Vol.:(0123456789) OPSEARCH https://doi.org/10.1007/s12597-020-00468-3 1 3 APPLICATION ARTICLE Optimum design and selection of wire rope for hot rolling shop applications Krishan Kumar 1  · Sube Singh 2  · S. S. Banwait 1 Accepted: 10 July 2020 © Operational Research Society of India 2020 Abstract Optimal selection of wire rope for various industrial applications is a multidisci- plinary procedure. In this paper, optimum selection of wire rope for winch trolley in hot rolling shop is comprehensively demonstrated using finite element analysis. Powerfoam wire rope can be operated at lower D/d ratio and have 2.5 times longer service life as compared to their stranded conventional counterpart. The parame- ter-based geometric models of commercially available multi-layer wire ropes of 1 + 6 + 6 strand construction are designed using modelling software, SolidWorks, and procedure is followed by finite element analysis on ANSYS. The service life of wire rope is a function of factor of safety. Finally, cost analysis is delivered for opti- mum selection of wire rope, as an economical insight of the study. Keywords Geometric modeling · Finite element analysis · Design · Optimum selection · Steel wire rope List of symbols F Axial tensile force (N) F f Frictional force b/w rails and wheels (N) F a Force to accelerate the trolley in horizontal direction (N) E Young modulus of elasticity (N/mm 2 ) v Poisson’s ratio a max Maximum acceleration of winch trolley (m/s 2 ) * Krishan Kumar erkrishan.bishnoi@gmail.com Sube Singh sube.ise@hotmail.com S. S. Banwait ssb@nitttrchd.ac.in 1 Department of Mechanical Engineering, National Institute of Technical Teachers Training and Research, Sector – 26, Chandigarh 160019, India 2 Department of Industrial and Systems Engineering, Indian Institute of Technology Kharagpur, Kharagpur 721302, India