Parametric studies of cross sectional stresses for wire ropes under tensile load using the finite element method

The fatigue life of wire ropes usually is determined by the appearance of wire breaks. Especially when loaded by cyclic tensile- or tension-tension-forces and in the absence of any supportive parts (e.g. sheaves or bearings) the wire breaks mostly occur at the contact areas of the inner rope structure. This leads to the deductive reasoning that the lifetime directly depends on the effective stresses at the single wire contact areas. Several attempts to research on the mechanical behaviour at the inside of wire ropes were already carried out, but up to date there is no satisfying solution to reliably determine stresses and strains across the rope’s transverse profile. Thus, computer based models for spiral and stranded wire ropes were modelled and numerically simulated under tensile load by the use of FEA-software. Through adequate grid partitioning precise stresses and deformations of the wire ropes under static axial loads were obtained. The complete approach was parameterized to finally carry out series of analyses about the influence of varying wire rope dimensioning parameters on the radial stresses and especially on the wire contact stresses. Within the outline of this paper also current practical benefits of using FEA in wire rope research are highlighted and finally an outlook on future prospects is given.

Author(s): J.C. Weis and K.-H. Wehking