Numerical Simulation On Laying Process And Strength Analysis Of Metal Wire Rope

Metal wire rope is an important kind of space spiral product. Since it has the characteristic of high strength, flexibleness and stability, it is widely applied in many fields, such as mechanism, architecture, transport, communication, aviation and aerospace, etc. Up to now, although the behaviors of stranded rope under loads, including tension, shear, bending and torsion, have been studied in many literatures, little information is available to predict the simulation for the laying process of wire rope, especially without regard to the self-rotating ratio and friction contact condition. Material non-linearity and contact non-linearity must be considered for the complicated deformation of laying wire rope. The formation stress affects the formability of wire rope, and the resultant residual stress greatly affects the structural strength. So the research of numerical simulation on the laying process and strength analysis of wire rope has been carried out in this paper.The space geometric model of wire rope with self-rotating ratio has been described and the model is an important component of finite element computation model for laying wire rope. Taking the laying process theory of wire rope and material non-linearity into consideration, and based on the principle of virtual work, elasto-plastic incremental FE equations have been established for the numerical simulation for laying wire rope.Friction contact model is another important component of finite element computation model for laying wire rope. It is a complicated nonlinear relationship between friction contact and deformation of wire rope. And friction contact has direct effect on the formability of wire rope. Friction contact routines carry out two tasks: to search the contact elements being in contact and to compute the contact forces. 3D Splitting-pinball contact searching model for laying wire rope has been adopted, and the accuracy has been improved by the Splitting-pinball algorithm.Using penalty method, the incremental constitutive relationship and contact element technology of contact interface have been discussed. And Radial-Return Mapping algorithm has been employed to handle stick/slip phases of friction. Based on penalty method and using Augmented Lagrangian method, computation model has been presented to calculate both the normal contact force and friction contact force. The advantage of Augmented Lagrangian method is that the exact solution can be obtained and that considerable savings in the CPU-time can be realized and ill-condition of governing equations can be decreased. In order to consider the effect of laying formation on the structural strength, Strength analysis model of metal wire rope has been presented in this paper. The behaviors of wires in simple strand and IWRC 7×7 Independent Wire Rope Core under loads are analyzed. With the third strength theory, the strength on the dangerous point in the wire cross is checked.With dual non-linearity of the laying process, based on the finite element computation model for laying wire rope, and considering the design principle and function requirement of the program system for numerical simulation and strength analysis of metal wire rope, function modules of the system has been established. And with graphical user interface (GUI) and opening structure of the commercial finite element ANSYS software, the program system for numerical simulation on laying process and strength analysis of metal wire rope (LayingWireRope) has been redeveloped with VC ++. The system can create data files, which are in the format of ANSYS parametric design language (APDL). And the data files can be directly accessed by ANSYS for the analysis of material non-linearity and contact non-linearity. Also, the system can analyze strength of wire rope. The key technologies, such as encapsulating ANSYS, programming registry and multi-process, terminating thread, etc., have been discussed so that the interface program can activate, run and close ANSYS.Using the developed program system, the effects of self-rotating...