The document discusses the design and selection of wire ropes, including their construction with strands of wires twisted around a core, different types of wire ropes used for various applications like mining hoists and cranes, and factors to consider like breaking strength, flexibility, and fatigue resistance. Procedures for selecting a suitable wire rope include determining the design load based on a safety factor, calculating rope diameter and wire size, and checking stresses and safety factors.
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Belt is a Flexible Mechanical element that transmit power from one shaft to another
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Like Comment and download
Belt is a Flexible Mechanical element that transmit power from one shaft to another
Belt is a Flexible Mechanical element that transmit power from one shaft to another
Gear Train
Ex: Automobile, engines etc.
Chain Drive
Ex : Bi-cycle , Motor cycle etc.
Belt Drive
Ex: Rice mills, sewing machine etc.
Rope Drive
Ex: lift, crane etc
Bearing failure and its Causes and Countermeasuresdutt4190
A brief review about bearing and failure of its various parts due to other possibilities than design such as manufacturing, improper service and handling and other similar aspects.
“V - Belts” - Design of Machine Element Umang Parmar
Introduction to V-Belts.
Construction of V-Belts.
Types of Standard Cross Section of V-Belts.
Designation of V-Belts.
Advantages of V-Belts & Limitation of V-Belts.
Application of V-Belts.
Definition, Use, Types of beariings, Types of Journal bearing, Materials for journal bearing, Failures of journal bearing, Design terms for journal bearing, Types of roller contact bearing, applications of roller contact bearing, Designation of roller contact bearing, Design terms for roller contact bearing, comparison between journal and roller bearings, characteristics of bearings, selection procedure of bearings
Springs - DESIGN OF MACHINE ELEMENTS-IIDr. L K Bhagi
Introduction to springs, Types and terminology of springs, Stress and deflection equations, Series and parallel connection, Design of helical springs, Design against fluctuating load, Concentric springs, Helical torsion springs, Spiral springs, Multi-leaf springs, Optimum design of helical spring
Notes on Wire rope, Construction/type of wire rope, Testing of wire rope, Application of wire rope, Safety factor, Examination of wire rope, Care & Maintenance, Rope splicing, Tucking, Rope Capel, Reliance Capel, Deterioration of rope, Maximising the life of rope behalf of mining
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2. What is Wire-Rope
How to Selection Wire-Rope,
To study Construction,
Classification ,designations,
To study various Stresses in wire ropes,
Selection of wire rope for given loads.
ObjectivesObjectives
3. Rope Drives
The rope drives are widely used where a large amount of power is to
be transmitted, from one pulley to another, over a considerable
distance.
It may be noted that the use of flat belts is limited for the
transmission of moderate power from one pulley to another when the
two pulleys are not more than 8 meters apart.
If large amounts of power are to be transmitted, by the flat belt, then
it would result in excessive belt cross-section.
The ropes drives use the following two types of ropes : 1. Fibre
ropes, and 2. Wire ropes.
The fibre ropes operate successfully when the pulleys are about 60
metres apart, while the wire ropes are used when the pulleys are up to
150 metres apart.
4. Fibre Ropes
The ropes for transmitting power are usually made from fibrous
materials such as hemp, manila and cotton. Since the hemp and manila
fibres are rough, therefore the ropes made from these fibres are not
very flexible and possesses poor mechanical properties.
The hemp ropes have less strength as compared to manila ropes.
When the hemp and manila ropes are bent over the sheave, there is
some sliding of the fibres, causing the rope to wear and chafe
internally. In order to minimise this defect, the rope fibres are
lubricated with a tar, tallow or graphite.
The lubrication also makes the rope moisture proof. The hemp ropes
are suitable only for hand operated hoisting machinery and as tie ropes
for lifting tackle, hooks etc.
The cotton ropes are very soft and smooth. The lubrication of cotton
ropes is not necessary. But if it is done, it reduces the external wear
between the rope and the grooves of its sheaves.
It may be noted that the manila ropes are more durable and stronger
than cotton ropes. The cotton ropes are costlier than manila ropes.
5. The fibre rope drives have the following advantages :
1. They give smooth, steady and quiet service.
2. They are little affected by out door conditions.
3. The shafts may be out of strict alignment.
4. The power may be taken off in any direction and in
fractional parts of the whole amount.
