A mechanical model for compaction of strands for wire ropes. (1st May 2023)

• Record Type: Journal Article
• Authors: Chen, Li; Magliulo, Marco; Elig, Marco; Beex, Lars A.A.
• Is Part Of: International journal of solids and structures. Volume 269(2023)
• Publication Date: 2023-05-01
• Subjects: Rope -- Strand -- Compaction -- Elastoplasticity -- Contact; Mechanics, Applied -- Periodicals; Structural analysis (Engineering) -- Periodicals; Elastic solids -- Periodicals; Mécanique appliquée -- Périodiques; Constructions, Théorie des -- Périodiques; Solides élastiques -- Périodiques; Elastic solids; Mechanics, Applied; Structural analysis (Engineering); Periodicals; 624.18
• DOI: 10.1016/j.ijsolstr.2023.112178
• Languages: English
• ISSNs: 0020-7683

Abstract

Abstract: Steel wire ropes are used for numerous industrial applications such as ships, elevators, cranes and bridges. A wire rope consists of numerous thin, steel wires and its geometrical construction can be explained in two steps. First, several wires are wrapped together in a helical shape called a strand. Second, several strands are wrapped together in a helical shape to form the final wire rope. In most cases, each strand is compacted before they are wrapped together to form the final wire rope. Compaction generally reduces contact stresses and thereby, extends ropes' service life. Not many models have been proposed to predict the compaction process and its influence on the strand's mechanical behavior during service. This contribution proposes a computationally efficient approach that consists of two elastoplastic mechanical models. The first model, describing the compaction process, is of a 2D plane strain nature and is therefore fast. Subsequently, the 2D geometry and plastic variables predicted by the compaction model are used to generate the initial geometry and initial plastic state of a 3D model, that is subsequently used to describe the strand's mechanical behavior during service (we limit ourselves to tension). The results of the approach, with and without the mapping of the plastic variables, are compared to experimental measurements and the results without compaction. This is investigated for two real world strands. Highlights: A two-step method for strand compaction and its effect on service life is proposed. The first step involves a fast 2D plane strain compaction simulation. The second step involves a 3D service simulation of compacted strand. Cross section shape and field of work hardening are inherited from step 1 by step 2. The numerically predicted force–displacement curves match the experimental ones.