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COLLEGE OF ENGINEERING AND ARCHITECTURE

Department of Mechanical Engineering

Chapter 2 WIRE ROPES

Machine Design 2

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Introduction

▪ Wire ropes are made of flexible, twisted strands of wire that

are usually laid over a core.

▪ Wire rope consists of multiple wires or strands, helically wound

or laid over an axis.

▪ Wires, strands and cores are independent that interact with

each other during service.

Reference: Design of Machine Elements by Virgil Moring Faires

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Introduction

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Introduction

▪ The term cable is often used interchangeably with wire rope.

▪ Wire rope refers to diameter larger than 3/8 inch (9.52 mm).

▪ Sizes smaller than this are designated as cable or cord.

Advantages of Wire Ropes

▪ Lighter in weight ▪ Offer silent operation

▪ Can withstand shock loads ▪ Reliable

▪ More durable ▪ Do not fail suddenly

▪ Efficiency is high ▪ Cost is low

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Construction of Wire Rope
▪ Wire ropes are designed in different steel grades, finishes and
variety of constructions to attain the best balance of
strength, abrasion resistance, crush resistance, bending
fatigue resistance and corrosion resistance for each
application.

▪ Wire ropes are made from cold drawn

wires that are first twisted into strands, and
then the strands are twisted into helices
about a core or central element.

▪ The central element is often an

independent wire rope core (IWRC) which
makes the rope much more resistant to
crushing.
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Construction of Wire Rope

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Wire Rope Classification
▪ “Lays” of a wire rope are descriptions of how wires and
strands of the rope are laid in helix.

Regular Lay or Cross Lay

▪ The wires and strands are twisted in opposite directions.
▪ The lay direction can be right (symbol Z) or left (symbol S).

Lang Lay or Parallel Lay (formerly Albert’s lay and Lang’s lay)
▪ The wires and strands are twisted in same direction.
▪ Lang lay ropes are more flexible than regular lay ropes and
also have greater wearing surface.

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Wire Rope Classification

Reverse Lay or Composite Lay

▪ The wires in the two adjacent strands are twisted in opposite
direction.

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Wire Rope Classification

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Other Wire Rope Classification

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Designation of Wire Rope

6x7
strand wire per strand

▪ The first number is the number of strands, and the second

number is the number wires per strand.

▪ The greater the number of wires in a strand,

the more flexible the rope.

▪ The fewer wires, the stiffer the rope.

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Proper Measurement

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Various Rope Sizes

▪ 6x7 – for haulage, rigging, guard rails tramways, guy wires

and power transmission
– provides maximum resistance to abrasion and wear

▪ 6x19 – general purpose rope, hoists, cranes, drilling, elevator

– compromise of flexibility and wear resistance

▪ 6x37 – steel mill ladles, high speed elevators, cranes, hoists

– extra flexible rope and useful where abrasion is not
severe and where relatively sharp bends must be
tolerated

▪ 8x19 – extra flexible hoisting rope applications

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Various Wire Rope Sizes

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Different Cores

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Strand Construction
▪ Strands are designed with various combination of wires and
wire sizes to produce the desired resistance to fatigue and
abrasion.

▪ Small number of large wires will have more abrasion

resistance and less fatigue resistance than a large number of
small wires.

Different Strand types

▪ Single size
▪ Seale
▪ Filler wire

▪ Warrington

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Strand Construction

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Characteristics
▪ Strength can be increased by:
▪ increasing the diameter of wire rope
▪ increasing the tensile strength of individual wires
▪ decreasing the air voids between the wires
▪ using a steel core construction
▪ Flexibility can be increased by:
▪ using more wires of smaller diameter
▪ decreasing the tensile strength of individual wires
▪ using a fiber core
▪ Robustness (or resistance to physical damage)
▪ increased by using fewer wires of larger diameter
▪ using a steel core
▪ coatings can be applied to protect against corrosion
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Factor Affecting Performance

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Factor Affecting Performance

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Materials
Steels
▪ Plow steel (PS) ▪ Alloy steel

▪ Mild plow steel (MPS) ▪ Stainless steel

▪ Improved plow steel (IPS) ▪ Copper

▪ Wrought iron ▪ Bronze

▪ Cast steel

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Materials
Vegetable fiber (Natural fiber)

▪ Cotton ▪ Hemp ▪ Jute/Flax

▪ Manila (abaca)

▪ Sisal

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Materials
Synthetic fiber
▪ Polyester
▪ Nylon

