What is the reason for the short service life of wire ropes?

The failure process of the wire rope is the fretting fatigue, that is, the compound effect of fretting wear and fatigue, to prolong the service life of the wire rope, it is necessary to effectively inhibit the failure process of the wire rope through technical measures, and the technical measures to prolong the service life of the wire rope include the measures in the manufacturing process of the wire rope and the measures in the use process. Technical measures to extend the service life in the manufacturing process: improve the wear resistance and corrosion resistance of the surface of the rope-making wire through surface treatment technology, such as phosphate-coated wire rope, which is to inhibit the fretting wear of the surface of the steel wire by phosphating the rope-making wire by manganese or zinc-manganese phosphating (manganese, zinc-manganese phosphating, that is, wear-resistant phosphating).

By applying the appropriate grease, the friction between the steel wires is reduced, and the occurrence of fretting wear is slowed down. The selection of high-quality steel, the less brittle inclusions in the steel, the better, to slow down the emergence of fatigue microcracks. Determine the appropriate steel wire production process, obtain the sotenite metallographic structure after heat treatment of the steel wire, obtain the best combination of high strength and high toughness after cold drawing, and improve the twisting process, the pre-deformer and the post-deformer are used in the wire rope twisting process to eliminate the residual stress after twisting, and the structure of the wire rope is stable and not loose after twisting.

Technical measures to extend the service life during use1When lifting, the wire rope is not overloaded. 2.

Try to use a larger diameter of the redirection pulley, the wire rope is subject to bending stress when changing direction around the pulley, the smaller the pulley diameter, the greater the bending stress of the wire rope, and the shorter the service life. 3.Relubrication of the wire rope, according to the lubrication status of the wire rope, the use of special relubricating agent for the wire rope can reduce the wear rate and prevent rust.

4.During the use of the wire rope, try not to rub against other objects. 5.

When the groove of the steel wire rope is seriously worn, it needs to be replaced in time. Wire rope failure process and prolongation of it. Size:

In order to avoid this from happening, first of all, do not buy and use those shoddy cheap and inferior wire rope products, the most advanced manufacturing technology of wire rope is phosphate coated wire rope.

The failure process of the wire rope is the result of the comprehensive effect of wear, fatigue and corrosion, and the phosphate-coated wire rope produced by the patented technology is directly twisted by using the phosphated steel wire, and the steel wire is not cold-drawn after phosphating. Preferential use of manganese or zinc-manganese phosphating coating, both of which are wear-resistant and corrosion-resistant phosphating, can greatly improve the wear resistance and corrosion resistance of the wire rope, not easy to wear and not easy to rust, so as to greatly extend the service life.

According to the current experimental data, the fatigue life of phosphate-coated wire rope is 3-4 times that of smooth wire rope, and with the study of phosphate solution, there is a possibility of greatly improving it. The service life of the wire rope is proportional to the fatigue life, and the longer the fatigue life, the longer the service life.

Commonly used wire rope varieties are phosphate-coated wire rope, galvanized wire rope, stainless steel wire rope or plastic-coated wire rope, which is used in atmospheric environments, and the manganese phosphate coated wire rope produced by patented technology has the longest service life, and hot-dip galvanized-phosphated double-coated wire rope is preferred in heavy corrosive environments. FYI.

The failure process of wire rope is the result of the comprehensive effect of wear, rust and fatigue, and fretting fatigue is the cause of wire rope. Users who have used wire ropes know that damaged wire ropes will be worn, rusted and broken, which can be seen from the appearance of the wire rope.

The way to extend the service life of the wire rope is to delay the occurrence of wear and corrosion, such as often oiling the wire rope, it is best to use manganese phosphate coating wire rope, the phosphate coating can improve wear resistance and corrosion resistance, and extend the fatigue life of the wire rope from the foundation.

The phosphate coated wire rope produced by the patented technology preferentially adopts manganese or zinc-manganese hail phosphating, compared with the smooth wire rope production process, only the final wear-resistant phosphating treatment process is added, and the wear resistance and corrosion resistance of the rope wire are greatly improved, and the phosphated steel wire is used to directly twist the wire rope. At present, the fatigue test data shows that the fatigue life of the phosphate coating wire rope is about 3-4 times that of the smooth wire rope of the same structure (under comparable conditions in the laboratory), and with the study of the wear-resistant phosphate formula, there is a possibility of significant improvement. If the company has a fatigue testing machine, it is recommended to do a comparative verification test of the fatigue life of phosphate-coated wire rope and smooth wire rope, which is the most credible data.

The unit use cost of wire rope can be calculated in this way, and the cost of purchasing wire rope is divided by the number of days of use, that is, the yuan day is calculated. Or the purchase cost of the elevator wire rope divided by the number of uses. It is also possible to divide the cost of buying a wire rope by the tonnage of the goods transported.

Based on this data, it can be compared to the use of wire rope to calculate more. Cheap wire rope does not mean low cost of use, and expensive wire rope does not mean high cost of use.

The service life of the wire rope is proportional to the fatigue life, according to the current wire rope market, the manganese phosphate coated wire rope is about twice that of the smooth wire rope, and the service life extension is much higher than the growth rate, therefore, the average daily use cost of the phosphate coated wire rope is only 30-45% of the smooth wire rope, the use cost is lower, and the cost is higher.

Therefore, the phosphate coated wire rope has a long service life and lower use cost, and the smooth wire rope must be completely eliminated, which is the general trend and the development trend of wire rope manufacturing technology. If you want to further study the problem of phosphate-coated wire rope, please refer to the relevant **, for reference only.

