International Journal of Technology and Emerging Sciences (IJTES)

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Volume 03 || Issue 02 || April 2023 || pp. 15 - 20 E-ISSN- 2583-1925

Study and Analysis of Failure Analysis of Wire Rope

Ram Kishore Prasad1, Abdul Razzaque Ansari2, MD. Asif Equbal3, Mukesh Kumar Sahu4
1
Cambridge Institute of Technology, Department of Mechanical Engineering, Ranchi, Jharkhand, India
2
Cambridge Institute of Technology, Department of Mechanical Engineering, Ranchi, Jharkhand, India
3
Cambridge Institute of Technology, Department of Mechanical Engineering, Ranchi, Jharkhand, India
4
Cambridge Institute of Technology, Department of Mechanical Engineering, Ranchi, Jharkhand, India

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Abstract Wire ropes operate at high stress levels and are almost Several materials can be used to create the core. It could be
invariably subject to fluctuating loads. The continuous degradation made of polypropylene, wire rope, or natural fibres. A centre
of wire rope affected with operative services will ultimately lead wire that acts as the axial component is frequently wrapped
to failure. In this present work the test sample was adopted as the helically around many metallic wires. It is important to
single steel wire. To explore the effects of the load, test on normal remember that strands make up the majority of a wire rope's
wire (steel) and fretting wire (steel) the, breaking tensile tests were load-bearing parts. The core's function is to give the strands
carried out for both types of wires samples by using a universal
the necessary support under typical bending and loading
tensile testing (UTM) machine (INSTRON limited high
Wycombe, Model No. 8801). circumstances.
This test (Tensile) includes three major stages (elastic
deformation, plastic deformation and finally the fracture failure) in
the process of breaking tensile.

Key Words: Wire rope failure, wire rope, Wear scar, Tensile test

1. INTRODUCTION

Steel Wire Ropes are frequently used for lifting devices

because of their distinctive design.

With numerous working components that cooperate to support or

move the load, wire rope might be compared to a sophisticated Fig.1: Wire Rope and its components
machine. Everywhere, including but not limited to suspension
bridges, towers, elevators, and the lifting and rigging industries,
wire ropes are employed. Wire
The wire rope is constructed from multiple steel wires that are
twisted together to create distinct threads that form a helical They are the smallest part that make up each of the distinctive
pattern around the centre. The advantages of this structure include individual strands of the rope. One of the various metallic
its tremendous strength, flexibility, and resistance to bending substances that can be used to manufacture wires is steel. Several
stresses. Many material and wire combinations have various types of wires are produced based on their strength and resistance
benefits, such as strength, flexibility, and resistance to corrosion, to wear, fatigue, and corrosion. Usually, the wires are either
crushing, and fatigue. Several structural components, including uncoated or have a beautiful polish. The most frequent cross-
rope, have the ability to withstand relatively large axial loads in section for wires is spherical. Nonetheless, profile wires are
comparison to bending and torsional loads [1-3]. Because of this occasionally used. Profile wires are defined as wires with a cross
quality, ropes were among the first tools employed by human section different than a spherical section.
civilization.
Strands
1.1. Main Components of the wire rope
One metallic wire that is very thin makes up the basic part. Figure Strands are composed of many wires that have been precisely
1. shows the various components and how the strands are arranged twisted and arranged. Then, the different strands are arranged in a
around the central core. helical pattern to surround the core. Larger diameter wires provide
more abrasion resistance, whilst smaller diameter wires have
higher flexibility.

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wire rope Lay length and lay angle b. Analysis of steel wire rope with fretting (artificial) with
reduced diameters of above stated wire 6 mm via
In its simplest and most fundamental form, the strand consists of experimental analysis in UTM.
three or four twisted wires, as was the case with Albert's initial
wire rope, which had three straightforward strands with four wires 2.1. Experimental based braking failure analysis of steel
each. Today, however, a single layer of wires that are organised wire with and without fretting
helically around a central wire make up the most fundamental
strand. The test sample was adopted as the single steel wire. The steel
wire is made of high-quality carbon structural steel by the process
1.2. Wear of cold drawing.

One of the main ways steel wire ropes degrade is through wear. The braking failure analysis was performed on the UTM machine
The friction between the wires of the rope causes internal wear, made of INSTRON limited high Wycombe, Model No. 8801
and bending the rope over sheaves or drums causes outside wear. (England) which is having maximum capacity of 100 kN.
The latter is more typical in the vast majority of rope applications.
The rope’s safe working life is shortened by the point contacts and Steel wire and its fretting have been measured with the help of
excessive wear caused by the bending pressures. digital screw gauge.

