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Design and Analysis of Steel Wire Rope of 2 Ton Overhead Crane

Hardik V. Solanki, Hardik N. Chauhan, Shivang S Jani

Abstract


Multi-strand wire rope designs and analyses for crane use have been reported. The major goal of this study is to determine the safest methods for handling wire ropes while extending their lifespan through bending and fatigue tests that are carried out on rope specimens until they fail. This is a suggestion for measuring the stress level of the inner and outer strand of wire. To construct a model for axial force and bending moment, various methods are employed. In order to make a critical
comparison of the analyzed and tested methodologies, the analytical results of wire rope have been compared with experimental data acquired on the rope (modulus of elasticity, wire fatigue tests, rope bending fatigue tests).


Keywords


Steel wire rope, life cycle, fatigue failure

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References


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Guerra-Fuentes, L., Torres-López, M., Hernandez-Rodriguez, M. A. L., & Garcia-Sanchez, E. (2020). Failure analysis of steel wire rope used in overhead crane system. Engineering Failure Analysis, 118, 104893.

Battini, D., Solazzi, L., Lezzi, A. M., Clerici, F., & Donzella, G. (2020). Prediction of steel wire rope fatigue life based on thermal measurements. International Journal of Mechanical Sciences, 182, 105761.

Shuangchang, F., Jie, C., & Xiaoqing, C. (2020, May). Analysis of the hidden danger for old elevator safety. In 2020 3rd International Conference on Electron Device and Mechanical Engineering (ICEDME) (pp. 605-608). IEEE.

Wahid, A., Mouhib, N., Ouardi, A., Sabah, F., Chakir, H., & ELghorba, M. (2019). Experimental prediction of wire rope damage by energy method. Engineering Structures, 201, 109794.

Zhou, P., Zhou, G., Zhu, Z., He, Z., Ding, X., & Tang, C. (2019). A review of non-destructive damage detection methods for steel wire ropes. Applied Sciences, 9(13), 2771.

Yaman, O., & Karakose, M. (2017, September). Auto correlation based elevator rope monitoring and fault detection approach with image processing. In 2017 International Artificial Intelligence and Data Processing Symposium (IDAP) (pp. 1-5). IEEE.

Pal, U., Mukhopadhyay, G., Sharma, A., & Bhattacharya, S. (2018). Failure analysis of wire rope of ladle crane in steel making shop. International journal of fatigue, 116, 149-155.

Mouradi, H., El Barkany, A., & El Biyaali, A. (2018). Steel wire ropes failure analysis: Experimental study. Engineering Failure Analysis, 91, 234-242.

Singh, R. P., Mallick, M., & Verma, M. K. (2016). Studies on failure behaviour of wire rope used in underground coal mines. Engineering failure analysis, 70, 290-304.

Tijani, A., Elghorba, M., Chaffoui, H., Mouhib, N., & Boudlal, E. (2016). Experimental life prediction of a 1+ 6 strand extracted from a 19x7 wire rope. IPASJ Int. J. Mech. Eng, 4(3), 23-29. Atmiya University Page 14

Shamsudin, S. R., Harun, M., Mohd Noor, M., Rahmat, A., & Abdul Malek, R. (2015). Failure analysis of crane wire rope. In Materials Science Forum (Vol. 819, pp. 467-472). Trans Tech Publications Ltd.

Peterka, P., Krešák, J., Kropuch, S., Fedorko, G., Molnar, V., & Vojtko, M. (2014). Failure analysis of hoisting steel wire rope. Engineering Failure Analysis, 45, 96-105.

Gerdemeli, I., Kurt, S., & Anil, A. S. (2014). Fatigue life analysis of wire rope strands with finite element method. In Key Engineering Materials (Vol. 572, pp. 513-516). Trans Tech Publications Ltd.

Senthil, S., Amudhan, K., & Gurusaravanan, G. A Comprehensive Study of Effect on Increasing the Wire Rope Diameter in Crawler Crane.

Moradi, S., Ranjbar, K., & Makvandi, H. (2012). Failure analysis of a drilling wire rope. Journal of failure analysis and prevention, 12(5), 558-566.

Kim, S. H., Bae, R. H., & Kwon, J. D. (2012). Bending fatigue characteristics of wire rope. Journal of mechanical science and technology, 26(7), 2107-2110.

Zhang, X. (2009, August). The research of stress monitor and broken testing for steel wire rope. In 2009 9th International Conference on Electronic Measurement & Instruments (pp. 3-1044). IEEE.