▪ Glass fibers ▪ Metallic wire

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Wire Rope End Terminations

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Uses of Wire Ropes
▪ Elevators ▪ Mine hoists

▪ Oil well drilling

▪ Cranes

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Uses of Wire Ropes
▪ Aerial conveyor ▪ Tramways

▪ Suspension bridge
▪ Haulage device

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Wire Rope Formulas
▪ Equivalent Bending Stress, 𝜎𝑏
𝑬𝑫𝒘 where:
𝝈𝒃 = 𝐷𝑤 – wire diameter
𝑫𝒔
𝐷𝑠 – sheave or drum diameter
𝐸 – modulus of elasticity
▪ Equivalent Bending Load, Fb
𝑨𝑬𝑫𝒘 𝐴 – total cross sectional area of the rope
𝑭𝒃 = 𝐷𝑟 – nominal diameter of the wire rope
𝑫𝒔
(should be in inches)
𝐹𝑢 – breaking strength of the wire rope
▪ Factor of Safety, N
𝐹𝑡 – total tensile force due to the load
𝑭 𝒖 − 𝑭𝒃
𝑵= (including acceleration of forces)
𝑭𝒕 ℎ – height/length of the rope (ft)

▪ Approximate weight of wire rope, Wr

𝑾𝒓 = 𝟏. 𝟓𝟖 𝑫𝒓 𝟐 𝒉 , 𝒍𝒃

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Wire Rope Formulas
▪ Acceleration force due to weight of the rope, Wra

𝑾𝒓 𝒂
𝑾𝒓𝒂 =
𝒈
▪ Acceleration force due to weight connected at the rope
end, WLa 𝑾𝑳 𝒂
𝑾𝑳𝒂 =
𝒈
▪ Total tension of the rope, Ft
𝑭𝒕 = 𝑾𝒓 + 𝑾𝑳 + 𝑾𝒓𝒂 + 𝑾𝑳𝒂
a a where:
Ft = Wr + WL + Wr + WL
g g 𝑎 – acceleration
𝑔 – standard gravitational acceleration
 a
Ft = (Wr + WL )1 +  𝑊𝐿 – useful load
 g
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Useful Tables
▪ Approximate Diameters and Areas
Rope 𝑫𝒘 𝑨, 𝒊𝒏𝟐
6x7 0.106 𝐷𝑟 0.38𝐷𝑟 2
6 x 19 0.063 𝐷𝑟 0.38𝐷𝑟 2
6 x 37 0.045 𝐷𝑟 0.38𝐷𝑟 2
8 x 19 0.050 𝐷𝑟 0.35𝐷𝑟 2

▪ Factor of Safety for Wire Ropes

Service 𝑫𝒘
Elevators 8 – 12
Mine hoists 2.5 – 5
Cranes motor-driven 4–6
Cranes hand-powered 3–5
Derricks 3–5

from: Design of Machine Members by Doughtie and Vallance

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Useful Tables
▪ Estimated Ultimate Strength, Fu
(in tons = 2000 lbs)

▪ For 6 x 19:
▪ VHS: 𝑭𝒖 ≈ 𝟒𝟖 𝑫𝟐𝒓

▪ IPS: 𝑭𝒖 ≈ 𝟒𝟐 𝑫𝟐𝒓

▪ PS: 𝑭𝒖 ≈ 𝟑𝟔 𝑫𝟐𝒓

▪ MPS: 𝑭𝒖 ≈ 𝟑𝟐 𝑫𝟐𝒓
▪ Traction steel:
𝑭𝒖 ≈ 𝟎. 𝟖𝟕 (𝑭𝒖 𝒇𝒐𝒓 𝑴𝑷𝑺)

from:
Design of Machine Elements
by Virgil Faires

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Useful Tables
Maximum Rated Load Of Passenger Elevators
(PSME Code)

▪ For an elevator having an inside net platform area of not

more than 4.65 m2
𝑾 = 𝟑𝟓. 𝟏 𝑨𝟐 + 𝟑𝟐𝟔. 𝟐𝟐𝟒 𝑨 ; 𝒌𝒈
▪ For an elevator having an inside net platform area of more
than 4.65 m2
𝑊 = 2.458 𝐴2 + 611.36 𝐴 − 621.4 ; 𝑘𝑔

Note:
Area must be in m2

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Sample Problems

1. Determine the probable bending stress and equivalent bending load in a

1.75-in, 6 x 19 steel rope made from 0.098-in wire, when it is used on a 90-i
n sheave.