5. They give high mechanical efficiency.
Advantages of Fibre Rope Drives
6. 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 meters apart), then wire ropes are used.
The wire ropes are widely used in elevators, mine hoists,
cranes, conveyors, hauling devices and suspension bridges.
7. 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.
The wire ropes are made from cold drawn wires in order to
have increase in strength and durability.
It may be noted that the strength of the wire rope increases as
its size decreases.
The various materials used for wire ropes in order of
increasing strength are wrought iron, cast steel, extra strong
cast steel, plough steel and alloy steel. For certain purposes, the
wire ropes may also be made of copper, bronze, aluminium
alloys and stainless steels.
8. Why Wire RopeWhy Wire Rope
Small Wires are stronger per cross sectional area
Excellent for Tension
Flexible-Can be wound
9. 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.
Advantages of Wire Ropes
11. The wires are first given special heat treatment and then cold
drawn in order to have high strength and durability of the rope.
The steel wire ropes are manufactured by special machines.
First of all, a number of wires such as 7, 19 or 37 are twisted into
a strand and then a number of strands, usually 6 or 8 are twisted
about a core or centre to form the rope as shown in Fig.
The core may be made of hemp, jute, asbestos or a wire of
softer steel. The core must be continuously saturated with
lubricant for the long life of the core as well as the entire rope.
The asbestos or soft wire core is used when ropes are subjected
to radiant heat such as cranes operating near furnaces. However,
a wire core reduces the flexibility of the rope and thus such ropes
are used only where they are subjected to high compression as in
the case of several layers wound over a rope drum.
12. Classification of Wire RopesClassification of Wire Ropes
1. Cross or regular lay ropes
2. Parallel or Lang lay ropes
3. Composite or reverse laid
ropes.
13. Stresses in Wire RopesStresses in Wire Ropes
1. Direct stress due to axial load lifted and
weight of the rope
2. Bending stress when the rope winds round
the sheave or drum.
3. Stresses during starting and stopping.
4. Stress due to change in speed
5. Effective stress.
d
W w
A
σ
+
=
r w
b b
E d A
W A
D
σ
× ×
= × =
2
( )
4
b w bW d n
π
σ= ×
2( )
st
W w
A
σ
+
=
2 1( )v v
a
t
−
=
b d aσ σ σ= + +
14. Procedure for Designing a Wire RopeProcedure for Designing a Wire Rope
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.
17. Design ConsiderationsDesign Considerations
Breaking strength
Flexibility
Crush resistance
Abrasion resistance
Fatigue Resistance increases with more wires.
Abrasion Resistance increases with larger wires
18. 1.Quantity in feet or pieces
2.Diameter & tolerance
3.Construction
4.Material
5.Length required
6.Reel or packaging requirements, if any
7.Specification or drawing, if applicable
8.Lubrication, if not covered by specification
9.Delivery requirements
10.Transportation preference
11.Certification required
12.Any other special information
When requesting a quotation or placing an order,
please give us the following information about
your requirements.
19. ExampleExample Select a wire rope for a vertical mine hoist to lift a load of 55 kNSelect a wire rope for a vertical mine hoist to lift a load of 55 kN
from a depthfrom a depth 300 metres. A rope speed of 500 metres / min is to be attained300 metres. A rope speed of 500 metres / min is to be attained
in 10 seconds.in 10 seconds.
Solution. Given :Solution. Given : W = 55 kN = 55 000 N ; Depth = 300 m ; v = 500 m/min ; t = 10 sW = 55 kN = 55 000 N ; Depth = 300 m ; v = 500 m/min ; t = 10 s
1. From Table 20.6, we find that the wire ropes for haulage purposes in
mines are 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
595 d2 = 825 000
∴ d 2 = 825 000 / 595 = 1386.5 or d = 37.2 say 38 mm
4. From Table 20.10, we find that for a 6 × 19 rope,
Diameter of wire, dw = 0.063 d = 0.063 × 38 = 2.4 mm
20. Questions?Questions?
1. Under what circumstances a fibre rope and a wire rope is
used ?What are the advantages of a wire rope over fibre
rope ?
2. Discuss the uses and construction of wire ropes. How are
wire-rope ends fastened ?
3. Give the application of the following wire ropes : (a) 6 ×
7 rope (b) 6 × 19 rope, and (c) 6 × 37 rope.