Wire Rope Strand Structure for Bending Durability and Wear Resistance
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Solution Overview
Problem
Existing elastic wires formed by swaging processing have non-uniform hardness distribution and rough surfaces, leading to poor bending durability.
Innovation Solution
A wire rope design with a core wire and side wires having a noncircular cross section, where the end portions of the side wires have a higher Vickers hardness by at least 1% compared to the non-contact portions, and an outer surface roughness of 0.10 μm or less, enhancing wear resistance and bending durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If swaging processing is performed on twisted wire to form elastic wire, then the wire achieves elastic functionality, but the hardness distribution becomes substantially uniform and surface roughness increases, resulting in poor bending durability
Solution Approach 1:
The patent applies local quality by creating a non-uniform hardness distribution in the side wires through controlled non-circular cross-sectional deformation. The swaging process is optimized to produce different hardness levels at different locations within the wire structure, specifically creating higher hardness in contact regions while maintaining lower hardness in non-contact regions. This localized property differentiation resolves the contradiction by preventing uniform hardness that leads to poor bending durability.
Solution Approach 2:
The patent utilizes parameter changes by modifying the cross-sectional geometry parameters of the side wires from circular to non-circular shapes through controlled swaging processing. By adjusting deformation parameters such as die geometry, compression ratio, and processing temperature, the patent achieves optimal hardness distribution and surface roughness characteristics that improve bending durability while maintaining elastic functionality.
2Reliability
If swaging processing is performed to create elastic wire, then elastic functionality is achieved, but surface roughness increases to above 0.10 μm, reducing bending durability
Solution Approach 1:
The patent applies parameter changes by optimizing swaging processing parameters including die surface finish, compression ratio, and multiple-pass deformation sequences. These parameter adjustments reduce surface roughness to 0.10 μm or less while maintaining the non-circular cross-section necessary for elastic functionality, thereby resolving the contradiction between elastic performance and surface quality.
Solution Approach 2:
The patent implements preliminary action by performing intermediate annealing or surface treatment steps before final swaging to prepare the wire surface for reduced roughness. This preliminary preparation allows the subsequent swaging process to achieve both the desired non-circular cross-section and low surface roughness without compromising elastic functionality.
3Ease of manufacture
If uniform hardness distribution is maintained in side wires, then manufacturing is simplified, but bending durability deteriorates due to rough surface and lack of contact portion hardening
Solution Approach 1:
The patent applies local quality by designing the swaging process to create spatially varying hardness properties within the side wires. The non-circular cross-section geometry naturally creates different stress and deformation states in different regions, resulting in higher hardness in contact portions and lower hardness in non-contact portions. This localized hardness differentiation improves bending durability while the overall process remains manufacturable through controlled deformation.
Solution Approach 2:
The patent utilizes asymmetry by intentionally creating non-uniform hardness distribution and non-circular cross-sectional shapes in the side wires. This asymmetric structure, where contact portions have different properties than non-contact portions, resolves the contradiction by preventing the uniformity that leads to poor bending durability while maintaining manufacturing feasibility through standardized swaging processes.
Data Source
AI summary
A wire rope includes a strand that is formed by winding a plurality of metal wires. The strand includes a core wire and side wires. Each of the side wires is arranged on an outer periphery of the core wire. In a transverse section of the strand, each of the side wires includes end portions positioned at opposite ends in a circumferential direction of the core wire. Each of the end portions includes a contact portion in contact with an end portion of an adjacent side wire, and a non-contact portion not in contact with the adjacent side wire. A Vickers hardness of the contact portion is higher by 1% or more than a Vickers hardness of the non-contact portion. A surface roughness Ra of an outer peripheral surface of each of the side wires is 0.10 μm or less.