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COLLEGE OF ENGINEERING AND ARCHITECTURE
Department of Mechanical Engineering
Chapter 1 WIRE ROPES
Machine Design 2
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Introduction
▪ Wire ropes are made of flexible, twisted strands of wire that
are usually laid over a core.
▪ Wire rope consists of multiple wires or strands, helically wound
or laid over an axis.
▪ Wires, strands and core are independent that interact with
each other during service.
Reference: Design of Machine Elements by Virgil Moring Faires
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Introduction
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Introduction
▪ The term cable is often used interchangeably with wire rope.
▪ Wire rope refers to diameter larger than 3/8 inch (9.52 mm).
▪ Sizes smaller than this are designated as cable or cord.
Advantages of Wire Ropes
▪ Lighter in weight ▪ Offer silent operation
▪ Can withstand shock loads ▪ Reliable
▪ More durable ▪ Do not fail suddenly
▪ Efficiency is high ▪ Cost is low
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Construction of Wire Rope
▪ Wire ropes are designed in different steel grades, finishes and
variety of constructions
▪ to attain the best balance of strength, abrasion
resistance, crush resistance, bending fatigue resistance
and corrosion resistance for each application.
▪ Wire ropes are made from cold drawn
wires that are first twisted into strands, and
then the strands are twisted into helices
about a core or central element.
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Different Cores
▪ The central element is often
an independent wire rope
core (IWRC)
▪ It makes the rope much
more resistant to crushing.
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Construction of Wire Rope
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Wire Rope Classification
▪ “Lays” of a wire rope are descriptions of how wires and
strands of the rope are laid in helix.
Regular Lay or Cross Lay
▪ The wires and strands are twisted in opposite directions.
▪ The lay direction can be right (symbol Z) or left (symbol S).
Lang Lay or Parallel Lay (formerly Albert’s lay and Lang’s lay)
▪ The wires and strands are twisted in same direction.
▪ Lang lay ropes are more flexible than regular lay ropes and
also have greater wearing surface.
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Wire Rope Classification
Reverse Lay or Composite Lay
▪ The wires in the two adjacent strands are twisted in opposite
direction.
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Wire Rope Classification
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Other Wire Rope Classification
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Designation of Wire Rope
6x7
strand wire per strand
▪ The first number is the number of strands, and the second
number is the number wires per strand.
▪ The greater the number of wires in a strand,
the more flexible the rope.
▪ The fewer wires, the stiffer the rope.
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Proper Measurement
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Various Rope Sizes
▪ 6x7 – for haulage, rigging, guard rails tramways, guy wires
and power transmission
– provides maximum resistance to abrasion and wear
▪ 6x19 – general purpose rope, hoists, cranes, drilling, elevator
– compromise of flexibility and wear resistance
▪ 6x37 – steel mill ladles, high speed elevators, cranes, hoists
– extra flexible rope and useful where abrasion is not
severe and where relatively sharp bends must be
tolerated
▪ 8x19 – extra flexible hoisting rope applications
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Various Wire Rope Sizes
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Strand Construction
▪ Strands are designed with various combination of wires and
wire sizes to produce the desired resistance to fatigue and
abrasion.
▪ Small number of large wires will have more abrasion
resistance and less fatigue resistance than a large number of
small wires.