Given: Find Fb:

6 x 19 steel rope AEDw AE (0.098in )
Dr = 1.75 in F b= = = _____
Ds 90in
Dw = 0.098 in
Ds = 90 in Use (for 6 x 19):
A = 0.38 Dr
2
Find Sb:
EDw E (0.098in ) A = 0.38(1.75in ) = _____
2
S b= = = _____
Ds 90in
Use (for steel):
E = 30106 psi

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Sample Problems

2. A wire rope is used with total load of 8500 kg and bending load of 55,000
kg. If the breaking strength of the rope is 120,000 kg, find the factor of saf
ety.
Given:
Ft = 8500 kg
Fb = 55000 kg
Fu = 120,000 kg

Find N:
Fu − Fb 120,000kg − 55,000kg
N= = = _______
Ft 8500kg

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Sample Problems

3. A 6 x 19 IPS wire rope with rope diameter of 2.5 in is to be used for hoisting
. Find the weight of the rope if the depth of the mine hoist is 110 m.

Given:
6 x 19 IPS
Dr = 2.5 in
h = 110m

Find Wr:

Wr = 1.58 Dr h
2

 3.28 ft 
= 1.58(2.5in ) (110m )   = ______
2

 1m 

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 Fu − Fb AEDw
N= F b= 35/35
Sample Problems Ft Ds

4. A 12.0 mm, 6 x 19 plow steel (PS) wire rope is bent around a 600 mm shea
ve and is used to carry 4,300 kg of load. What is the factor of safety for thi
s application?
Given: Find A: (for 6 x 19): Find E(for steel):
6 x 19 PS
A = 0.38 Dr
2
Dr = 12.0 mm 2 E = 30106 psi
Ds = 600mm  1in 
A = 0.3812.0mm  
WL = 4300 kg= Ft  25.4mm 
A = ____

Find Fu:
Find Dw (for 6 x 19):
PS: 𝑭𝒖 ≈ 𝟑𝟔 𝑫𝟐𝒓
2 Dw = 0.063Dr
 1in  2000lbs
 1in 
F u = 3612.0mm   D w = 0.06312.0mm 
 25.4 mm  ton 
 25.4 mm 
Fu = _____ D w = ____

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Sample Problems

Find Fb:
AEDw
F b= = _____
Ds

Find N:
Fu − Fb Fu − Fb
N= = = _______
Ft 2.205lbs
4300kg 
1kg
Fu − Fb
N= = _______
2.205lbs
4300kg 
1kg

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 Fu − Fb AEDw
N= F b= 37/48
Sample Problems Ft Ds

5. A vertical mine hoist is used to carry 8 metric tons of ore at a height of

100 meters. The load is to start from rest and will attain a maximum spe
ed 160 meters per minute in 10 seconds. A 6 x 19 IPS wire rope is used f
or hoisting on a sheave 1.0 m in diameter. Find the factor of safety if
44.5 mm diameter ropes will be used for this application.
Given: Find A: (for 6 x 19): Find Dw (for 6 x 19):
WL = 8 metric tons
h = 100 m A = 0 . 38 Dr
2
Dw = 0.063Dr
2
vi = 0 m/min  1in   1in 
A = 0.38 44.5mm   D w = 0.063 44.5mm  
vf = 160 m/min  25.4mm   25.4 mm 
t = 10 s A = _____ D w = _____
6 x 19 IPS
Ds = 1.0 m Find E(for steel):
Dr = 44.5 mm Solve for Fb:
E = 3010 psi6

IPS: 𝑭𝒖 ≈ 𝟒𝟐 𝑫𝟐𝒓 F b=
AEDw
= _____
2
 1in  2000lbs Ds
F u = 42 44.5mm  
 25.4 mm  ton
Fu = _____
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 Fu − Fb  a
N= Ft = (Wr + WL )1 +  38/48
Sample Problems Ft  g

Find WL: Find Wr:

2205lbs Wr = 1.58 Dr h
2
WL = 8MT 
 3.28 ft 
2
1MT  1in 
WL = ______ Wr = 1.58 44.5mm   (100m ) 
 
 25.4mm   1m 
Wr = ______
Find a:
𝑣𝑓 − 𝑣𝑖 Find Ft:
𝑎=  m 
𝑡  0 . 2667 
Ft = (Wr + WL )1 +
2

160
m
−0
m s 
min   1 min   m 
a= min  9 . 807 
10 sec  60 sec  Ft = ______  s 2

m
a = 0.2667 2
s
Solve for N:

Fu − Fb
N= = _______
Ft

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Practice Problem

6. What is the maximum rated in kg of an elevator having

a 2.5 m2 floor area.

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