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The present invention relates to a cord for a tyre for a vehicle and a
tyre provided with said cord.
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There are known vehicle tyres which have a carcass provided with a
metallic reinforcement including cords, each cord consisting of a
metallic core thread and two concentric shells of metallic threads
arranged around the core thread. In these cords, the shell threads are
wound helicoidally in the same direction (i.e., they have a so-called
"Lang Lay" type winding), in a "S" (right-handed) or "Z" (left-handed)
configuration.
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The cords of the type described are very compact and their
manufacturing costs are low. However, they have the disadvantage of
having low resistance to fatigue and being subject to breaking and
migration (displacement) of the core thread.
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During the running of a vehicle, the cords of the tyre carcass are
subjected to alternating bending stresses, particularly on the sidewalls,
when the tyre enters and leaves the contact area with the ground (the
footprint). In the case of a carcass having cords with core thread, these
alternating bending stresses can easily lead to the breakage of the core
thread.
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Also in the case of a carcass having reinforcing cords with core
thread, the core thread has a low degree of attachment to the
innermost shell of threads. Therefore, during the production of the tyre,
and also when it is in use, in other words during the running of the
vehicle, the core thread may slip longitudinally within the radially
innermost shell of threads, with consequent migration of the core thread
beyond the ends of the cord.
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In particular, during the production of a tyre, the migration of the core
threads beyond the cords causes what is known as the brush effect.
This consists in the emergence of portions of metallic core threads from
the edges of the carcass ply or plies. These portions of projecting
metallic threads are hazardous to tyre production workers, since they
can cause wounds and injuries.
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On the other hand, if the migration of the core threads occurs during
the running of the vehicle, this can bring said threads to the surface of
the tyre, thus forming a passage through which moisture and water can
reach the metallic reinforcement and initiating a process of corrosion
(rusting) which is propagated along the core threads within the cords,
leading to the separation of the rubber from the metallic reinforcement
and the breaking of the aforesaid cords.
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There are also known tyres having carcass cords formed from a
strand of metallic core threads and two concentric shells of metallic
threads arranged around the core strand. In these cords, the metallic
threads of the core strand are wound together helicoidally in a
predetermined direction ("S") and the metallic threads of the inner shell
are wound helicoidally in the same direction ("S") around said strand,
while the metallic threads of the outer shell are wound helicoidally in
the opposite direction ("Z") around said inner shell.
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The Applicant has found that when these cords with core strands are
deformed, a phenomenon of rubbing ("fretting") occurs among the
threads, particularly between the threads of the core strand and the
threads of the inner shell. The extent of this fretting is greater than that
of the fretting between the threads of cords having core thread, and
causes a rapid wear of the cords.
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The object of the present invention is to eliminate the disadvantages
of the known cords.
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In a first aspect, the invention relates to a cord for a tyre including a
strand of metallic core threads and at least two shells of metallic
threads arranged around said strand, said threads of said strand and of
said shells being wound helicoidally, characterized in that said threads
of said strand and of said shells have a "Lang Lay" type winding.
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Typically, the number of said threads of said strand is in the range
from 2 to 5. In a preferred embodiment of the invention, the number of
threads in said strand is three.
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The number of threads of said radially inner shell is in the range
from 5 to 9. In one embodiment, the number of said shell threads is 6.
-
The number of threads of said radially outer shell is in the range
from 10 to 15. In one embodiment, the number of said shell threads is
12.
-
In one embodiment, said threads of said core strand and of said
shells have a "S" winding.
-
In a further embodiment, said threads of said core strand and of said
shells have a "Z" winding.
-
In a second aspect, the invention relates to a tyre for a motor
vehicle, having a carcass including reinforcing cords, each of said
cords including a strand of metallic core threads and at least two shells
of metallic threads arranged around said core strand, said threads of
said core strand and of said shells being wound helicoidally,
characterized in that said threads of said core strand and of said shells
have a "Lang Lay" type winding.
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The cord according to the invention is particularly advantageous.
This is because it has a greater tensile strength and lower bending
rigidity than conventional cords with core thread, as well as it has a
greater resistance to fretting than conventional cords provided with
core strand.
