1、BRITISH STANDARD AEROSPACE SERIES CONFIRMED APRIL 1998 BS 2W 12:1989 Specification for Preformed zinc coated carbon steel wire rope (metric and inch series) UDC 629.7.02:679.73:669.146.99 426:669.58BS2W12:1989 This British Standard, having been prepared under the directionof the Aerospace Standards
2、Policy Committee, waspublished under the authorityof the Board of BSI andcomes into effecton 29September1989 BSI 04-2000 BS W9 first published 1946 BS 2W9 first revised August 1965 BS W12 first published January1968 First joint revision as BS 2W 12 September 1989 The following BSI references relate
3、to the work on this standard: Committee reference ACE/14 Draft for comment 87/78220 DC ISBN 0 580 17313 5 Committees responsible for this British Standard The preparation of this British Standard was entrusted by the Aerospace Standards Policy Committee (ACE/-) to Technical Committee ACE/14, upon wh
4、ich the following bodies were represented: British Independent Steel Producers Association Civil Aviation Authority (Airworthiness Division) Federation of Wire Rope Manufacturers of Great Britain Ministry of Defence Society of British Aerospace Companies Limited Stainless Steel Wire Export Group Ame
5、ndments issued since publication Amd. No. Date of issue CommentsBS2W12:1989 BSI 04-2000 i Contents Page Committees responsible Inside front cover Foreword ii Section 1. General 1 Scope 1 2 Definitions 1 Section 2. Zinc coated carbon steel wire used in the manufacture of wire rope 3 Material 2 4 Manu
6、facture 2 5 Dimensional tolerances on diameter 2 6 Performance requirements 2 7 Marking 3 Section 3. Preformed zinc coated carbon steel wire ropes 8 Designation 4 9 Material 4 10 Dimensions 4 11 Mass 4 12 Manufacture 4 13 Performance requirements 4 14 Protective treatment 6 15 Winding reels 6 16 Mar
7、king 6 Appendix A Surface defect test for rod 7 Appendix B Measurement of actual diameter of preformed wire rope 7 Appendix C Types of construction 7 Appendix D Elongation test 8 Appendix E Proof test 8 Appendix F Preforming test 8 Appendix G Endurance test 8 Appendix H Handling precautions with wir
8、e ropes 11 Figure 1 Schematic diagram for endurance test equipment and test conditions 9 Figure 2 Test pulleys for use in endurance test 10 Table 1 Cast analysis 2 Table 2 Tolerances on diameter 2 Table 3 Tensile strength limits 2 Table 4 Torsional limits 2 Table 5 Principal properties of preformed
9、wire rope 5 Table 6 Dimensions of pulleys used in endurance test 10 Table 7 Breaking strength after endurance test 11 Publications referred to Inside back coverBS2W12:1989 ii BSI 04-2000 Foreword This British Standard, prepared under the direction of the Aerospace Standards Policy Committee, is a re
10、vision of BSW12:1968, which is withdrawn, and it supersedes BS2W 9:1965, which is also withdrawn. This British Standard specifies requirements for carbon steel wire used in the manufacture of wire ropes, and requirements for preformed zinc coated wire rope for aerospace applications. It complies wit
11、h ISO2020 published by the International Organization for Standardization (ISO) in respect of wire rope diameters and strengths in metric units, and also specifies the requirements for preformed “P” series zinc coated wire rope in imperial units that do not comply with ISO 2020. In order to meet the
12、 severe conditions in which wire rope operates in the control systems of modern aircraft, some requirements are more fully specified than in earlier standards. The composition of the wire, examination for decarburization and compliance with certain requirements of BS2763 are now specified, together
13、with dimensional tolerances and an elongation test to establish that the elongation is within limits at stated increments of force. This standard is in three sections, the first covering scope and definitions, the second specifies the properties of the wire from which the rope is manufactured, whils
14、t the third specifies the requirements for the wire rope. Tests to be performed on both the wire and the rope are given, together with information on construction, storage and handling of wire ropes. NOTEManufacturers of wire rope to this standard will be expected to operate a quality control system
15、 at least equivalent to BS5750-2. A British Standard does not purport to include all the necessary provisions of a contract. Users of British Standards are responsible for their correct application. Compliance with a British Standard does not of itself confer immunity from legal obligations. Summary
16、 of pages This document comprises a front cover, an inside front cover, pagesi andii, pages1 to12, an inside back cover and a back cover. This standard has been updated (see copyright date) and may have had amendments incorporated. This will be indicated in the amendment table on the inside front co
17、ver.BS2W12:1989 BSI 04-2000 1 Section 1. General 1 Scope This British Standard specifies the material properties, mechanical properties and test requirements for zinc coated carbon steel wire used in the manufacture of wire ropes (section2) and the construction, mechanical properties and test requir
