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1. INTRODUCTION
Wire ropes are belonging to the class of complex systems due to the large number of
components that build them and their complicated processes of operations. It is
generally a set of multiple strands wound around a central core strand and each strand
is comprised of several wires helically wound [1] (Fig.1).
This specific structure permits the wire ropes to resume loads despite the break of
one or more wires. Furthermore, they are able to carry loads in the longitudinal
direction while being flexible in the lateral direction [2].
Despite all the advantages that this conception represents, it is an accepted fact
that wire ropes are consumable with a limited life and it should be replaced before the
risk of failure becomes unfortunate. Industrial experience shows that sudden breaking
of a large part of wire ropes in service is most often due to the cumulative damage of
wires [3][4]. This is particularly insidious because of its hidden nature, which may
lead to serious accidents.
As part of this problem, this study focuses on the mechanical behaviour of one of
the components of the wire rope which is the central core strand of which several lots
were artificially damaged at different percentages (14%, 28%, 42%, 57% and 71%
broken wires). Based on an experimental tensile tests, the evolution of damage is
determined and subsequently the critical life fraction c is defined. Such a study could
be beneficial for manufacturers because of its low cost and speed.
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Mechanical Behaviour of Damaged Central Core Strand Constituting A Steel Wire Rope
Hoist Under The Effect of A Static Load
Figure 2 Steel Wire Rope of type 19x7 and antigyratory construction (1x7 + 6x7 + 12x7)
Figure 3 Experimental setup of a central core sample extracted from wire rope
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The mechanical properties of the virgin specimen are reported in the table1.
Table 1 The mechanical properties of central core strand
Mechanical
properties
Value
Tensile
strength
1561 MPa
Elastic
limit
1367 MPa
Young
modulus
189 GPa
Poissons
ratio
= 0,3
3.2 Tensile tests of tested specimens of the extracted central core strand at
different percentages of damage
Experimental results according to the number of broken wires (virgin, 14%, 28%,
42%, 57% and 71% broken wires) are given in Figure 5. The curves describe on 3D
the evolution of strength (N) versus displacement (mm).
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Mechanical Behaviour of Damaged Central Core Strand Constituting A Steel Wire Rope
Hoist Under The Effect of A Static Load
Figure 5 Evolution of the strength (N) versus displacement (mm) for different levels of
damage
When carrying out the tests and according to the results shown in Figure 5, it was
found that the ultimate strength drop depending on the number of broken wires.
Therefore, following this reaction of studied strand (central core), it was possible to
assess the damage at each level of damage by similarity to the behavior of a material
under cyclic loads
Fur = Fu D = 0
Fur = Fa D = 1
The variation of the static damage according to the life fraction is illustrated by
the curve in figure 6:
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Increased damage means the increase in strength loss in static tensile samples.
This loss changes when artificial damage becomes more important.
The curve in Figure 6. allowed us to identify three stages of damage using the
curvature change [7]. The first stage corresponds to its initiation; until = 2/7 broken
wires (28% damage), damage grows relatively slowly. Then there is the stage II
which is within the range of = [28%, 71%] when the damage becomes progressive
and predictive maintenance is essential to industrial. The critical life fraction c =71%
is the bridge between the progressive damage of stage II and stage III where the
damage is accelerating sharply and the break could be brutal. This means that from
71% of broken wires, the central core strand, the heart of wire rope, is declared in
default.
, =
and u =
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Mechanical Behaviour of Damaged Central Core Strand Constituting A Steel Wire Rope
Hoist Under The Effect of A Static Load
The variation of the damage according to with as a parameter and that of the
linear Miner rule is shown in Figure7. Each curve is associated to a loading level.
Figure 7 Evolution of Damage by unified theory and Miner law in function of the life
fraction
It is noted that the damage curve approaches gradually the bisector (the linear
Miner law) versus for high levels of loading.
Arguably Miner law provides greater safety and simplicity for the user that the
unified theory. It is for this reason that many researchers adopt this law for damage
study of wire ropes.
Figure 8 Comparison of damage according to the unified theory and the Miner law with static
damage
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Comparing the damage curves of two calculation methods and the curve of the
cumulative damage (Miner law), we see that the curve of static damage is similar to
that of the damage according to the theory unifies for loading levels = 2.26 and
=2.14 in the predefined stage I ( = [0%, 28%]). However, it is clear that the curve
deviates from static damage in stage II ( = [28%, 71%] ) and stage III ( = [71, 1%])
to lie beyond Miner.
4. CONCLUSION
Concerning the study of central core strand extracted from wire rope hoist, it was
possible to follow the evolution of damage to each percentage of damage based solely
on easy tensile tests. Two damage quantification methods were used for this study: the
method of calculation of static damage and the method of calculation by unified
theory. Comparisons of results have shown good agreement. Three stages of damage
were determined; Stage I [0, 28%] corresponding to the initiation of the damage, stage
II [28%, 71%] for the progressive damage that requires predictive maintenance and
stage III [71%, 1] where the damage is brutal, so the strand (central core) is declared
in default. Furthermore, a study of the behavior of an entire wire rope is being
established with data the cable geometry and the damage of the coiled strand and the
central core.
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