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Performance of wire rope in a machine is affected by design of its sheaves and drums. Information about design of sheave and drum (diameter, the shape of the groove profiles and
corresponding radius, the drum pitch and the fleet angle) is given in this article. Other useful technical information on wire ropes – measurement of diameter; generally accepted
design factors; capacity of drums and reels; reserve strength; wire rope clips and wire rope end connections is also given in this article.
It can be seen that, a rope bent around a pin of its own diameter will have only 50% of the strength attributed to it in the standard test. This is called '50% efficiency'. Even at D/d
ratios of 40, there may be a loss of up to 5%.
In view of above, relevant standard or statutory requirement shall be followed. In absence of such requirements, the diameter of drum or sheave shall not be less than that given in
the table below.
A too narrow groove will crush the rope and damage the wires soon. In too wide groove, the rope will wear more quickly at the point of contact and also cut a false groove in the
pulley. In wide groove, the rope will not have lateral support and it will flatten under load. A rope shall be supported by the groove for one third of its circumference.
Recommended groove dimensions for sheave and drum are as under.
Pitch (p): The pitch shall not be smaller than 2.065 x groove radius and larger than 2.18 x groove radius.
The cranes are designed for four mechanism classes (Class 1 to 4) based on different duty factors (for strength and wear) and average life (running time per day and total life). For
more information on various terms, please refer the specification.
Grooving of Drums
The contour at the bottom of the grooves shall be circular over an angle of approximately 120 degrees. The depth of the groove shall be not less than 0.35 times the diameter of the
rope. The grooves of the drum shall be so pitched that there is, between adjacent turns of the rope, a clearance of not less than:
Grooving of Sheaves
Sheaves shall be grooved to a depth of not less than 1.5 times the diameter of the rope. The contour at the bottom of the grooves shall be circular over an angle of approximately
130 degrees.
Fleet Angle
Where a wire rope leads over a sheave and on to a drum, the rope will not remain in alignment with the sheave but will deviate to either side depending on the width of the drum
and the distance from the fixed sheave.
The fleet angle is the angle created at the point of intersection of a line drawn from the inside edge of the drum flange and along the centre line of the rope lead, and a line drawn
from the centre of the drum at right angle to it. This angle is formed at the lead pulley. On a crane fitted with a grooved drum the angle should never exceed 4 degree and on a
crane fitted with a flat-faced drum the angle should be between ½ degree and 2 degree maximum. If this angle is more, there will be heavy wear of the rope and groove sides.
To ensure the correct fleet angle, the following formula may be useful in finding the height of the lead pulley or the width of the drum, when one of these two measurements is
known.
C = A/B where,
C = Constant having maximum value as under.
Diameter of a wire rope is the diameter of a circle circumscribing the strands. Care should be taken to see that it is measured correctly as shown above. The actual diameter usually
varies from the nominal diameter of a rope. As per IS 2266, actual diameter can vary by -1% to 4 % of the nominal diameter of the rope.
When measuring the rope diameter, don't measure the layer on the reel. Measure the rope when it is straight. To find the correct diameter at a point in a rope, the callipers must be
placed over each pair of opposite strands, i.e. three separate readings for a six strand rope. The readings are then averaged.
The rope you are going to replace may be worn out and may measure less than the new rope. Measurement of rope to know its size shall be carried out where it is not worn out.
Where,
A = Depth of rope space in inches or mm
B = Diameter of drum in inches or mm
C = Width of drum between flanges in inches or mm
K = π / 12 D2 when capacity is required in feet
K = π / 1000 D2 when capacity is required in meters
K = Constant for a given wire rope diameter (As per table below) and
D = Rope diameter in inches or mm
Reserve Strength
The reserve strength of a wire rope is the strength of the rope exclusive of the outer layer of wires, which are damaged. Following are the approximate reserve strengths expressed
as a percentage of the total strengths of well lubricated new ropes.
Percentage of Total
Fibre Core Steel Core
Construction
Inner Wires Inner Wires
Outer Wires (Reserve Outer Wires (Reserve
Strength) Strength)
6×7 – 6×6/1 84 16 71 29
6×19 Group
6×19 – 6×12/6/1 63 37 54 46
6×19 – 6×9/9/1 66 34 57 43
6×16 – 6×10/5+5F/1 63 37 54 46
6×19 – 6×12/6+6F/1 55 45 47 53
6×19 – 6×6 and 6/6/1 59 41 52 48
6×37 Group
6×37 – 6×18/12/6/1 48 52 41 59
6×29 – 6×14/7+7F/7/1 50 50 43 57
6×31 – 6×16/8+8F/6/1 49 51 42 58
6×37 – 6×15/15/6/1 50 50 43 57
6×41 – 6×16/8 and 8/8/1 48 52 56 44
6×36 – 6×14/7 and 7/7/1 50 50 43 57
8×19 Group
8×19 – 8×12/6/1 63 37 48 52
8×19 – 8×9/9/1 66 34 51 49
8×16 – 8×10/5+5F/1 63 37 47 53
8×19 – 8×12/6+6F/1 55 45 42 58
8×19 – 8×6 and 6/6/1 59 41 44 56
Others
6×12 – 6×12/ F.C. 100 - - -
6×24 – 6×15/9/F.C. 63 37 - -
17×7 – 11/6×6/1 55 45 52 48
18×6 – 12/6×6/1 57 43 54 46
Wire rope clips are made from two types of materials. They are malleable iron and drop forged steel. Malleable wire rope clips are to be used only for non-critical, light duty
applications with small applied loads. They should not be used for lifting or suspending load.
For more information on wire rope clips, please refer article titled Rigging Hardware – Wire Rope Clips.
The swaging or clamping process compresses the rope to varying degrees causing a slight loss of rope strength.
Most of wire ropes have an actual breaking strength up to approximately 5%-15% higher than the breaking strength listed in catalogue. Due to this, wire ropes with even swaged
fittings don’t fail at listed breaking strength and some manufacturers claim their assembly to have 100 % efficiency.