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Nylon Sheave Conversion: Overcoming Engineering Challenges
WS Hampshire is an industry-leading custom fabricator of non-metallic materials. With decades of experience, we create top-quality made-to-order parts and OEM fabricated components for a broad range of industries and applications. Our Timco Technical Thermoplastics, Ryertex Composites, and other innovative materials, paired with our technical expertise, have made us a recognized leader in non-metallic material fabrication for applications such as nylon sheaves, bushings, bearings, and wear pads.
We recently encountered a complex project that allowed us to showcase our underlying commitment to engineering excellence and safety.
The Customer’s Dilemma: Bearing Walk-Out in Nylon Sheaves
A long-time customer in the lifting industry contacted us about converting a pair of cast iron sheaves to nylon. Their goal was to extend the life of their wire ropes while reducing maintenance costs.
The customer had previously worked with another vendor and experienced difficulties with the bearings “walking out” of the sheave. To rectify this issue, they suggested we add snap rings to create a bearing retainer.
Engineering Analysis: Uncovering the Root Cause
After a comprehensive analysis of the nylon material properties and sheave design drawings, our team concluded that the issue went far beyond a simple bearing retention problem. The following calculations supported our conclusion:
- With a .625″ wire rope on the first sheave, we calculated a bore pressure of almost 4,000 psi and a groove pressure of ~2,750 psi.
- With a .750″ rope on the second sheave, we discovered an alarming bore pressure of almost 5,900 psi with a groove pressure of ~2,000 psi.
While both groove pressures remained within acceptable limits for the nylon material, the bore pressures exceeded safe operating levels. The root cause of the bearing “walk-out” was this overloading issue.
Innovative Solution: Steel Sleeve Integration
We suggested adding a steel sleeve between the nylon sheave and bearing to address the high bore pressures. This innovative solution would provide the following advantages:
- Significantly increase the load-carrying capacity of the bore
- Reduce rope wear
- Maintain a safer working environment for personnel and equipment
Lessons Learned: Safety First in Custom Fabrication
Even though the proposed project did not result in immediate new business, the solution demonstrated our commitment to engineering integrity and safety. By preventing potential catastrophic failures, we showcased the value of our expertise and comprehensive analysis capabilities for custom fabrication projects.
At WS Hampshire, we specialize in solving complex engineering challenges for a variety of industries and applications. Whether you require custom solutions for structural fiberglass, electrical insulation, or thermal insulation, our expert team can apply our fabrication skills and material knowledge to your next project.
Safe and Reliable Solutions by WS Hampshire
WS Hampshire has extensive experience developing innovative, custom solutions for non-metallic fabrication projects. Our nylon sheaves in particular offer distinct advantages over metallic sheaves in a wide range of industrial applications. We work closely with our clients to replace traditionally used materials with products better suited for their application, leading to reductions in long-term operating expenses and downtime.
Contact us today to learn how our capabilities can benefit your next project.