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WHAT IS A WIRE ROPE
Fig. Illustrates the component parts of wire ropes. In general, a wire rope consists of a number of wire strands formed helically about a central axis. The most popular ropes have six or eight strands supported by an axial member known as the core. There are other constructions but they are less common. Each strand is composed of a number of individual wires which have been formed helically about an axial member called the center. This center supporting member of the strand is generally once or more wires, however, it may be natural fibers (cotton, sisal, etc) or synthetic fibers (rayon, nylon, polypropylene).
RAW MATERIALS
Ungalvanized (Bright) steel wire
Bright steel wire is chiefly used for wire ropes of which the (rope) life is determined by wear and deterioration rather than by Comosion. When comparing the effects of wear and deterioration with that of corrosion one should bear in mind that even a bright wire rope can to some extent be protected from corrosion by adequate lubrication and maintenance with a suitable wire rope lubricant.
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Drawn galvanized steel wire
The wire is drawn to a diameter larger than the required final diameter, then it is hot dip galvanized and afterwards drawn to the right size. During this last phase the wire is drawn cold and thereby the quality of the bright raw material which was partically lost by the galvanizing process is restored. Therefore the international Standards do not make a distinction between bright wire and drawn galvanized wire where resistance to bending and torsion is concerned. Moreover, the smoothness and density of the zine coating are improved by posidrawing so that it offers far better protection then a zinc coating of the same thickness applied by drawing after Galvanizing.
Stainless steel wire
Wire ropes made of stainless steel wire are extremely resistant to corrosion and moreover, to temperature, up to 1050 O Originally only the A.I.S. types 304 and 302 were used for rope making but today almost all our stainless steel wire ropes are made of steel according to A.I.S.I. type 316 which was better mechanical properties and a higher resistance to electrolytic corrosion, which increased resistance to a seawater.
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TENSILE STRENGTHS OF STEEL WIRE
Steel wire is a made in various tensile strengths to meet the different requirements of a particular job. For the production of our ropes we use wires in the following tensile strength ranges.
1470 N/sq. mm (= 150 kgf/sq.mm )
1570 N/sq. mm (= 160 kgf/sq.mm )
1770 N/sq. mm (= 180 kgf/sq.mm )
1960 N/sq. mm (= 200 kgf/sq.mm )
2160 N/sq. mm (= 220 kgf/sq.mm )
In the U.S.A the various grades are designated as follws:
Traction steel
Mild plow steel (MPS)
Plow steel (PS)
Improved plow steel (IPS)
Extra improved plow steel (EIPS)
The most common grade is ‘Improved Plow Steel’ which comes nearest to our 1770 N/sq.mm (+=180 kgf/sq.mm tensile strength.
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TENSILE GRADES
MANUFACTURING STRANDARDS
| ISO |
Metric |
American |
| 960 N/mm |
200 kgf/mm |
Extra Improved Plow Steel (EIPS) |
| 1770 N/mm |
180 kgf/mm |
Improved Plow Steel (IPS) |
| 1570 N/mm |
160 kgf/mm |
Plow Steel (PS) |
| 1420 N/mm |
145 kgf/mm |
Traction Steel |
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Diameter of wire ropes
The diameter of a wire rope is the diameter of the circle which encloses all of the wires. When measuring wire rope it is important to take the greatest distance of the outer limits of the Crown’s of two opposite strands. A measurement across the valleys will result in incorrect lower readings.
Method of measuring diameter
Caliper, fitted with jaws broad enough to cover not less than two adjacent strands (see figure). 
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Safety factor of wire rope
It is difficult to fix the safety factor for each type of wire rope to be used for various equipments, as this factor depends not only on the load carried, but also on the speed of rope working, the kinds of fitting used for rope ends, the acceleration and deacceleration, length of rope, the number, size and arrangements of sheave and drums etc. the following safety factor are minimum requirements for safety and economy in the common installation.
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| Purpose |
Min.S.F. |
| Elevator |
10 |
Crane, Hoist Derrick, Sling |
6 |
Guy or Stay, Horizontal Pull or Traction |
4 |
Main Wire of Aerial Rope Way |
3 |
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