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Failure analysis for hoisting wire ropes with local accumulated broken wire damage on the surface

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Abstract

Surface broken wire (BW) damage to hoisting steel wire ropes (SWR) is unavoidable during the service process, and it continues to accumulate locally during the evolution process. The specific influence analysis of the surface damage with local cumulative BWs on the performance of the hoisting SWR is insufficient at present, which seriously affects the safety of the rope system. In this paper, a failure analysis method for the state of surface cumulative BW rope based on the integration of finite element (FE) and mechanical tension is proposed. First, a method for creating an FE model of surface BW damage is presented, and the stress-strain distribution features of damaged section under tensile load are revealed. Then, the residual mechanical strength of SWR under local cumulative BW damage is determined by performing a tensile test. Finally, based on the analysis of FE and breaking behavior, combined with the regulations, the state of the damaged SWR is comprehensively evaluated. The results show that the breaking position of the SWR under mechanical tension is the maximum stress distribution in the simulation analysis, which verifies the consistency between the simulation and the experiment; and the accumulation degree and distribution of local BW affect the residual mechanical strength of the SWR. This method explores the influence of different degrees of local BW damage on the mechanical properties of the SWR, which provides a direct basis for the non-destructive evaluation of the SWR state.

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Acknowledgments

This work was supported by the Fundamental Research Funds for the Central Universities [2022QN1044, 2021YCPY 0203]; the Jiangsu Outstanding Postdoctoral Program [2022ZB 518]; the Open fund project of State Key Laboratory of Mining Response and Disaster Prevention and Control in Deep Coal Mines [SKLMRDPC21KF21]; the National Natural Science Foundation of China [61971423]; and by the Project Funded of the Priority Academic Program Development of Jiangsu Higher Education Institutions (PAPD), China.

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Authors and Affiliations

  1. Jiangsu Key Laboratory of Mine Mechanical and Electrical Equipment, School of Mechatronic Engineering, China University of Mining and Technology, Xuzhou, 221116, China

    Ping Zhou, Gongbo Zhou, Lianfeng Han, Xiaodong Yan & Hanyu Wang

  2. School of Mechatronic Engineering, Jiangsu Normal University, Xuzhou, 221116, China

    Zhenzhi He

Authors
  1. Ping Zhou
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  2. Gongbo Zhou
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  3. Lianfeng Han
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  4. Xiaodong Yan
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  5. Hanyu Wang
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Corresponding author

Correspondence to Gongbo Zhou.

Additional information

Ping Zhou received the Ph.D. in Mechanical Engineering from the China University of Mining and Technology, Xuzhou, China, in 2021. He is currently a lecturer at the School of Mechanical Engineering, China University of Mining and Technology, Xuzhou, China. His current research interests include industrial failure analysis and Intelligent nondestructive testing.

Gongbo Zhou (M’12–SM’19) received the Ph.D. from the School of Mechanical and Electrical Engineering, China University of Mining and Technology, in 2010. He is currently a Professor with the School of Mechatronic Engineering, China University of Mining and Technology. His current research interests include failure analysis, deep learning and intelligent fault diagnosis.

Lianfeng Han received the B.S. in Mechanical Engineering from the China University of Mining and Technology, Xuzhou, China, in 2020. He is currently pursuing the Ph.D. in Mechatronic Engineering with the China University of Mining and Technology, Xuzhou, China. His research interests include system modeling and intelligent network monitoring.

Xiaodong Yan received the B.S. from Yancheng Institute of Technology in 2018. He is currently pursuing the Ph.D. in Mechanical Engineering from China University of Mining and Technology. His research interests include engineering failure analysis and piezoelectric vibration energy harvesting technology.

Hanyu Wang received the B.S. in Mechanical Engineering from the China University of Mining and Technology, Xuzhou, China, in 2021. He is currently pursuing the M.S. in Mechatronic Engineering with the China University of Mining and Technology, Xuzhou, China. His research interests include deep learning, machine vision and engineering failure analysis.

Zhenzhi He received the Ph.D. from Huazhong University of Science & Technology, Wuhan, China, in 2014. He is currently an Associate Professor of Mechanical Engineering, Jiangsu Normal University, Xuzhou, China. He is also a postdoctoral researcher at China University of Mining and Technology. His research interests include nondestructive testing, signal processing, and electromechanical system design in industry.

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Zhou, P., Zhou, G., Han, L. et al. Failure analysis for hoisting wire ropes with local accumulated broken wire damage on the surface. J Mech Sci Technol 37, 3459–3468 (2023). https://doi.org/10.1007/s12206-023-0611-6

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  • DOI: https://doi.org/10.1007/s12206-023-0611-6

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