JB/T 11167-2011 Rolled Sheave Standard for Crane Wheels
JB/T 11167-2011 is the product standard for rolled sheaves used in cranes. It specifies the classification, diameter range, technical requirements, and test methods for rolled sheaves, and is applicable to rolled sheaves used in the hoisting and luffing mechanisms of overhead, gantry, and tower cranes.
JB/T 11167-2011 is the product standard governing rolled sheaves for cranes, defining the diameter range, technical requirements, test methods, and inspection rules. Compared with cast sheaves, rolled sheaves offer significant advantages including lower dead weight, higher strength, and longer service life, making them the mainstream choice in modern crane design.
Rolled Sheave Manufacturing Process and Key Characteristics
The manufacturing process for rolled sheaves under JB/T 11167-2011 begins with heating steel billets and hot-rolling them into shape — the roller cavity directly forms the rope groove and wheel flange in a single pass. After rolling, the sheave blank undergoes normalizing to relieve rolling stress and refine the grain structure, followed by machining (turning of the bore and end faces). Unlike cast sheaves, rolled sheaves are free from casting defects, and the metal flow lines run continuously along the circumference.
Key advantages of rolled sheaves: fatigue strength 30%–50% higher than cast sheaves, 20%–30% lighter in weight (thinner wall thickness with no compromise in strength), superior dimensional accuracy (groove consistency far exceeding cast sheaves), better surface finish (reducing wire rope wear), and higher production efficiency suited to batch manufacturing. Kelude rolled sheaves are applicable to cranes with sheave diameters from Φ200 to Φ1000 mm.
Diameter Range and Dimensional Tolerances
The standard specifies the following sheave diameter range: Φ200, Φ250, Φ315, Φ355, Φ400, Φ450, Φ500, Φ560, Φ630, Φ710, Φ800, Φ900, and Φ1000 mm. Rope groove dimensions are determined by the mating wire rope diameter: groove bottom radius R = (0.53–0.57)d (where d is the wire rope diameter), groove depth ≥ 1.75d, and groove angle between 30° and 45°.
Dimensional tolerance requirements: sheave diameter tolerance to h11 grade (for a Φ500 mm sheave, the diameter tolerance is 0 to −0.32 mm); radial runout at the groove bottom ≤ 0.3 mm (precision grade) or ≤ 0.6 mm (standard grade); bore tolerance to H7 grade. Face runout of the sheave end faces relative to the bore axis ≤ 0.15 mm (precision grade) or ≤ 0.30 mm (standard grade).
Heat Treatment and Wear Resistance
Heat treatment requirements under the standard: the rope groove surface must undergo induction hardening or carburizing and quenching — hardened layer depth ≥ 2 mm, with a surface hardness of HRC 45–55. The wheel flange and hub may receive overall quenching and tempering (hardness HB 250–300) depending on usage requirements. After heat treatment, sheaves must be tempered to relieve residual stress, and quenching cracks are not permitted.
Rope groove wear limits: the sheave must be replaced when the groove bottom diameter wear exceeds 25% of the wire rope diameter (e.g., a sheave matched with a Φ20 mm wire rope must be replaced once groove bottom wear reaches 5 mm or more). Replacement is also required when groove wall thickness wear exceeds 20% of the original wall thickness, or when the groove radius R has enlarged due to wear to the point where the wire rope sits loose in the groove.
Inspection and Acceptance
Factory Acceptance Test items: visual inspection (surface defects and machining quality), dimensional inspection (diameter, groove dimensions, bore tolerance), hardness test (3 measurement points on both the groove surface and the core), and static balancing test (unbalance torque ≤ sheave dead weight × 0.002·R, where R is the radius in meters). Type tests are conducted once every 5 years.
In-service inspection: every 3 months, check groove wear amount and surface condition, and verify sheave bearing rotation smoothness and axial clearance (replace the bearing if clearance exceeds 2 mm). Measure the groove bottom diameter every 6 months. Perform Magnetic Particle Inspection (MPI) annually, with particular attention to the R transition zone at the wheel flange root and the keyway area.
Sheave Diameter
Φ200–Φ1000 mm
D/d Ratio
Overhead cranes ≥ 20
Steel mill cranes ≥ 30
Rope Groove Radius
R = (0.53–0.57)d
Weight Advantage
20%–30% lighter than cast
Fatigue Strength
30%–50% higher than cast
Bearing Life
8,000–12,000 operating hours
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| Parameter | Rolled Sheave | Cast Sheave |
|---|---|---|
| manufacturing process | Hot-rolled billet forming | Molten steel/Hot metal (molten iron)Casting Hot-rolled billet forming |
| metal flow line | Continuous distribution | Discontinuous |
| Fatigue Strength | High | General |
| Weight | Light(Light20%~30%) | Heavy |
| Applicable diameter | Φ200~Φ1000mm | Φ200~Φ2000mm |
| Cost | Moderate batch production | Low for single-piece and small-batch |
FAQ: Rolled vs. Cast Sheaves, Wear Limits & Bearing Care
Q: What are the advantages of rolled sheaves over cast sheaves?
A: Rolled sheaves offer continuous metal flow lines, delivering 30%–50% higher fatigue strength than cast sheaves. They are also free from casting defects, 20%–30% lighter, dimensionally more accurate, and faster to produce. Cast sheaves, on the other hand, can be manufactured in larger diameters (>1000 mm) and complex geometries, with a broader range of material options. As a general selection guideline, rolled sheaves are the preferred choice for diameters from Φ200 mm to Φ1000 mm.
Q: What are the wear limits and replacement criteria for the rope groove?
A: The sheave must be replaced when the groove bottom diameter wear exceeds 25% of the wire rope diameter, or when the groove wall thickness wear exceeds 20% of the original wall thickness. Replacement is also required if the groove bottom radius (R) has enlarged due to wear, causing the wire rope to loosen or slip out of the groove. Worn rope grooves can be reconditioned by build-up welding.
Q: What are the matching requirements between sheave and wire rope?
A: The ratio of sheave diameter (D) to wire rope diameter (d) must meet the following minimums: D/d ≥ 20 for overhead hoisting applications, D/d ≥ 25 for gantry cranes, and D/d ≥ 30 for metallurgical duty. The rope groove radius should be R = (0.53–0.57)d. A groove that is too shallow (groove depth < 1.75d) increases the risk of the wire rope jumping out of the groove.
Q: What are the maintenance intervals and lubrication requirements for sheave bearings?
A: Relubricate with lithium-based grease every 3 months. Annually, clean the bearings and replace with fresh grease. The bearing operating temperature should not exceed 80°C. If noticeable rotation resistance or axial clearance exceeding 2 mm is detected, disassemble and inspect the bearing, replacing it if necessary. Typical bearing service life ranges from 8,000 to 12,000 operating hours.
