Beruflich Dokumente
Kultur Dokumente
BUREAU OF STANDARDS
George K. Burgess, Director
NONDESTRUCTIVE TESTING OF
WIRE HOISTING ROPE BY
MAGNETIC ANALYSIS
BY
R. L. SANFORD, Physicist
Bureau of Standards
PRICE, 10 CENTS
$1.25 PER VOLUME ON SUBSCRIPTION
Sold only by the Superintendent of Documents, Government Printing Office
Washington, D. C.
WASHINGTON
GOVERNMENT PRINTING OFFICE
1926
T 315
ABSTRACT
CONTENTS
Page
I. Introduction 497
II. Magnetic analysis 498
III. Magnetic exploration 499
IV. Effect of stress 504
V. Effect of wear 510
VI. Effect of repeated stress 514
VII. Other effects 515
VIII. Summary and conclusions 516
I. INTRODUCTION
It is difficult to tell just when a hoisting rope should be removed
from service and a new one substituted. While it is desirable to
utilize the full life of the rope, it is dangerous and oftentimes very
expensive to leave a rope in place too long. The resulting damage
may amount to many times the cost of putting in a new rope before
the end of the useful life of the old one has been reached, to say nothing
of the life hazard. By the present methods of visual inspection it is
impossible to ascertain the conditions of a rope with certainty.
The inspector must depend upon his judgment, based upon accu-
mulated experience, together with certain arbitrary rules with regard
to the number and distribution of broken wires. Under these
497
498 Technologic Payers of the Bureau of Standards [Vol.20
. -XL
coil was approximately 191 times the current in amperes. There was
also an outer auxiliary winding of 1,189 turns.
Several test-coil systems were used during the course of the investi-
gation. These coils were wound on interchangeable fiber forms
which could be mounted within the magnetizing solenoid. The test
coils used were either single, double, or triple. The electromotive
force induced in a single coil depends upon the rate of change in the
magnetic flux in the specimen which is linked with the test coil. The
disadvantage of this type of test coil is that changes of flux, due to
fluctuations in the magnetizing current, give indications which can
not be distinguished from those caused by irregularities in the material
itself.
The character of the record obtained depends not only upon the
type of test coil used, but also upon the indicating instrument. A
reflecting galvanometer of the moving-coil type is generally used. If
the instrument has a short period and is critically damped, the instru-
ment behaves as a voltmeter, and the deflection at any instant is pro-
portional to the rate of change of flux finked with the test coil. This
rate depends not only upon the local variations in the magnetic
permeability or cross section of the specimen, but also upon the speed
with which the coil is traveling. If the galvanometer is heavily over-
damped so that the principal control is electromagnetic, then the
instrument behaves as a fluxmeter, and the deflection at any instant
is proportional to the total change in flux linkage since the start.
\^/\4 \A'VV vV / /
in. (D
match. Note that the most serious defect, that at B, gives a mag-
netic indication which might very well have been disregarded if the
defect had not been known to be there.
In view of the difficulties just indicated, which are typical of the
results of previous investigations, and of the fact that wire rope is in
itself a rather complicated structure, the investigation has been of a
fundamental nature, consisting in a study of the magnetic properties
of hard-drawn steel wires of which rope is made and the effect upon
them of various influences known to cause deterioration in wire rope
in service.
The material used in the investigation was furnished by the
American Steel & Wire Co., and consisted
of four grades of patented
steel wire known to the trade as " crucible cast steel," " extra strong
crucible cast steel," "plow steel," and " monitor plow steel." The
wires were 0.1 inch in diameter and had tensile strengths ranging from
190,000 to 250,000 lbs./in. 2 .
The influences which have so far been made the subjects of study
were stress, wear, and fatigue. In view of the fact that under
service conditions a hoisting rope always under stress and that the
is
stress is continually varying while the rope is being used, this element
was considered first.
in the coil and the field is reversed, the deflection of the galvanometer
isproportional to the difference in number of turns of the two parts
and the ferric induction (B-H) in the specimen. This is easy to see
from the following equations.
Let A 1 and A 2 and , N
and N2 be the area and number of turns of
the outer and inner coils, respectively, and a the area of the specimen.
H is the magnetizing force and B the flux density in the specimen.