2.LITRATURE REVIEW 2.2. The Stress calculation is given as

Because to the ubiquitous use of wire ropes, various academics σ=F/A 1.1
have done substantial research on the material's pertinent
characteristics over time. In order to assess the tribological
Here, σ refers to the stress
characteristics of ropes, Mc Coll et al. [4] examined the impact of
F is the force applied and
low viscosity oils, with and without graphite additions, on the
A denotes the area of the surface. The unit of stress is Pascal
fretting behaviour of a high-strength eutectoid steel rope wire. The
or N/m2.
surface property of the fretting scar was investigated. In a series of
investigations on the fretting wear and fatigue of steel wires,

Zhang et al. [5] investigated the wear depth and the fracture life 2.3. The Strain calculation is given as
under contact loads following each fretting friction test.

Cruzado et al. [6–7] planned numerous experimental programme x 2.2

and investigated the effects of these 2elements on the fretting wear Strain =
L
behaviour of the thin steel wires for dry friction. This is because
the effect of the contact pressure and crossing angle on the wear of
the rope wires is highly essential. Forcing fatigue experiments Where,
were extensively used by Wang et al. [8–9] to study the failure Change in dimension is x,
mechanism of hoisting rope. Under various displacement The original dimension is L.
amplitudes and strain amplitudes, he examined the wear
mechanism of the fretting contact scars and fretting fatigue life. Figures 2 to 3 show the images taken by the optical microscope
The impact of various corrosive fluids on the fretting fatigue and the scanning electron microscope (SEM) for the normal steel
damages of mine rope wires was investigated in light of the wire and the fretting wire.
complex hoisting situations.
Figures 2 and 3 shows the images of normal steel wire (7 mm) and
Wang et al. [10-11] also investigated the dynamic wear evolution the fretting wire of the same diameter having the reduced diameter
and crack propagation of steel wires under fretting-fatigue. The after the fretting is 6 mm.
wear depth and wear scar profiles were quantitatively analysed.
Although there are substantial discrepancies between the wear
characteristics of wires and ropes, Oksanen et al. [12–13] used
studies to better understand the rope's wear by examining the wear
mechanisms between the roller and the wire rope. In a previous
study, we conducted a number of friction and wear experiments on
a home-built test rig and looked at the tribological properties of
the winding hoisting ropes in various sliding scenarios [14].

a. Analysis of steel wire rope (unused) with different

diameters with 7 mm and its tensile test by using Universal
Testing Machine (UTM) and compare its performance and
failure analysis.

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 3.1 Performance Analysis (With Fretting for Steel
Wire of diameter 7 mm)

Fig. 2. Steel wire diameter (7 mm)

Fig.5. Stress-strain curve of Steel Wire of diameter 7 mm with

fretting.

Figures 4 and 5 shows the stress-strain diagram of steel wire (7

mm) and the fretting wire of 6 mm respectively.

In x axis there is strain and in y axis there is stress in MPa.

These graphs are plotted on the basis of experimental works. The

main results are shown in the Table 1.

Fig. 3. Scanning electron microscopy (SEM) Fretting of steel

Table: 1. Stress-strain property comparison of Steel Wire of
wire (7 mm)
diameter 7 mm without fretting and with fretting
3. ANALYSIS OF STEEL WIRE OF DIAMETER 7
MM WITH AND WITHOUT FRETTING

Fig.4. Stress-strain curve of Steel Wire of diameter 7 mm

without fretting

© 2023, IJTES | Volume 03 || Issue 02 || April 2023 | Page 17

 S.No Wire Tensile Modulus Tensile
Diameter extension of strain at
at Max Elasticity Max
(mm) Load (MPa) Load

Wire (mm) (%)

Dia =

7 mm

Wire Without 10.10 61200.5 13.4

Length Fretting Fig. 7. Meshing of without fretting steel wire (7 mm)

(mm) =
90 mm
With 7.8 76855.2 9.96 Fig.8. shows the deformation on steel wire after application of
Max tensile force which have been simulted by the software.
Fretting
Load

(kN)=

45.08

4.SIMULATION BASED ANALYSIS

4.1. Analysis of Steel Wire (7 mm)- without fretting

Fig.6. shows the geometric modelling in ANSYS of solid structure Fig.8. Deformation of without fretting steel wire (7 mm)
ABAQUS of steel wire similer to the wire which have been used
Fig.9. shows the Von Mises stress on steel wire after application
in the experimental analysis i.e. it have lay length of 90 mm and
of tensile force which have been presented here after simultion by
diameter of 7 mm.
the software.

Fig.9. Von Mises stress on without fretting steel wire (7 mm).