Different Strand types
▪ Single size
▪ Seale
▪ Filler wire
▪ Warrington
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Strand Construction
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Characteristics
▪ Strength can be increased by:
▪ increasing the diameter of wire rope
▪ increasing the tensile strength of individual wires
▪ decreasing the air voids between the wires
▪ using a steel core construction
▪ Flexibility can be increased by:
▪ using more wires of smaller diameter
▪ decreasing the tensile strength of individual wires
▪ using a fiber core
▪ Robustness (or resistance to physical damage)
▪ increased by using fewer wires of larger diameter
▪ using a steel core
▪ coatings can be applied to protect against corrosion
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Factor Affecting Performance
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Factor Affecting Performance
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Materials
Steels
▪ Plow steel (PS) ▪ Alloy steel
▪ Mild plow steel (MPS) ▪ Stainless steel
▪ Improved plow steel (IPS) ▪ Copper
▪ Wrought iron ▪ Bronze
▪ Cast steel
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Materials
Vegetable fiber (Natural fiber)
▪ Cotton ▪ Hemp ▪ Jute/Flax
▪ Manila (abaca)
▪ Sisal
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Materials
Synthetic fiber
▪ Polyester
▪ Nylon
▪ Glass fibers ▪ Metallic wire
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Wire Rope End Terminations
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Uses of Wire Ropes
▪ Elevators ▪ Mine hoists
▪ Oil well drilling
▪ Cranes
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Uses of Wire Ropes
▪ Aerial conveyor ▪ Tramways
▪ Suspension bridge
▪ Haulage device
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𝐸 – modulus of elasticity of wire material 27/35
Wire Rope Formulas
▪ Equivalent Bending Stress, 𝜎𝑏 𝟑
𝑬𝒓𝑫𝒘 where: 𝐄𝐱𝐩𝐞𝐫𝐢𝐦𝐞𝐧𝐭𝐚𝐥𝐥𝐲 𝐄𝐫 = 𝐄
𝟖
𝝈𝒃 = 𝐷𝑤 – wire diameter
𝑫𝒔
𝐷𝑠 – sheave or drum diameter
for Steel Rope: 𝐄𝐫 = 𝟏𝟐 × 𝟏𝟎𝟔 𝐩𝐬𝐢
𝐸𝑟 – modulus of elasticity of entire rope
for wrought Iron Rope: 𝐄𝐫 = 𝟏𝟏 × 𝟏𝟎𝟔 𝐩𝐬𝐢
𝐴 – total cross sectional area of the rope
▪ Equivalent Bending Load, Fb 𝐹𝑢 – breaking strength of the wire rope
𝑨𝑬𝒓𝑫𝒘 𝐹𝑡 – total tensile force due to the load
𝑭𝒃 =
𝑫𝒔 (including acceleration of forces)
▪ Factor of Safety, N 𝐷𝑟 – nominal diameter of the wire rope
(should be in inches)
𝑭 𝒖 − 𝑭𝒃
𝑵= ℎ – height/length of the rope (ft)
𝑭𝒕
▪ Approximate weight of wire rope, Wr
𝑾𝒓 = 𝟏. 𝟓𝟖 𝑫𝒓 𝟐 𝒉 , 𝒍𝒃
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Wire Rope Formulas
▪ Acceleration force due to weight of the rope, Wra
𝑾𝒓 𝒂
𝑾𝒓𝒂 =
𝒈
▪ Acceleration force due to weight connected at the rope
end, WLa 𝑾𝑳 𝒂
𝑾𝑳𝒂 =
𝒈
▪ Total tension of the rope, Ft
𝐹𝑡 = 𝑊𝑟 + 𝑊𝐿 + 𝑊𝑟𝑎 + 𝑊𝐿𝑎
𝑎 𝑎 where:
𝐹𝑡 = 𝑊𝑟 + 𝑊𝐿 + 𝑊𝑟 + 𝑊𝐿
𝑔 𝑔 𝑎 – acceleration
𝒂 𝑔 – standard gravitational acceleration
𝑭𝒕 = 𝑾𝒓 + 𝑾𝑳 𝟏 +
𝒈 𝑊𝐿 – useful load
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Useful Tables
▪ Approximate Diameters and Areas
Rope 𝑫𝒘 𝑨, 𝒊𝒏𝟐