The flux turns (4>N) linked with the two coils are
{4>N) t = N B a + Nt
t H {A x -a)
(<t>N) 2 = N2 B a + N2 H (A 2 -a)
Since the coils are connected in opposition, the flux turns indicated
by the ballistic galvanometer upon reversal will be
Since
Table 1. Values of magnetic induction (B) for various degrees of stress for
crucible-cast-steel wire
H
25,500 51,000 76,500 102,000 127,500
75 16, 520 16, 620 16, 200 15, 700 15, 150 14,600
100 17, 600 17, 300 16, 900 16, 370 15, 880 15, 350
150 18, 640 18, 250 17, 780 17, 280 16, 800 16,350
200 19, 200 18, 850 18, 400 17, 940 17, 500 17, 030
.
In Figure 7 are shown graphically the results for no load and for a
load giving a stress of 51,000 lbs/in. 2 The magnetic induction (B)
.
but the curves cross and for higher values of magnetizing force the
magnetic induction is reduced by tension. With these data before
us it is easy to see how the effects of stress may interfere with the
proper estimation of mechanical quality in terms of magnetic prop-
erties. We can now explain the small apparent effect of the notch
filed at B in record No. 4 of Figure 4. The normal effect of the
reduction in area would be an apparent decrease in the magnetic
permeability. Actually, however, on account of the higher stress,
Ultimate Strenjtk
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Effect of Tension.
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tfajnet/z/'nj Force - Gilberts per cm.
AB
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used the effect is practically negligible for loads up to 50,000 lbs. /in. 2
or more. If this is the case, there should be little irregularity in an
exploration record if a magnetizing force as great as 75 gilberts per
AB
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3000 -
o
s
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-^-^^H=50
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Fig. 9. Showing the relation between stress and the change in magnetic induction
AB for three values of magnetizing force
with about 100 gilberts per centimeter. In the lower record, the
amplitude of the deflections not due to flaws is greatly reduced but
the effect of the flaws is still definite and distinct. It appears, there-
the stress distribution which may
fore, that the effect of variations in
arise from variable conditions during the process of manufacture, and
which do not constitute defects from the practical point of view, may
be eliminated by the use of a sufficiently high value of magnetizing
making magnetic-exploration records. It is probably safe to
force in
assume also that effects which are evident at low magnetizing forces
but which disappear at high magnetizing forces are due to variations
in stress distribution. It would not be desirable to eliminate the
#/-
Fig. 10. Elimination of stress effects by the use of higher magnetizing force
p = a+(3H
510 Technologic Payers of the Bureau of Standards [Volzo
V. EFFECT OF WEAR
The most obvious result of service in a hoisting rope is wear.
This may
occur on the outside of the rope where it is visible, or it
may take place on the inside where it can not be seen. In either
case, it removes material and weakens the rope. Wear does not
take place uniformly along the length of an individual wire but is
concentrated at points where it comes in contact with other objects.
We have already seen in Figure 4 that the magnetic effect of a reduc-
tion in section may not be proportional to the amount of material
removed. It is also conceivable that the removal of material from
the outside of a wire may so modify the stress distribution within
the wire as to change its mechanical effectiveness. In order to
2 Sanford, B. S. Sci. Paper No. 496: 1924.
Sanford] Testing Wire Rope by Magnetic Analysis 511
ments on wear have been described previously, 3 but for the sake of
/SOOO
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400
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e ^^^L UQ o
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600
/*
400 f
I
/
200 /
r
JO 20 30 40 SO
% fted in Area
Fig. 13. Relation between per cent reduction in area by
wear and change in magnetic induction for H=20
AB is the change in induction
6 Z20
o
2,
S O o
S3 oo n O <b i
i 200
)
<s
C3
O /O ZO SO 40 SO 60 70
Per cent reduction in area
Fig. 14. Increase in tensile strength of steel wire resulting
from reduction in area by wear
fore the fatigue test was started, after 501,300 repetitions of stress
and again after 543,500 repetitions. The maximum fiber stress
was 32,200 lbs. /in. 2 The 501,300 repetitions resulted in a small
.
Moore and Kommers, Univ. of 111. Engr. Exp. Sta., Bui. No. 124; 1921.