Fig.6. Geometry modelling of steel wire without fretting (7
mm) Fig.10. shows the strain on the steel wire after the application of
tensile force.
Fig.7. shows the meshing of the steel wire after modelling and
selection of material properties it is next step in the analysis.

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 Fig.12. shows the meshing of steel wire with fretting of
having 7 mm diameter.

Fig.10. Strain on without fretting steel wire (7 mm)

4.2.With Fretting of steel wire (7mm) Fig.13. Application of force on steel wire with fretting (7mm)
Fig.11. shows the geometric modelling in ANSYS of frettiing of
Fig.13. shows the application of force on steel wire with
steel wire. Frettiing have been taken here at the between of the
fretting.
wire or at the centre length of the wire.

Fig. 14. Deformation of steel wire with fretting (7mm).

Fig. 11.Geometry modelling of steel wire with fretting (7mm)
Fig.14. shows the deformation after the simulation of the fretting
steel wire of 7 mm diameter.

Fig. 15. Analysis of Stress on steel wire with fretting (7mm)

Fig.15. shows the strees on the fretting steel wire.

Fig. 12.Meshing of steel wire with fretting (7mm)

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 [5] Zhang DK, Ge SR, Qiang YH. Research on the fatigue and
fracture behavior due to the fretting wear of steel wire in hoisting
rope. Wear 2003;255:1233–7.
[6] Cruzado A, Hartelt M, W€asche R, Urchegui MA, G_omez X.
Fretting wear of thin steel wires Part 1: influence of contact
pressure. Wear 2010;268:1409–16.
[7] Cruzado A, Hartelt M, W€asche R, Urchegui MA, G_omez X.
Fretting wear of thin steel wires Part 2: influence of crossing
angle. Wear 2011;273:60–9.
Fig. 16. Analysis of Strain on steel wire with fretting (7mm) [8] Wang DG, Zhang DK, Ge SR. Effect of displacement

Fig.16. shows the simulated result of strain of fretting steel amplitude on fretting fatigue behavior of hoisting rope wires in
wire having 7 mm diameter. low cycle fatigue. Tribol Int 2012;52:178–89.
[9] Wang DG, Zhang DK, Ge SR. Fretting–fatigue behavior of
5. CONCLUSIONS
steel wires in low cycle fatigue. Mater Des 2011;32:4986–93.
1. For steel wire having diameter 7 mm without fretting maximum
tensile stress (  ) is obtained by experimental results is [10] Wang DG, Zhang DK, Zhao WJ, Ge SR. Quantitative
1171.50 (MPa) while by the simulation in ANSYS it is analyses of fretting fatigue damages of mine rope wires in
obtained as 1109 (MPa). different corrosive media. Mater Sci Eng A 2014; 596:80–8.
2. For the wire with fretting (reduced diameter = 6 mm) maximum [11] Wang D, Li X, Wang X, et al. Dynamic wear evolution and
tensile stress is obtained as 1427.82 (MPa) while by the crack propagation behaviors of steel wires during fretting-fatigue.
ANSYS it is obtained as 1485 (MPa).
Tribol Int 2016;101:348–55.
3. For steel wire having diameter 7 mm without fretting modulus [12] Oksanen V, Andersson P, Valtonen K, Holmberg K,
of elasticity (E) is obtained 63289.42 (MPa) by experimental
Kuokkala VT. Characterization of the wear of nodular cast iron
results. For the same wire with fretting (reduced diameter = 6
mm) maximum modulus of elasticity (E) is obtained as rollers in contact with wire ropes. Wear 2013;308: 199–205.
78854.32 (MPa). [13] Oksanen V, Valtonen K, Andersson P, Vaajoki A, Laukkanen
A, Holmberg K, et al. Comparison of laboratory rolling–sliding
So it can be concluded that by the fretting of wire results in
higher modulus of elasticity (E). wear tests with in-service wear of nodular cast iron rollers against
wire ropes. Wear 2015;340:73–81.

REFERENCES [14] Chang XD, Peng YX, Zhu ZC, et al. Tribological properties
of winding hoisting rope between two layers with different sliding

[1] Leschen Wire Rope Company, in Wire Rope Handbook, St. parameters. Adv Mech Eng 2016;8(12):1–14.

Joseph, Mo, 1971.

[2] A. Castello, Theory of wire rope (2nd ed.), Springer Publishing,
1997.

[3] K. Freyer, Wire Ropes: Tension, Endurance, Reliability,

Springer , 2007.
[4] McColl IR, Waterhouse RB, Harris SJ, Tsujikawa M.
Lubricated fretting wear of a high-strength eutectoid steel rope
wire. Wear 1995;185:203–12.

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