Mapelli, C., & Barella, S. (2009). Failure analysis of a cableway rope. Engineering Failure Analysis, 16(5), 1666-1673.

Torkar, M., & Arzenšek, B. (2002). Failure of crane wire rope. Engineering failure analysis, 9(2), 227-233.

Zhang, D., Feng, C., Chen, K., Wang, D., & Ni, X. (2017). Effect of broken wire on bending fatigue characteristics of wire ropes. International journal of fatigue, 103, 456-465.

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Onur, Y. A., İmrak, C. E., & Onur, T. Ö. (2017). Investigation on bending over sheave fatigue life determination of rotation resistant steel wire rope. Experimental Techniques, 41(5), 475-482.

Fang, G., & Cheng, J. (2022). Design and Implementation of a Wire Rope Climbing Robot for Sluices. Machines, 10(11), 1000.

Lesňák, M., Procházka, J., Hlavatý, I., Pištora, J., & Kostiuková, G. (2014). Study of steel wire ropes defects. In Applied Mechanics and Materials (Vol. 683, pp. 55-60). Trans Tech Publications Ltd.

Casey, N. F., & Lee, W. K. (1989). The fatigue failure of large diameter six strand wire rope. International journal of fatigue, 11(2), 78-84.

Argatov, I. I., Gómez, X., Tato, W., & Urchegui, M. A. (2011). Wear evolution in a stranded rope under cyclic bending: Implications to fatigue life estimation. Wear, 271(11-12), 2857-2867.

Bonneric, M., Aubin, V., & Durville, D. (2019). Fatigue damage mechanisms in steel cable under bending loading. Engineering Failure Analysis, 106, 104184.

Zhiqian, R., & Xun, C. (2017). Research on fatigue life of steel wire ropes under impact loads based on double Pareto lognormal distribution. Advances in Mechanical Engineering, 9(8), 1687814017715978.

Mouhib, N., Wahid, A., Sabah, F., Chakir, H., & ELghorba, M. (2021). Experimental characterization and damage reliability analysis of central core strand extracted from steel wire rope. Engineering Failure Analysis, 120, 105103.

Seelam, A. B., Jawed, M. S., & Krishanmurthy, S. H. (2021). Design and analysis of elevator wire ropes. International Journal for Simulation and Multidisciplinary Design Optimization, 12, 20.

Guerra-Fuentes, L., Torres-López, M., Hernandez-Rodriguez, M. A. L., & Garcia-Sanchez, E. (2020). Failure analysis of steel wire rope used in overhead crane system. Engineering Failure Analysis, 118, 104893.

Battini, D., Solazzi, L., Lezzi, A. M., Clerici, F., & Donzella, G. (2020). Prediction of steel wire rope fatigue life based on thermal measurements. International Journal of Mechanical Sciences, 182, 105761.

Shuangchang, F., Jie, C., & Xiaoqing, C. (2020, May). Analysis of the hidden danger for old elevator safety. In 2020 3rd International Conference on Electron Device and Mechanical Engineering (ICEDME) (pp. 605-608). IEEE.

Wahid, A., Mouhib, N., Ouardi, A., Sabah, F., Chakir, H., & ELghorba, M. (2019). Experimental prediction of wire rope damage by energy method. Engineering Structures, 201, 109794.

Zhou, P., Zhou, G., Zhu, Z., He, Z., Ding, X., & Tang, C. (2019). A review of non-destructive damage detection methods for steel wire ropes. Applied Sciences, 9(13), 2771.

Yaman, O., & Karakose, M. (2017, September). Auto correlation based elevator rope monitoring and fault detection approach with image processing. In 2017 International Artificial Intelligence and Data Processing Symposium (IDAP) (pp. 1-5). IEEE.

Pal, U., Mukhopadhyay, G., Sharma, A., & Bhattacharya, S. (2018). Failure analysis of wire rope of ladle crane in steel making shop. International journal of fatigue, 116, 149-155.

Mouradi, H., El Barkany, A., & El Biyaali, A. (2018). Steel wire ropes failure analysis: Experimental study. Engineering Failure Analysis, 91, 234-242.

Singh, R. P., Mallick, M., & Verma, M. K. (2016). Studies on failure behaviour of wire rope used in underground coal mines. Engineering failure analysis, 70, 290-304.

