How are Metal Wire Ropes Made? Factors To Choose The Right Rope

Metal wire ropes , industrial ropes or cables are basically the combinations of several metallic wires, twisted together for extra strength and endurance. This product is widely used in various heavy duty industries like mining, shipping, transportation, loading/ unloading and even for transmission of electricity.

If recalling the history, the industrial ropes were invented by a German mining engineer Wilhelm Albert and used for mining at Harz Mountains Saxony, Germany. These cables proved to be superior from other ropes and metallic chains in performance and were widely accepted around the world.

If recalling the history, the industrial ropes were invented by a German mining engineer Wilhelm Albert and used for mining at Harz Mountains Saxony, Germany. These cables proved to be superior from other ropes and metallic chains in performance and were widely accepted around the world.

Also Read:How Are Welding Electrodes Made?

For a layman, the manufacturing process of industrial ropes is the same as that ropes made up of natural yarn or synthetic polymer. But in an actual sense, these industrial ropes have to undergo a lot of engineering processes. They are twisted into strands about a core rope and then laid down into cables. The core ropes are made up of Natural or manmade

Manufacturing Process of Industrial Ropes – Watch Video On, Next Page, to see the process-

The core ropes are made up of Natural or manmade fibres which enable firm cushioning to the wires, maintain the rope structure and provide internal lubrication. To know better about the industrial ropes the engineer should have the clear understanding of the terminologies like Rope Diameter, Length, Layout type and its Dimensions, Tensile Strength, Type of Core used and Strands.

Watch video below-

 Selection and Quality of Materials

Before manufacturing of the industrial ropes, it is necessary to decide the dimensions and the core of the cable. Firstly the raw material is selected for the steel wire, fibre/core and the lubrication for both wire and core. Determine the Diameter, length, weight and tensile strength of the Steel wire. The Core use of the cable can be made up of natural fibres like Jute, Manila or Manmade fibres like polyethylene or polypropylene.

Heat Treatment-

Annealing is a typical heat treatment given to the steel wires in forming industrial ropes. This process is given to alter the physical and chemical properties of the steel that enhance its ductility and reduces hardness. The raw material is heated till glowing stage and then slowly cooled down to room temperature. With the help of such heat treatment, the metal becomes soft and can be prepared for shaping, forming and stamping.

Pickling

Due to heat treatments, that metal surface tends to be oxidized and leaves scales on the surface. The surface treatments of the industrial ropes are done by the process of pickling. This process helps in removing impurities from the surface like stains, rust, and other inorganic contaminants.

Also Read:How Are Welding Electrodes Made?

Wire Drawing-

After the succession of the above treatment processes, the wire drawing is done. It is basically a metal forming process which is typically used to reduce the cross-section of the wire by pulling the wire in a single or multiple strands through drawing dies.

Lubrication-

The industrial ropes are galvanised and oil impregnation is done for better lubrication. Lubrication helps in reducing friction among the strands and helps in the proper movement of the rope over sheaves or spooling on drums. It also helps from corrosion and it is recommended to regular lubrication for prolonged use.

Stranding

Standing is combining the steel wires into cables. This process is very important because through this we are able to specify our requirements in the industrial rope formation. The things to be considered here are a number of wires, strands, and core formation. The stranding speed depends on the feed to the rotating drums. During this process, the diameter of the cable, diameter of the core, type, and direction of lay are specified.

Also Read:How Are Welding Electrodes Made?

Rope forming

In the industrial rope forming mechanism, the strands are pulled further through rollers and they are rotated to give the shape of the rope and this feed is further provided to the drums which help in pressing and shaping the rope.

Winding/ Closing Operation

At the end of this process, the industrial rope is properly winded on the spool with any foul and is finished in the required length as specified. The rope ending is done by either seizing the rope end or welding it. Sometimes a loop is formed or an attaching is added at the end as per the industrial requirement.

Factors to choose the right Industrial Rope-

Strength: The strength of the rope mainly depends upon the tensile strength of the steel used and the type of construction.

Abrasion resistance: Ropes with larger outer diameter should be preferred for heavy and better performance.

Flexibility: With the increase in the number of wires or strands, the flexibility increases of the cable.

Preformed wires: These wires are very safe, easy to use and provide greater resistance to fatigue.

Tensile Strength: The greater the tensile strength, the better it works against wear and tear.

Also Read:How Are Welding Electrodes Made?

Testing

Testing of the industrial wires is done to ensure better industrial performance. The testing includes tensile test, Torsion and bending test which help in determining the minimum breaking force of the cable. The dimensioning is done with the help Vernier Callipers and measuring tapes to determine the diameter and length of the cable.