WIRE ROPES

Considering the bending and tensile stresses

in the rope d diameter of wire rope, cm

dw diameter of wire, cm
d
D EE d D diameter of pulley or sheave, cm

Fo, F load or tension per fall of rope, kgf

d E' P breaking strength of rope, kgf
min d
A area of useful cross section of the rope,
For 6 x 19 group of ropes

P FO cm 04

D
50000
min E corrected modulus of elasticity of steel
2
ropes; 0.8 x 10 kgf/ cnm
For 6 x 37 group of ropes
stress factor or design factor =
n
' x
Duty
Fo factor
d
DD. 36000
min tensile strength ofthe wire, kgf/ cm

Dlia d as a function of the number of bends in the system

No.
of
bends
1 2 3 4 5
7 3 10 11 12 13 14 15
16
16

Pain d16 |20 23 25 26.5|28 30|31 32 33|34 35 36 37 37.5 38

RATIO OF DRUM DIAMETER
FACTORS OF SAFETY:|
TO ROPE DIAMETER

*Minimum D/d Class Classes Class

Rope application
Purpose Rope
Class 12&34 1 - 2 &3
Fixed guys, jib cranes or 3.5 4.0 4.5
Mining All
100 100 100 ancillary applications
installations ropes
flexible
6 x37 15 17 22
cranes (example: mobile
Cranes & Hoists 6x 19 19 23 27 Crawler tower) Where jibs| 4.0 4.5 5.5
23 are supported by ropes
6x19 F 18 20
and hoists in
for S0 m/min speeds t o beranes
of rope general hoist blocks 4.5 5.0
alo 6.0
inereased by 8% for each additional 50 m/min.
Larger ratios to be used for non rotatingg ropes. Mining installations 10 or as laid in codes.

IS: 3938- 1967

DESIGN DATA -PSG TECH 9.1

 N life in number of cycles
bearing pressure on projected
area oftherrope on
Fatigue loading of ropes the
sheave,kgf/ cm

0.006

P 2F
dD
min
0.004

2 nF 6x37
d D min2 0.002 6x 19
(p / )

0 2x10 4x10 6x10 8x10 10x10

D mind ratio must be selected from the Number of Bends to Failure
above value for survival through N cycles
(p/o)Pressure ratio obtained from graph for N
bends to failure

MECHANISM
DUTY FACTOR AND LIFE OF
Average Life
Duty factor
Mechanism
Running Days per year
Wear hours per day| Total life hours on 20 years life
Class Strength
0.4 0.5 Over 2500 250
1 1.0
1.2 0.5 1.5 Over 9000 300

1.4 0.6 3.0 Over 26000 333

1.6 0.7 Over 6 Over 40000 333

4

for the appropriate class by the duty factor

The design factor is obtained by multiplying the factor of safety
Length of the drum,
ROPE DRUMS

No. of turns on the drum for one rope, L 27 s for one rope

Hi
Z 2
l, for two ropes

nHalinttalanlhiuaamunanuundlualhunlaualyahaadl

DESIGN DATA - PSG TECH

9.2
 DIAMETER OR GROOVE OF SHEAVES AND DRUMS

Rope diameter
Minimum groove number of turns on the drum for rope
d, mm
diameter, mm member
d+0.8 ratio of the pulley system
19 d+1.6 D drum diameter, cm
21 29 D Flange diameter of rope drum, cm
d+2.4
over 29 H Height to which the load is raised, cm
d+3.2
S Pitch of the grooves on the drum, cm
Depth of grooves to be less than 0.1 d. 1 Distance between the grooves of two
Wall thickness of C I rope pulleys, cm
drums;
L length of drum, cm
w
=0.02 D
+( 0.6 to 1.0) Cm
W wall thickness, cm
Dr (D +6 d)
Minimum Clearance between ropes
Maximum bending stress
8 F,LD Dia. of rope, Minimum
, b .D,)z mmn clearance
between the
Over
including ropes,
mm
Maximum shear stress 12 1.5

T
16M,D 12 29 2.5
D-D) 9 3.0
1. The pitch must be selected allowing
Crushing stress, ,= WFS for the minimum clearance
2. The lead angle must be less than the
allowable fleet angle of 5°
M torque on drum, kgf l cm
Total normal stress, G,= O,+o - F , (D min + d ) / 2

F load on the drum, kgf

Combined equivalent stress 2
bending stress, kgf / cm
. o+4T compressive stress, kgf/ cm
2

2
shear stress, kgf / cmn
ROPE SHEAVES
total normal stress, kgf / cm
Minimum depth of groove
2
combined
equivalent stress, kgf/ cm
1.5 d
Outside diameter of sheave [o] design stress, kgf/cm
d s minimum diameter of sheave, cm
ds0 d,+ 2tsg
depth of sheave groove, cm

