-kip cage. How
much is the deflection of the cable due to the load and the
additional energy absorbed? (d) For educational purposes and
for a load of 0.2 𝐹𝑢 , compute the energy that this 400-ft rope
can absorb.
Continuation:

(a) Include the inertia force but

take the static view and compute
the factor of safety with and
without allowances for the
bending load.
Continuation

(b) If N =1.35 , based on fatigue,

what is the expected life?
Continuation

(c) Let the cage be at the bottom of the shaft and ignore
the effect of the rope’s weight. A load of 14 kips is
gradually applied on the 6-kip cage. How much is the
deflection of the cable due to the load and the
additional energy absorbed?
(d) For educational purposes and for a load of 0.2 𝐹𝑢 ,
compute the energy that this 400-ft rope can absorb.
EXERCISE 3: WIRE ROPES
Instruction:
1. Written solution on a long bond paper.
2. Take a photo of your solution.
3. Upload your solution in the google form provided.
Exercise no. 3: Wire Ropes by Faires
A skip for a mine shaft weighs 2000lb and is to lift a
maximum load of 3000lb from a depth of 1000ft. The
maximum speed of 20fps is attained in 5 sec. (a) What sizes of
6 x 19, IPS rope and sheave should be used for indefinite life
and for N=1.3 on the basis of fatigue? (b) What is the design
factor on the static basis? (c) What sizes of rope and sheave
are required if the number of cycles (bending and unbending)
in the desired life is 200,000? What is the corresponding static
design factor? (d) What is the elongation of the rope found in
(c) if the 3000lb load is added while the hoist hangs free at the
bottom?