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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 629.7.02:679.73:669.146.99 426:669.58 Licensed Copy: sheffieldun sheffieldun, na, Tue Nov 28 14:32:57 GMT+00:00 2006, Uncontrolled Copy, (c
2、) BSI BS 2W 12:1989 This British Standard, having been prepared under the direction of the Aerospace Standards Policy Committee, was published under the authority of the Board of BSI and comes into effect on 29 September 1989 BSI 04-2000 BS W9 first published 1946 BS 2W9 first revised August 1965 BS
3、 W12 first published January 1968 First joint revision as BS 2W 12 September 1989 The following BSI references relate 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 Bri
4、tish Standard was entrusted by the Aerospace Standards Policy Committee (ACE/-) to Technical Committee ACE/14, upon which the following bodies were represented: British Independent Steel Producers Association Civil Aviation Authority (Airworthiness Division) Federation of Wire Rope Manufacturers of
5、Great Britain Ministry of Defence Society of British Aerospace Companies Limited Stainless Steel Wire Export Group Amendments issued since publication Amd. No.Date of issueComments Licensed Copy: sheffieldun sheffieldun, na, Tue Nov 28 14:32:57 GMT+00:00 2006, Uncontrolled Copy, (c) BSI BS 2W 12:198
6、9 BSI 04-2000i Contents Page Committees responsibleInside front cover Forewordii Section 1. General 1Scope1 2Definitions1 Section 2. Zinc coated carbon steel wire used in the manufacture of wire rope 3Material2 4Manufacture2 5Dimensional tolerances on diameter2 6Performance requirements2 7Marking3 S
7、ection 3. Preformed zinc coated carbon steel wire ropes 8Designation4 9Material4 10Dimensions4 11Mass4 12Manufacture4 13Performance requirements4 14Protective treatment6 15Winding reels6 16Marking6 Appendix A Surface defect test for rod7 Appendix B Measurement of actual diameter of preformed wire ro
8、pe7 Appendix C Types of construction7 Appendix D Elongation test8 Appendix E Proof test8 Appendix F Preforming test8 Appendix G Endurance test8 Appendix H Handling precautions with wire ropes11 Figure 1 Schematic diagram for endurance test equipment and test conditions9 Figure 2 Test pulleys for use
9、 in endurance test10 Table 1 Cast analysis2 Table 2 Tolerances on diameter2 Table 3 Tensile strength limits2 Table 4 Torsional limits2 Table 5 Principal properties of preformed wire rope5 Table 6 Dimensions of pulleys used in endurance test10 Table 7 Breaking strength after endurance test11 Publicat
10、ions referred toInside back cover Licensed Copy: sheffieldun sheffieldun, na, Tue Nov 28 14:32:57 GMT+00:00 2006, Uncontrolled Copy, (c) BSI BS 2W 12:1989 ii BSI 04-2000 Foreword This British Standard, prepared under the direction of the Aerospace Standards Policy Committee, is a revision of BS W12:
11、1968, which is withdrawn, and it supersedes BS 2W 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 with ISO 2020 publ
12、ished 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 severe condit
13、ions 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 BS 2763 are now specified, together with dimensio
14、nal 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, whilst the third s
15、pecifies 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 at least equ
16、ivalent to BS 5750-2. 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 of pages Th
17、is document comprises a front cover, an inside front cover, pages i and ii, pages 1 to 12, 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 cover. Lic
18、ensed Copy: sheffieldun sheffieldun, na, Tue Nov 28 14:32:57 GMT+00:00 2006, Uncontrolled Copy, (c) BSI BS 2W 12:1989 BSI 04-20001 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
19、 the manufacture of wire ropes (section 2) and the construction, mechanical properties and test requirements for preformed zinc coated carbon steel wire ropes (metric and inch series) (section 3). NOTEThe titles of the publications referred to in this standard are listed on the inside back cover. 2
20、Definitions For the purposes of this British Standard the following definitions apply. 2.1 wire a single 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
21、 more layers, around a core 2.4 preformed wire rope a wire rope in which the finished strands are formed 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 ro
22、pe is designated 2.6 actual diameter the measured diameter of the wire or rope 2.7 lay the designation 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
23、, measured parallel to the longitudinal axis, in which the wire in the strand or the strand in the rope 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 e
24、longation that length by which the rope extends between defined upper and lower limits of force (i.e. between first and second reading), expressed as a percentage of the gauge length measured at the lower limit Licensed Copy: sheffieldun sheffieldun, na, Tue Nov 28 14:32:57 GMT+00:00 2006, Uncontrol
25、led Copy, (c) BSI BS 2W 12:1989 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 section 1 and section 3 of BS 2763:1982 except for wire diameters. 3.2 Cast analysis The c
26、ast analysis of the wire shall comply with Table 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 process is used the purity of the slab zinc shall be not less than 98.5 %. 3.3.2 The weig