DESIGN DATA -
PSG TECH 9.3
 ENGINEERING PURPOSES
GENERAL
WIRE ROPES FOR

37
Group 6 x

6 x 14/7+7 F/7/1
6x 14/7 and 7/7/1
6 x 16/8 + 8 F/6/1 6 x 15/15/6/1

6 x 18/ 12/6/1 6 x 16/8 and 8/ 8/1

Nominal Breaking strength of Rope, Tonnes

Diameter of Approximate Tensile strength of Tensile strength of
Rope weight wire 160 to 175 wire 175 to 190
mm kgf/ m 2 2
kgf/ mm kgf/ mm
10 0.45 6.2 6.8

12 0.60 8.1 8.9

14 0.74 10.3 11.3

16 0.92 12.7 13.9

18 1.32 18.3 20.0
20 1:58 21.4 23.5
22 1.81 24.6 26.9
24 2.10 28.4 31.0
25 2.37 32.5 35.6
29 2.99 40.6 44.7
32 3.69 50.3 55.4
35 4.48 61.0 67.1
38 5.32 72.6 79.8
41 6.25 85.3 93.5
44 7.24 99.1 108.7
48 8.32 113.8 125.0
51 9.46 129.1 142.2
S4 10.68 146.3
160.5
57 11.98 163.6 179.8
64 14.79 202.2
221.5
70 17.88 244.9 268.2

NOTE 1: To find the aggregate breaking strength, add 21 % to the figures in columns 3 and *.

NOTE 2: To find the nominal breaking strength with a hard drawn wire main core add 7.5 % to
the figures given in columns 3 and 4.

NOTE 3: To find the weight with a wire main core, add 11 % to the figures in column2.

IS 2266 1963

DESIGN DATA
- PSG TECH
9.4
 WIRE ROPES FOR GENERAL ENGINEERING PURPOSES (contd..)

Group 6 x 19
6x 12/6/1 6x 12/6+6 F/1
6x9/9//1 6x 10/5+5 F/1

Nominal Breaking strength, Tonnes

Diameter Approximate
mm weight Tensile strength of Tensile strength of
kgf/ m wire 160 to 175 wire 175 to 190
kgf/ mm kgf/mm
8 0.24 3.4 3.7
10 0.44 6.6 7.2
2 0.54 8.6 9.4
14 0.76 10.9 11.9
16 0.94 13.4 14.7
18 1.25 19.3 21.1
20 1.47 22.6 24.6
22 1.84 25.9 28.4
24 2.13 30.0 33.0

25 2.41 34.0 37.6

29 3.05 43.2 47.2

32 3.76 53.3 58.4

35 4.55 64.5 70.6

38 5.43 76.7 84.3

6.37 90.4 99.1

44 7.38 104.7 114.8

48 8.48 119.9 132.1

51 9.64 137.2 150.4

54 10.89 154.4 169.7

NOTE 1: To find the aggregate breaking strength, add 14.25 % to the figures in columns 3 and4

NOTE 2: To find the nominal breaking strength with a hard drawn wire main core add 7.5 % to
the figures given in columns 3 and 4.
E 3 : To find the weight with a wire main core, add 11 % to the figures in column 2,

IS 2266 -

1963

DESIGN DATA -

PSG TECH 9.5

 WIRE ROPES FOR GENERAL ENGINEERING PURPOSE (contd..)

(For lifts and hoists)

6x 19 group (contd..)
6x 12/6/1 6x 12/6+6 F/1 6x9/9/1

Nominal Breaking strength, Tonnes

Diameter Approximate
mm weight Tensile strength of Tensile strength of
kgf/m wire 110 to 125 wire 125 to 140
kgf/ mm kgf/ mm
0.15 1.5 1.7

8 0.25 2.3 2.7

10 0.40 4.0 4.5
12 0.55 5.5 6.0
14 0.75 7.7 8.8
16 0.95 9.6 11.0
18 1.25 12.7 14.2
20 1.45
15.0 17.0
22 1.85 18.8 21.2
25 2.25 23.0
26.0

NOTE 1: To find the aggregate breaking strength, add 14.25

columns 3 and 4. percent to the figures given in
NOTE 2: The nominal breaking strengths of dual tensile
ropes of 6 19 x

construction, having outer wires of ll0 to 125 kgf/ mm2 (9/9/1 ) seale
tensile strength and inner
wires of 125 to 140 kgf/ mm t ensile
strength, are the same as given in column 4.
IS 2365 - 1963

9.6 DESIGN DATA - PSG TECH