6x7 0.106 𝐷𝑟 0.38𝐷𝑟 2
6 x 19 0.063 𝐷𝑟 0.38𝐷𝑟 2
6 x 37 0.045 𝐷𝑟 0.38𝐷𝑟 2
8 x 19 0.050 𝐷𝑟 0.35𝐷𝑟 2
▪ Factor of Safety for Wire Ropes
Service N
Elevators 8 – 12
Mine hoists 2.5 – 5
Cranes motor-driven 4–6
Cranes hand-powered 3–5
Derricks 3–5
from: Design of Machine Members by Doughtie and Vallance
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Useful Tables
▪ Estimated Ultimate Strength, Fu
(in tons = 2000 lbs)
▪ For 6 x 19:
▪ VHS: 𝑭𝒖 ≈ 𝟒𝟖 𝑫𝟐𝒓
▪ IPS: 𝑭𝒖 ≈ 𝟒𝟐 𝑫𝟐𝒓
▪ PS: 𝑭𝒖 ≈ 𝟑𝟔 𝑫𝟐𝒓
▪ MPS: 𝑭𝒖 ≈ 𝟑𝟐 𝑫𝟐𝒓
▪ Traction steel:
𝑭𝒖 ≈ 𝟎. 𝟖𝟕 (𝑭𝒖 𝒇𝒐𝒓 𝑴𝑷𝑺)
from:
Design of Machine Elements
by Virgil Faires
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Useful Tables Note: Area must be in m2 31/35
Maximum Rated Load Of Passenger Elevators
(PSME Code)
▪ For an elevator having an inside net platform area of not
more than 4.65 m2
𝑾 = 𝟑𝟓. 𝟏 𝑨𝟐 + 𝟑𝟐𝟔. 𝟐𝟐𝟒 𝑨 ; 𝒌𝒈
▪ For an elevator having an inside net platform area of more
than 4.65 m2
𝑾 = 2.458 𝑨2 + 611.36 𝑨 − 621.4 ; 𝒌𝒈
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Sample Problems
1. Determine the probable bending stress and equivalent bending load in a 1.
75-in, 6 x 19 steel rope made from 0.098-in wire, when it is used on a 90-in
sheave.
Given: Find Fb:
6 x 19 steel rope AErDw AEr 0.098in
Dr = 1.75 in Fb = =
Dw = 0.098 in Ds 90in
Ds = 90 in Fb = __________
Find 𝛔𝐛 :
Find A: (using 6 x 19):
ErDw Er 0.098in 𝐴 = 0.38𝐷𝑟 2
σb = =
Ds 90in 2
𝐴 = 0.38 1.75𝑖𝑛
σb = _________
𝐴 = _________
Use (for steel):
Er = 12 × 106 psi
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Sample Problems
2. A wire rope is used with total load of 8500 kg and bending load of 55,000
kg. If the breaking strength of the rope is 120,000 kg, find the factor of
safety.
Given:
Ft = 8500 kg
Fb = 55000 kg
Fu = 120,000 kg
Find N:
Fu − Fb 120,000kg − 55,000kg
N= =
Ft 8500kg
N = __________
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Sample Problems
3. A 6 x 19 IPS wire rope with rope diameter of 2.5 in is to be used for hoisting.
Find the weight of the rope if the depth of the mine hoist is 110 m.
Given:
6 x 19 IPS
Dr = 2.5 in
h = 110 m
Find Wr:
Wr = 1.58Dr 2 h
2 3.28ft
Wr = 1.58 2.5in 110m ×
1m
Wr = __________
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𝐅𝐮 − 𝐅𝐛 𝐀𝐄𝐫𝐃𝐰
𝐍= 𝐅𝐛 = 35/35
Sample Problems 𝐅𝐭 𝐃𝐬
4. A 12.0 mm, 6 x 19 plow steel (PS) wire rope is bent around a 600 mm sheave
and is used to carry 4,300 kg of load. What is the factor of safety for this
application?
Given: Find A (using 6 x 19):
6 x 19 PS
A = 0.38Dr 2
Dr = 12.0 mm 2
Ds = 600mm 1in
A = 0.38 12 mm × = _________
Ft = 4300 kg 25.4mm
Find Er (for steel):
Find Fu:
Er = 12 × 106 psi
Using PS: Fu ≈ 36 D2r
2
1in Find Dw (using 6 x 19):
Fu = 36 12mm ×
25.4mm Dw = 0.063Dr
2000lbs 1in
Fu = _________tons × Dw = 0.063 12mm ×
ton 25.4mm
Fu = _________ Dw = _______
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𝐅𝐮 − 𝐅𝐛
𝐍= 36/35
Sample Problems 𝐅𝐭
4. A 12.0 mm, 6 x 19 plow steel (PS) wire rope is bent around a 600 mm sheave
and is used to carry 4,300 kg of load. What is the factor of safety for this
application?