18、ements for preformed zinc coated carbon steel wire ropes (metric and inch series) (section3). NOTEThe titles of the publications referred to in this standard are listed on the inside back cover. 2 Definitions For the purposes of this British Standard the following definitions apply. 2.1 wire a singl
19、e continuous length of steel, cold drawn from rod 2.2 strand an assembly of wires spun helically, in one or more layers, around a core 2.3 wire rope an assembly of strands spun helically, in one or more layers, around a core 2.4 preformed wire rope a wire rope in which the finished strands are forme
20、d into the helical shape they will assume in the finished rope, thus lying naturally in their true position without constraint 2.5 nominal diameter the value by which the diameter of the wire or rope is designated 2.6 actual diameter the measured diameter of the wire or rope 2.7 lay the designation
21、of the direction in which the wires are spun in the strand and the strands are spun in the rope. It will be either right-hand (RH) or left-hand (LH) 2.8 lay length that distance in a strand or rope, measured parallel to the longitudinal axis, in which the wire in the strand or the strand in the rope
22、 makes one complete turn (or helix) about the axis of the strand or rope 2.9 king wire (core wire) a single wire forming the core of a strand 2.10 core the central member of a strand or rope 2.11 elongation that length by which the rope extends between defined upper and lower limits of force (i.e. b
23、etween first and second reading), expressed as a percentage of the gauge length measured at the lower limitBS2W12:1989 2 BSI 04-2000 Section 2. Zinc coated carbon steel wire used in the manufacture of wire rope 3 Material 3.1 Grade The wire used in the manufacture of wire ropes shall comply with sec
24、tion1 and section3 of BS2763:1982 except for wire diameters. 3.2 Cast analysis The cast analysis of the wire shall comply withTable 1. Table 1 Cast analysis 3.3 Zinc coating 3.3.1 The wire shall be uniformly zinc coated by either the hot dip process or the electrolytic process. If the hot dip proces
25、s is used the purity of the slab zinc shall be not less than98.5%. 3.3.2 The weight of the zinc coating shall be determined by one of the methods given in section2 of BS443:1982, and shall comply with class Z requirements of BS2763. 3.3.3 The adhesion of the zinc coating shall comply with BS443. 4 M
26、anufacture 4.1 The wire shall be manufactured to circular section within the range of diameters shown inTable 2 by cold drawing from rod complying with3.1 and3.2, and which is free from surface defects when tested in accordance withAppendix A. The wire shall be supplied in the zinc coated condition
27、complying with3.3. NOTEThe decarburization test (see6.4) should be carried out before the zinc coating is applied. 4.2 The finished wire shall be free from harmful defects. 5 Dimensional tolerances on diameter 5.1 The finished wire shall comply with the tolerances shown inTable 2. Individual measure
28、ments shall lie within the tolerance given inTable 2. 5.2 The diameter shall be taken as the mean of two measurements made at right angles to each other on a straight piece of wire. Table 2 Tolerances on diameter 6 Performance requirements 6.1 Selection of test pieces Samples for all tests shall be
29、cut from each end of each coil of finished wire as drawn. 6.2 Tensile strength test 6.2.1 When tested in accordance with BS4545 the tensile strength of the wire, calculated on the nominal diameter, shall meet the requirements of grade1860 or1960 of BS2763. 6.2.2 The tensile strength of the wire shal
30、l be specified by the rope maker. 6.2.3 The tensile strength of any wire shall meet the limits shown inTable 3 for the appropriate tensile grade numbers and nominal wire diameters. Table 3 Tensile strength limits 6.3 Torsional test When tested in accordance with BS4545 the test piece shall withstand
31、 the number of twists shown inTable 4. When failure occurs, the primary fracture shall be perpendicular to the longitudinal axis of the wire. Table 4 Torsional limits Element(s) Min. Max. % % Carbon 0.5 0.85 Silicon 0.35 Manganese 0.4 0.9 Phosphorus 0.030 Sulphur 0.035 Nominal wire diameter Toleranc
32、e From Up to but excluding Plus Minus mm mm mm mm 0.20 0.40 0.01 0.01 0.40 0.80 0.015 0.015 Nominal wire diameter Plus tolerance From Up to but excluding mm mm N/mm 2 0.20 0.25 340 0.25 0.40 300 0.40 0.80 260 Tensile grade: average tensile strength Number of twists N/mm 2(minimum) 1860 1960 where L
33、is the free length between grips (in mm); d is the nominal diameter of wire (in mm). L 100d -25 L 100d -22 BS2W12:1989 BSI 04-2000 3 6.4 Decarburization test When tested in accordance with BS6617-1 the wire shall show a radial depth of decarburization (total and partial) not greater than1.5% of the
