Nonlinear Modeling of Flexible Cable Loads on Large Sheaves

Stress analysis of the components of a sheave used to transfer loads between the lift span and counterweight in a movable span bridge is investigated. Stress analysis is a requirement for properly designing such sheaves. Modeling of the mechanism of load transfer from the wire ropes to the sheave is accomplished in three ways: (1) the traditional manner using a uniform pressure distribution; (2) using a varying pressure distribution developed from belt/pulley theory; and (3) using the finite-element method with nonlinear contact elements between the wire rope and the sheave. Internal stresses in the sheave are calculated using uniform distributed pressure and a varying pressure distribution. It is determined that the load distribution on the sheave from the wire ropes is precisely the same for the nonlinear contact analysis and the belt/pulley analysis. The internal stress analysis results show that the traditional, uniformly distributed load representation is less conservative than the more realistic belt/pulley load representation. A methodology is developed that can be utilized to more accurately model the load transfer representation without the complexity of nonlinear analyses.