Tijani, A., Elghorba, M., Chaffoui, H., Mouhib, N., & Boudlal, E. (2016). Experimental life prediction of a 1+ 6 strand extracted from a 19x7 wire rope. IPASJ Int. J. Mech. Eng, 4(3), 23-29. Atmiya University Page 14

Shamsudin, S. R., Harun, M., Mohd Noor, M., Rahmat, A., & Abdul Malek, R. (2015). Failure analysis of crane wire rope. In Materials Science Forum (Vol. 819, pp. 467-472). Trans Tech Publications Ltd.

Peterka, P., Krešák, J., Kropuch, S., Fedorko, G., Molnar, V., & Vojtko, M. (2014). Failure analysis of hoisting steel wire rope. Engineering Failure Analysis, 45, 96-105.

Gerdemeli, I., Kurt, S., & Anil, A. S. (2014). Fatigue life analysis of wire rope strands with finite element method. In Key Engineering Materials (Vol. 572, pp. 513-516). Trans Tech Publications Ltd.

Senthil, S., Amudhan, K., & Gurusaravanan, G. A Comprehensive Study of Effect on Increasing the Wire Rope Diameter in Crawler Crane.

Moradi, S., Ranjbar, K., & Makvandi, H. (2012). Failure analysis of a drilling wire rope. Journal of failure analysis and prevention, 12(5), 558-566.

Kim, S. H., Bae, R. H., & Kwon, J. D. (2012). Bending fatigue characteristics of wire rope. Journal of mechanical science and technology, 26(7), 2107-2110.

Zhang, X. (2009, August). The research of stress monitor and broken testing for steel wire rope. In 2009 9th International Conference on Electronic Measurement & Instruments (pp. 3-1044). IEEE.

Mapelli, C., & Barella, S. (2009). Failure analysis of a cableway rope. Engineering Failure Analysis, 16(5), 1666-1673.

Torkar, M., & Arzenšek, B. (2002). Failure of crane wire rope. Engineering failure analysis, 9(2), 227-233.

Zhang, D., Feng, C., Chen, K., Wang, D., & Ni, X. (2017). Effect of broken wire on bending fatigue characteristics of wire ropes. International journal of fatigue, 103, 456-465.

Battini, D., Solazzi, L., Lezzi, A. M., Clerici, F., & Donzella, G. (2020). Prediction of steel wire rope fatigue life based on thermal measurements. International Journal of Mechanical Sciences, 182, 105761

Onur, Y. A., İmrak, C. E., & Onur, T. Ö. (2017). Investigation on bending over sheave fatigue life determination of rotation resistant steel wire rope. Experimental Techniques, 41(5), 475-482.

Fang, G., & Cheng, J. (2022). Design and Implementation of a Wire Rope Climbing Robot for Sluices. Machines, 10(11), 1000.

Lesňák, M., Procházka, J., Hlavatý, I., Pištora, J., & Kostiuková, G. (2014). Study of steel wire ropes defects. In Applied Mechanics and Materials (Vol. 683, pp. 55-60). Trans Tech Publications Ltd.

Casey, N. F., & Lee, W. K. (1989). The fatigue failure of large diameter six strand wire rope. International journal of fatigue, 11(2), 78-84.

Argatov, I. I., Gómez, X., Tato, W., & Urchegui, M. A. (2011). Wear evolution in a stranded rope under cyclic bending: Implications to fatigue life estimation. Wear, 271(11-12), 2857-2867.

Bonneric, M., Aubin, V., & Durville, D. (2019). Fatigue damage mechanisms in steel cable under bending loading. Engineering Failure Analysis, 106, 104184.

Zhiqian, R., & Xun, C. (2017). Research on fatigue life of steel wire ropes under impact loads based on double Pareto lognormal distribution. Advances in Mechanical Engineering, 9(8), 1687814017715978.

Mouhib, N., Wahid, A., Sabah, F., Chakir, H., & ELghorba, M. (2021). Experimental characterization and damage reliability analysis of central core strand extracted from steel wire rope. Engineering Failure Analysis, 120, 105103.

https://www.rentlgh.com/blog/howdoes-that-work-industrial-wire-rope-explained

https://www.researchgate.net/figure/Composition-of-plain-carbon-steel-by-mass percentage-for-wire-rope_tbl1_331293419

https://wirerope.net/azwr/wire-rope-classification

https://crane1.com/about-s/blog/causes-hoist-wire-rope-failures/


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