34、diameter. 6.5 Ductility wrap test 6.5.1 When tested in accordance with the wrap test given in BS4545 the wire shall not fracture. 6.5.2 The test piece shall be wrapped for eight complete close turns around a mandrel of the same diameter as the wire under test, and shall then be unwrapped for seven c
35、omplete turns. 6.6 Retests Should any test piece fail to meet the requirements of6.2 to6.5, two further test pieces in respect of each failure shall, if the wire manufacturer so desires, be cut from the same end of the coil of wire from which the failed test piece was cut, and shall be subjected to
36、repeat tests in6.2 to6.5. If both additional test pieces meet the requirements, the coil shall be accepted. If either fails, the coil shall be deemed not to comply with this standard. 7 Marking Each coil of wire shall have attached securely to it a durable tally or label, which bears the following i
37、nformation: a) the number of this British Standard, i.e. BS 2W 12 1) ; b) the manufacturers name or identification mark; c) the inspectors stamp; d) the coil number and steel cast identity; e) the nominal size and specified tensile grade of the wire. 1) Marking BS2W12 on or in relation to a product
38、represents a manufacturers declaration of conformity, i.e. a claim by or on behalf of the manufacturer that the product meets the requirements of the standard. The accuracy of the claim is therefore solely the responsibility of the person making the claim. Such a declaration is not to be confused wi
39、th third party certification of conformity, which may also be desirable.BS2W12:1989 4 BSI 04-2000 Section 3. Preformed zinc coated carbon steel wire rope 8 Designation The designation of a preformed wire rope shall be in terms of its nominal diameter for a metric series rope, or its “P” number for a
40、n inch series rope as listed inTable 5. 9 Material Preformed wire ropes shall be manufactured from zinc coated carbon steel wire complying with section2. 10 Dimensions The actual diameter of a preformed wire rope, when measured in accordance with Appendix B, shall be between the maximum and minimum
41、dimensions given inTable 5. 11 Mass The maximum mass per unit length of preformed wire rope, for a designated size, shall not exceed the figure given inTable 5. 12 Manufacture 12.1 Construction Preformed wire ropes shall be manufactured to the construction shown inTable 5. NOTE 1For ropes designated
42、2.4mm diameter two types of construction are permitted. The purchaser should state in his contract and order which type of construction is required. NOTE 2The types of construction are described inAppendix C. 12.2 Core strand The core strand of a preformed wire rope shall be of sufficient diameter t
43、o give full support to the outer strands. 12.3 King wire The king wire of each strand shall be of sufficient diameter to give full support to the outer wires. NOTEThe king wire of a strand may be of different tensile grade from the outer wires. 12.4 Length of lay The length of lay of the strands sha
44、ll be between six and eight times the diameter of the rope, for both limits of size given inTable 5. The strands shall be in right-hand ordinary lay. 12.5 Preforming The strands shall be preformed during manufacture in such a manner that the finished wire rope satisfies the test specified in13.6. 12
45、.6 Joints When it is necessary to introduce new lengths of wire, joints in different wires shall be distributed as far apart as possible. The ends shall be tucked in, and in no case shall more than one joint occur in6m of strand. For wire of0.20mm diameter and larger, joints shall be made by welding
46、 or brazing. 12.7 Defects Each length of finished rope shall be of uniform lay and shall be free from irregularities, including kinks and open and unequally tensioned strands. 12.8 Lubrication 12.8.1 The purchaser shall state in his contract and order if a lubricated rope is required. 12.8.2 Where a
47、 lubricated wire rope has been specified a lubricant shall be applied during stranding and wiped well back. 12.8.3 The lubricant shall have good lubrication properties in the temperature range 54 C to+121 C and shall be resistant to oxidation. It shall not induce corrosion. NOTELubricant XG 284 is a
48、ccepted as being suitable and the properties specified for this material should be taken as a basic requirements for this application. (See Def Stan 01-5.) 2) 13 Performance requirements 13.1 General The tests given in13.3 to13.8 shall be undertaken on all preformed wire ropes manufactured to this B
49、ritish Standard by the rope manufacturer to the satisfaction of the inspecting authority. 13.2 Selection of test pieces Samples for all tests shall be cut from each end of each length of preformed wire rope produced. 13.3 Minimum breaking force test 13.3.1 When tested to destruction in accordance with ISO3108 a test piece, selected as in13.2, shall withstand a breaking force not less than that specified inTable 5. The reference to ISO2408 in ISO3108 shall be read asTable 5 of this BritishStandard for this test.
