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

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.