A Finite Element Model for a 6 x K31WS+FC Wire Rope and a Study on Its Mechanical Responses with or without Wire Breakage

The special spatial structure and the long-term harsh working environment make the transient response of wire rope complicated, so accurate assessment and prediction of its mechanical characteristics are of great significance to ensure the safe and stable operation of related equipment. In this paper, a method is proposed for the analysis of the mechanical characteristics of a 6 x K31WS + FC wire rope with or without wire breakage. Firstly, an accurate parametric geometric model of the wire rope is established based on the Frenet frame method, the material properties of the wire rope are acquired by experiments, and the finite element model of the wire rope is built. Then, a mechanical model of the wire rope is proposed to verify the validity of the finite element model. Finally, the influences of the number, distribution, and location of the broken wires on the mechanical characteristics of the wire rope are thoroughly analyzed. This work proposes a comprehensive framework that can quantitatively analyze the mechanical characteristics of the complex wire rope with or without wire breakage, which provides a practical method for its reliability and maintenance evaluation and has guiding significance for the shape design and structural optimization of the wire rope.