Factors affecting the service of large-diameter wire rope
Service life of large-diameter wire rope is a major concern in the surface coal mining industry. Differences in rope construction may play an important role in service life and performance. Many of the factors affecting large rope service life could be economically studied and remedial proposals evaluated using small rope if results from small rope tests could be reliably projected to large rope behavior. An experimental study to explore this possibility was begun. A fatigue machine to test large-diameter wire rope was designed, constructed, and operated. Fatigue life results were plotted and compared with results from small-diameter wire rope by employing the Drucker--Tachau Bearing Ratio. Examination of fatigue-tested ropes disclosed broken wires, cracked wires, and wear patterns. Most severe damage was in double-flex regions caused by wire notching between strands and the IWRC, not between adjacent strands. Selected sections of field ropes from seven mines at scattered sites across the U.S. were also examined for broken wires, cracks and wear. From 29 hoist and 32 drag rope sections dissected, worst damage was found in the drag rope near the sockets. Wire notching between strands and the IWRC was seldom more severe than external abrasion. Hoist rope damage was generally worst due to rope on sheave abrasion at the point sheave. Based on the markedly deleterious effects of high loads in the bending fatigue tests, and the observations of damage in both drag and hoist ropes, it is concluded that rope life in surface coal mining draglines can be extended by reducing overloads on both hoist and drag, and by reduced drag rope whip, in addition to other good maintenance practices that would lessen external abrasion.
- Research Organization:
- Battelle Pacific Northwest Labs., Richland, WA (United States)
- DOE Contract Number:
- ET-76-C-01-9099
- OSTI ID:
- 6647589
- Report Number(s):
- FE-9099-1
- Country of Publication:
- United States
- Language:
- English
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Related Subjects
HOISTS
ROPES
MINING EQUIPMENT
SERVICE LIFE
SURFACE MINING
UNDERGROUND MINING
COAL MINING
CRACKING
DYNAMIC LOADS
ELONGATION
FAILURE MODE ANALYSIS
FATIGUE
MINING
TENSILE PROPERTIES
TEST FACILITIES
WEAR
CHEMICAL REACTIONS
DECOMPOSITION
EQUIPMENT
MECHANICAL PROPERTIES
PYROLYSIS
SYSTEM FAILURE ANALYSIS
SYSTEMS ANALYSIS
THERMOCHEMICAL PROCESSES
012000* - Coal
Lignite
& Peat- Mining