Tight-Wire Sag Chart

 
Ok folks, for all you engineering geniuses out there, here's the formula for figuring your sag in a steel wire.  Have a blast with this one.  If you want to save your brain cells for something a bit more useful keep scrolling and you will find the charts already made up (from 6' to 100') for your printing needs.
 
The wire sag is used for turbine machinery alignment; the internal parts of the turbine must be accurately aligned to a centerline. The wire is the centerline reference but the wire sag must be accounted for to get accurate centerline. Alignment of the turbine components has to be within thousands of an inch.  Below is a sample calculation based on the parabolic approximation, but don't use it for actual design!

d=wl^2/8T - Where d = wire sag; w = weight of the wire per unit length; l = horizontal span between supports; and
                     T  = the horizontal tension in the wire.

The 0.016 inch diameter steel wire weighs about 0.0007 pounds per foot. So for a 10 foot span between level supports, and 30 pounds tension at a given temperature, the sag at the low point (mid point of the span) is d=wl^2/8T = 0.0003 feet, or about 3/1000 of an inch. For a 100 foot span with that same tension, d = wl^2/8T = 0.03 feet (about 3/8 of an inch). Now to get the wire deflections at other points in the span, let's take the 100 foot span case, using the parabolic approximation y=ax^2 (letting the low point of the curve be at origin (0,0)), then you can solve for 'a' using the condition that y=.03 when x = 50, and get a = .03/2500 = 0.000012; so now, for the 100 foot span case, you have y = .000012x^2, which defines the shape of the curve, and where y is the value measured up from the low point. For example, at x= 0 (low point) y = 0, implying a sag of 0.03 -y = .03'; or at the 1/4 points, where x = 25, y= .0075, and the deflection at that point is .03 -y = .03 - .0075 = .0225 feet.

Note also that if the wire is subject to temperature variations, it's tension and sag will change (more sag , less tension, when hot; less sag, more tension, when cold.).

That just seems like too much work.  Let's just print out the pages below and save our strength.
 


The following pages will show the how much sag to factor into a wire with a diameter of .016"  and a 30-pound weight attached to one end.  These charts are  for precision alignment of turbine components and other close tolerance machinery. 

 
  Page 1
6' - 34'

Page 2
34' - 49'

Page 3
49' - 61'

Page 4
61' - 70'

  Page 5
70' - 79'

Page 6
79' - 86'

Page 7
86' - 95'

Page 8
95' - 100'

 

 



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