27、ht of the zinc coating shall be determined by one of the methods given in section 2 of BS 443:1982, and shall comply with class Z requirements of BS 2763. 3.3.3 The adhesion of the zinc coating shall comply with BS 443. 4 Manufacture 4.1 The wire shall be manufactured to circular section within the
28、range of diameters shown in Table 2 by cold drawing from rod complying with 3.1 and 3.2, and which is free from surface defects when tested in accordance with Appendix A. The wire shall be supplied in the zinc coated condition complying with 3.3. NOTEThe decarburization test (see 6.4) should be carr
29、ied 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 in Table 2. Individual measurements shall lie within the tolerance given in Table 2. 5.2 The diamete
30、r 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 cut from each end of each coil of finished wire as drawn. 6.2 Tensile
31、 strength test 6.2.1 When tested in accordance with BS 4545 the tensile strength of the wire, calculated on the nominal diameter, shall meet the requirements of grade 1860 or 1960 of BS 2763. 6.2.2 The tensile strength of the wire shall be specified by the rope maker. 6.2.3 The tensile strength of a
32、ny wire shall meet the limits shown in Table 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 BS 4545 the test piece shall withstand the number of twists shown in Table 4. When failure occurs, th
33、e primary fracture shall be perpendicular to the longitudinal axis of the wire. Table 4 Torsional limits Element(s)Min.Max. % Carbon0.50.85 Silicon0.35 Manganese0.40.9 Phosphorus0.030 Sulphur0.035 Nominal wire diameterTolerance From Up to but excluding PlusMinus mmmmmmmm 0.200.400.010.01 0.400.800.0
34、150.015 Nominal wire diameter Plus tolerance FromUp to but excluding mmmmN/mm2 0.200.25340 0.250.40300 0.400.80260 Tensile grade: average tensile strength Number of twists N/mm2 (minimum) 1 860 1 960 where L is the free length between grips (in mm); d is the nominal diameter of wire (in mm). L 100d
35、- -25 L 100d - -22 Licensed Copy: sheffieldun sheffieldun, na, Tue Nov 28 14:32:57 GMT+00:00 2006, Uncontrolled Copy, (c) BSI BS 2W 12:1989 BSI 04-20003 6.4 Decarburization test When tested in accordance with BS 6617-1 the wire shall show a radial depth of decarburization (total and partial) not gre
36、ater than 1.5 % of the diameter. 6.5 Ductility wrap test 6.5.1 When tested in accordance with the wrap test given in BS 4545 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
37、be unwrapped for seven complete turns. 6.6 Retests Should any test piece fail to meet the requirements of 6.2 to 6.5, 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,
38、and shall be subjected to repeat tests in 6.2 to 6.5. 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,
39、 which bears the following information: a) the number of this British Standard, i.e. BS 2W 121); 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 BS 2W 12 on
40、or in relation to a product 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 declarat
41、ion is not to be confused with third party certification of conformity, which may also be desirable. Licensed Copy: sheffieldun sheffieldun, na, Tue Nov 28 14:32:57 GMT+00:00 2006, Uncontrolled Copy, (c) BSI BS 2W 12:1989 4 BSI 04-2000 Section 3. Preformed zinc coated carbon steel wire rope 8 Design
42、ation 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 an inch series rope as listed in Table 5. 9 Material Preformed wire ropes shall be manufactured from zinc coated carbon steel wire complying with section 2. 10 Dim
43、ensions The actual diameter of a preformed wire rope, when measured in accordance with Appendix B, shall be between the maximum and minimum dimensions given in Table 5. 11 Mass The maximum mass per unit length of preformed wire rope, for a designated size, shall not exceed the figure given in Table
44、5. 12 Manufacture 12.1 Construction Preformed wire ropes shall be manufactured to the construction shown in Table 5. NOTE 1For ropes designated 2.4 mm diameter two types of construction are permitted. The purchaser should state in his contract and order which type of construction is required. NOTE 2
45、The types of construction are described in Appendix C. 12.2 Core strand The core strand of a preformed wire rope shall be of sufficient diameter to 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 wi
46、res. 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 shall be between six and eight times the diameter of the rope, for both limits of size given in Table 5. The strands shall be in right-hand ordinary lay. 12.
47、5 Preforming The strands shall be preformed during manufacture in such a manner that the finished wire rope satisfies the test specified in 13.6. 12.6 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
48、 be tucked in, and in no case shall more than one joint occur in 6 m of strand. For wire of 0.20 mm diameter and larger, joints shall be made by welding 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 u
49、nequally 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 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 accepted as being suitable and the properties specified for this ma