Failure analysis of wire-breaks in aluminum conductor production and investigation of early failure reasons for transmission lines

Karabay, Sedat; Ertürk, Alpay Tamer; Zeren, Muzaffer; Yamanoğlu, Rıdvan; Karakulak, Erdem

doi:10.1016/j.engfailanal.2017.09.007

Cited by 26 publications

(19 citation statements)

References 23 publications

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“…The low-cycle strain fatigue demonstrates a typical feature in which plastic deformation occurs before the fatigue failure of metallic materials. However, the high-cycle stress fatigue usually results in elastic deformation, and the dislocation density does not significantly increase [30][31][32]. Figure 19 shows the scanning electron microscope (SEM) photographs of the fracture of the broken aluminum wire in the Level 6 wind simulation experiment.…”

Section: Surface Yield Line Of Aluminum Wiresmentioning

confidence: 99%

Research on Failure Mechanisms of Broken Strands of Jumper Wires for EHV Transmission Lines in Strong-Wind Areas

Han

Yongjie

et al. 2019

Metals

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The jumper wires of an extra-high voltage (EHV) transmission line in strong-wind areas in Northwest China frequently break down. We installed some acquisition devices to collect the data of the jumper wires and wind speed in the fault area of one 750-kV transmission line. We also developed a swing simulation machine based on the collected data. The machine could simulate the swing condition of the jumper wires under various wind speeds. We analyzed the broken aluminum wires obtained from the simulation experiment of jumper wires. Yield lines appeared on the surface of the broken aluminum wires in the simulation experiment. Proliferation of dislocation and grain deformation occurred in the broken aluminum wires using transmission electron microscopy observation. The results show that the aluminum wires in the experiment under a Level-6 wind and above were in a full yield state and demonstrated strain-fatigue failure condition. The fracture of the broken aluminum wires showed distinct strain-fatigue fracture characteristics using the scanning electron microscope fracture morphology analysis. From the combination of the abovementioned research, we conclude that the failure mechanism of the broken strands of the jumper wires of the EHV transmission line in the strong-wind area is mainly a strain-fatigue failure mechanism.

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Section: Surface Yield Line Of Aluminum Wiresmentioning

confidence: 99%

Research on Failure Mechanisms of Broken Strands of Jumper Wires for EHV Transmission Lines in Strong-Wind Areas

Han

Yongjie

et al. 2019

Metals

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“…3 Similar approaches applied to other processes such as tube rotary draw bending and wire drawing have shown that defects can be avoided by using optimum conditions of process variables. 4,5 JingDong et al 6 have highlighted the need to focus on improving part quality by determining FIGURE 2 Deformation of bottom panel of a can subjected to a buckle pressure test optimum process parameters using an alternative to the time-consuming "trial-and-error" procedure. However, this can be very complex, since part quality is also influenced by geometry, material, surface roughness, lubrication, and machine features.…”

Section: Figure 1 Metal Can Showing Expansion Ringsmentioning

confidence: 99%

“…Parameter optimisation is of major importance in Can manufacturing, given the variety of methods having been used to improve sheet forming processes by controlling design variables . Similar approaches applied to other processes such as tube rotary draw bending and wire drawing have shown that defects can be avoided by using optimum conditions of process variables . JingDong et al have highlighted the need to focus on improving part quality by determining optimum process parameters using an alternative to the time‐consuming “trial‐and‐error” procedure.…”

Section: Introductionmentioning

confidence: 99%

Process parameter optimisation of a minster draw‐redraw system

Seechurn

Ramlugun

2019

Engineering Reports

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Non‐conformance in Unit Depth Value (UDV) of expansion rings for metal cans makes them prone to major defects, such as swells and distortions, during the Drawing/Redrawing industrial process. In this paper, with the aim of improving the manufacturing process quality, the process parameters for the Minster Draw/Redraw machine at a generic company are optimised so as to obtain the desired UDV. The Taguchi method is used to determine the most influential process parameters. Nine experiments have been performed with four selected parameters, namely, Upper Blank Holder Pressure, Lower Blank Holder Pressure, Profile Pad Pressure, and Inner Ram Value. A multiple‐linear regression analysis is also conducted to demonstrate the relationship between UDV and the considered parameters. The best settings for the respective process parameters are obtained via Analysis of Means (ANOM). Furthermore, Analysis of Variance (ANOVA) shows that the Inner Ram Value is the process parameter that most significantly affects the formation of expansion rings. The same methodology proposed in this study can easily be extended to find the optimum settings of process parameters for different can heights. Finally, an equation is formulated to predict the setting values of the most significant process parameters under user‐specified UDVs.

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“…To explore the causes of failure of wire rope, Singh et al [8] analyzed the probable reason for failure of two wire ropes used in different underground coal mines in India and found that excessive wear is the major cause of failure. Additionally, with the aim of investigating the possible origin of wire-breaks, Karabay et al [13] analyzed wire defects and damages during aluminum continuous casting and the wire drawing process.…”

Section: Introductionmentioning

confidence: 99%

Evolution Properties of Tribological Parameters for Steel Wire Rope under Sliding Contact Conditions

Chang

Peng

Zhu

et al. 2018

Metals

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Friction and wear seriously affect the safety use of winding hoist wire rope and the damage is a gradual process in practical application. In this paper, the tribological properties of a wire rope under different sliding distances were investigated. The evolutions of the coefficient of friction (COF), temperature rise, and wear characteristics under different contact loads and strokes were analyzed by a series of experiments. The results show that fluctuation of the friction is large in the early stages (before 10 min) and the major peaks depend on the stroke. When the contact load is 150 N, the COF increases most rapidly. It grows from approximately 0.48 to approximately 0.61 with the sliding distance. Additionally, the temperature rise in the wear region is higher under the large stroke (30 mm) and contact load (150 N). The maximum temperature rises are approximately 7.5 • C and 7.1 • C, respectively. Furthermore, it is approximately after 7200 mm that the temperature rise reaches a relatively stable stage. The wear scar region increases with the sliding distance and the maximum wear loss is approximately 65.5 mg at a load of 150 N. The major wear mechanisms of the wire rope are fatigue and adhesion wear.

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Failure analysis of wire-breaks in aluminum conductor production and investigation of early failure reasons for transmission lines

Cited by 26 publications

References 23 publications

Research on Failure Mechanisms of Broken Strands of Jumper Wires for EHV Transmission Lines in Strong-Wind Areas

Research on Failure Mechanisms of Broken Strands of Jumper Wires for EHV Transmission Lines in Strong-Wind Areas

Process parameter optimisation of a minster draw‐redraw system

Evolution Properties of Tribological Parameters for Steel Wire Rope under Sliding Contact Conditions

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