Given: Find Fb: Solve for N:
6 x 19 PS
Dr = 12.0 mm
AErDw Fu − Fb
Fb = N=
Ds = 600mm Ds Ft
Ft = 4300 kg AErDw
Fb = Fu − F b
1 in N=
600 mm 2.205lbs
25.4 mm 4300kg
1kg
Fb = ________
N = _______
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𝐅𝐮 − 𝐅𝐛 𝐀𝐄𝐫𝐃𝐰
𝐍= 𝐅𝐛 = 37/48
Sample Problems 𝐅𝐭 𝐃𝐬
5. A vertical mine hoist is used to carry 8 metric tons of ore at a height of 100 mete
rs. The load is to start from rest and will attain a maximum speed 160 meters pe
r minute in 10 seconds. A 6 x 19 IPS wire rope is used for hoisting on a sheave 1.
0 m in diameter. Find the factor of safety if 44.5 mm diameter ropes will be used
for this application.
Given: Find Fu: Find A: (using 6 x 19):
WL = 8 MT Using IPS: Fu ≈ 42 D2r A = 0.38Dr 2
h = 100 m 1in
2 2
1in
vi = 0 m/min Fu = 42 44.5mm × A = 0.38 44.5mm ×
25.4mm 25.4mm
vf = 160 m/min
t = 10 s 2000lbs A = _________
Fu = ______tons ×
6 x 19 IPS ton
Ds = 1.0 m Find Dw (using 6 x 19):
Fu = _______
Dr = 44.5 mm Dw = 0.063Dr
Find Er(for steel): 1in
Dw = 0.063 44.5mm ×
25.4mm
Er = 12 × 106 psi
Dw = ________
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𝐅𝐮 − 𝐅𝐛 𝐚
𝐍= 𝐅𝐭 = 𝐖𝐫 + 𝐖𝐋 𝟏+ 38/48
𝐅𝐭 𝐠
Sample Problems
5. A vertical mine hoist is used to carry 8 metric tons of ore at a height of 100 mete
rs. The load is to start from rest and will attain a maximum speed 160 meters pe
r minute in 10 seconds. A 6 x 19 IPS wire rope is used for hoisting on a sheave 1.
0 m in diameter. Find the factor of safety if 44.5 mm diameter ropes will be used
for this application.
Given: Find Wr:
WL = 8 MT
Wr = 1.58Dr 2 h
h = 100 m 1in
2
3.28ft
vi = 0 m/min Wr = 1.58 44.5mm × 100m ×
25.4mm 1m
vf = 160 m/min
t = 10 s Wr = ______
6 x 19 IPS Convert WL: Find a:
Ds = 1.0 m vf − v i
2205lbs
Dr = 44.5 mm WL = 8MT × a=
1MT t
m m
Find Fb: WL = ______ 160 − 0 1min
a= min min ×
AErDw 10 sec 60sec
Fb =
Ds m
a = 0.2667 2
Fb = _________ s
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5. A vertical mine hoist is used to carry 8 metric tons of ore at a height of 100 mete
rs. The load is to start from rest and will attain a maximum speed 160 meters pe
r minute in 10 seconds. A 6 x 19 IPS wire rope is used for hoisting on a sheave 1.
0 m in diameter. Find the factor of safety if 44.5 mm diameter ropes will be used
for this application.
Given: Find Ft:
WL = 8 MT a
h = 100 m Ft = Wr + WL 1+
g
vi = 0 m/min
m
vf = 160 m/min 0.2667 2
Ft = Wr + WL 1+ s
t = 10 s m
9.807 2
6 x 19 IPS s
Ds = 1.0 m Ft = ______
Dr = 44.5 mm
Solve for N:
Fu − Fb
N=
Ft
N = _______
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Sample Problems
6. What is the maximum rated in kg of an elevator having a 2.5 m2 floor area.
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