Factors such as the wire rope is not wear-resistant, easy to rust, overloaded, the radius of the rope pulley is too small and the maintenance is not in place will cause the wire rope to be damaged quickly, in order to prolong the service life of the wire rope, it is recommended to use manganese phosphate coated wire rope.

At present, the first time in the field of wire rope in the world to take prevention and control measures for fretting fatigue is the phosphate coated wire rope produced by patented technology, which is the most advanced technology in the field of wire rope in the world. The fatigue life is 3-4 times that of the smooth wire rope with the structure (under comparable conditions in the laboratory), which can be verified by fatigue test, such as macro Qianguo has its own fatigue testing machine to do its own comparative test, such test results are the most credible, the service life of the wire rope is proportional to the fatigue life, and the service life is extended in proportion to the long fatigue life.

According to the current wire rope market, the first of manganese phosphate coated wire rope is higher than that of smooth wire rope, and the service life extension is much higher than the growth rate of **, so the average daily use cost of phosphate coated wire rope is only about 30% of that of smooth wire rope, and the use cost is lower and more cost-effective.

Phosphate coated wire rope is produced by patented technology, because it is difficult to buy at present, you need to ask a few more wire rope manufacturers, please note that the name of the wire rope must be indicated in the purchase of the state potato ticket, such as the phosphate coated wire rope to prevent illegal enterprises from infringing on their legitimate rights and interests, in addition, the patented products are generally sprayed with the patent number on the outer packaging of the wire rope, and the warranty should have the main technical indicators, such as the type of phosphate film and film weight (the size of the phosphate film, wear resistance, corrosion resistance, etc. have an important impact on the service life of the wire rope), for reference only.

The use time of wire rope is short, there may be a variety of reasons, including the selection of wire rope is unreasonable, the use of the wire rope in the process of overload, wire rope maintenance is not in place, etc., the wire rope failure process is the result of the comprehensive effect of wear, rust and fatigue, as long as the wear can be inhibited, control rust and fatigue, the service life can be extended.

Commonly used steel Huaiyuan wire rope varieties are phosphate-coated wire rope, galvanized steel wire rope, stainless steel wire rope or plastic-coated wire rope lead disorder, used in atmospheric environment, the patented technology produces the longest service life of manganese phosphate coated wire rope, and the hot-dip galvanized - phosphated double-coated wire rope is preferred in heavy corrosion environment.

The steel wire of the smooth wire rope is not made of any kind of wear-resistant protective coating, and the smooth wire is very easy to wear and corrode, resulting in a short service life of the smooth wire rope.

The upgraded product of smooth steel land wire rope is the manganese phosphate wear-resistant coating wire rope, and the steel wire is 15 30 grams of manganese phosphate film, which is a wear-resistant protective coating to prevent the wear effect from exceeding the daily lubrication of the wire rope, which is the reason for the trembling of the service life of the manganese phosphate wear-resistant coating to be greatly improved.

Used in the atmospheric environment, the fatigue life of the manganese phosphate wear-resistant coating wire rope is the longest, the surface of the steel wire has a manganese phosphate film, the thickness is generally 15-40 grams square meters, the role of the manganese phosphate film is to prevent fretting wear and rust oxidation, the effect of the phosphate film is more than every day to oil the wire rope maintenance, therefore, the fatigue life of the manganese phosphate wear-resistant coating wire rope is three to five times that of the smooth wire rope, and many domestic enterprises have obtained patent authorization to produce manganese phosphate wear-resistant coating wire rope, The light with the surface of the wire rope belongs to the outdated process, the smooth rubber staring at this wire rope because of the short life of Liang Xun is being completely eliminated.

Commonly used wire ropes for cranes are phosphate-coated wire ropes, galvanized steel wire ropes, and stainless steel wire ropes, which are used in atmospheric environments, and the manganese-phosphated coated wire ropes produced by patented technology have the longest service life, and hot-dip galvanized-phosphated double-coated wire ropes are preferred in heavy corrosive environments.

Failure of wire rope will occur serious wear and corrosion, phosphating coating to improve the wear resistance and corrosion resistance of the wire surface, Chibi is not easy to wear and corrosion is the reason for improving the service life of the wire rope, smooth wire rope is being completely eliminated. Phosphate coated wire rope, preferentially use manganese or zinc-manganese phosphating, compared with the smooth wire rope production process, only increase the wear-resistant phosphating treatment process before rope making, the wear resistance and corrosion resistance of the steel wire are greatly improved, and the phosphated steel wire is directly twisted without cold drawing. At present, the fatigue test data shows that the fatigue life of the phosphate coated wire rope is about 3-4 times that of the same structure smooth wire rope (under comparable conditions in the laboratory), and it is not easy to wear and not easy to rust is the reason for the super large extension of the service life of the wire rope.

Although the price of manganese phosphate coated wire rope is higher than that of smooth wire rope, because of its long service life, the average daily cost is only 30-45% of that of smooth wire rope.

There are two main factors that affect the life of wire rope: production process factors and use factors. In the production process of wire rope, the quality of the wire and twisting process must be ensured, which can basically ensure the quality of the wire rope and prolong the service life of the wire rope.

Zhengshen believes that the use factor is also a major aspect that affects the life of the wire rope. All kinds of damage caused in use will reduce the life of the wire rope, among which mechanical damage is one of the main damages of the wire rope, which is mainly manifested as wear, broken wire, overload, rust and so on.