The Failure of a Steel Wire Rope: A Root Cause Analysis

The study identifies cyclic stresses as the primary cause of steel wire rope failure, resulting in fatigue failure characterized by a smooth surface with beach marks. Fatigue cracks initiate on the surface and propagate perpendicular to the longitudinal axis, with a martensitic phase observed on the wire surface indicating the formation of a hard surface layer. Repeated twisting and contact with groove flanges and sheaves during hoist operation exacerbate fatigue failure, leading to surface fractures. Understanding these mechanisms is essential for preventing similar issues, suggesting the implementation of measures like improved maintenance practices or design modifications to mitigate cyclic stress effects.