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Characteristics and advantages of the invention will now be
illustrated with reference to one embodiment shown by way of example
and without restrictive intent in the attached figures, in which:
- Fig. 1 is a partial perspective view of a cord for a tyre, made
according to the invention;
- Fig. 2 is a cross-sectional view of the cord of Fig. 1;
- Fig. 3 is a partial perspective view of a conventional cord with core
thread;
- Fig. 4 is a cross-sectional view of the cord of Fig. 3;
- Fig. 5 is a partial perspective view of a conventional cord with a core
strand;
- Fig. 6 is a cross-sectional view of the cord of Fig. 5;
- Fig. 7 shows the scale for measuring the degree of wear of the
threads used in the description of the present invention, based on the
known Wallace method;
- Fig. 8 is a partial view, in cross section, of a tyre having a carcass
including cords made according to the invention;
- Fig. 9 is a photographic reproduction, enlarged 40 times, of the cross
section of a cord according to the invention, in the initial condition, in
other words before a fatigue test (alternate bending);
- Figs. 10 and 11 are photographic reproductions, enlarged 40 times,
of two cross sections of the cord of Fig. 9, taken within the interval of
one pitch, on completion of said fatigue test;
- Fig. 12 is a photographic reproduction, enlarged 40 times, of the
cross section of a conventional cord such as that of Figs. 3 and 4, in
the initial condition, in other words before a fatigue test (alternate
bending);
- Figs. 13 and 14 are photographic reproductions, enlarged 40 times,
of two cross sections of the cord of Fig. 12, taken within the interval of
one pitch, on completion of said fatigue test;
- Fig. 15 is a photographic reproduction, enlarged 40 times, of the
cross section of a conventional cord such as that of Figs. 5 and 6, in
the initial condition, in other words before a fatigue test (alternate
bending);
- Figs. 16 and 17 are photographic reproductions, enlarged 40 times,
of two cross sections of the cord of Fig. 15, taken within the interval of
one pitch, on completion of said fatigue test.
-
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Figs. 1 and 2 show a preferred embodiment of a cord 1 for a tyre,
made according to the invention. Said cord 1 comprises a core strand
2, an inner shell 3 and an outer shell 4. The core strand 2 consists of
three metallic threads 5 wound together helicoidally with a "S" winding;
the inner shell 3 consists of six metallic threads 6 wound helicoidally in
a "S" winding around the threads of the core strand, and the outer shell
4 consists of twelve metallic threads 7 wound helicoidally in a "S"
winding around the threads of the inner shell. As shown, the direction
of winding of the threads of the core strand 2, and of the threads of
both shells 3 and 4, is the same ("Lang Lay" type winding) in the cord 1
according to the invention. In this particular case, the winding of the
threads is of the "S" type. In the above embodiment, the winding pitch
is 14 mm.
-
The diameter of the aforesaid threads 5, 6 and 7 can vary from
0.10 mm to 0.40 mm, and does not have to be identical for all the
threads of the cord.
-
Preferably, the diameter of the strand threads is smaller than that of
the threads of the two concentric shells. Preferably, the diameter of the
strand threads is in the range from 0.10 mm to 0.15 mm, while that of
the shell threads is in the range from 0.20 mm to 0.30 mm, the
difference between said values being at least 0.05 mm, and preferably
at least 0.10 mm.
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In all cases, the diameter of the threads and the number of threads
in the strand and in the shells are interdependent, since they are
related to the requirement of having compact cords, of small diameter,
which at the same time are highly penetrable by the rubberizing
material.
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A cord in which the threads of the core strand 2 and the threads of
both shells 3 and 4 have a "Z" winding has a performance similar to
that of the corresponding cord with the "S" winding.
-
Figs. 3 and 4 show a conventional cord 11 for a tyre, including a
core thread 12, an inner shell 13 and an outer shell 14. The inner shell
13 consists of six metallic threads 16 wound helicoidally in a "S"
winding around the core thread 12, and the outer shell 14 consists of
twelve metallic threads 17 wound helicoidally in a "S" winding around
the threads of the inner shell.
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Figs. 5 and 6 show a conventional cord 21 for a tyre, including a
core strand 22, an inner shell 23 and an outer shell 24. The strand 22
consists of three metallic threads 25 wound together helicoidally in a
"S" winding; the inner shell 23 consists of nine metallic threads 26
wound helicoidally in a "S" winding around the strand threads 22, and
the outer shell 24 consists of fifteen metallic threads 27 wound
helicoidally in a "Z" winding around the threads of the inner shell. A
small thread ("wrap") 28 is wound around the threads 27 of the outer
shell 24. Therefore, in the cord 21 the threads 26 of the inner shell 23
and the threads 27 of the outer shell 24 are wound in opposite
directions.
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Fig. 8 shows a tyre 30 having a carcass 31 provided with reinforcing
cords 1 according to the invention, as shown in Figs. 1 and 2.
-
The Applicant has conducted a number of tests, comparing the
performance of cords made according to the invention with that of
conventional cords. The results of the tests are shown below.
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In one set of tests (Tests 1 - 4), three conventional cords provided
with a core thread (of the type shown in Figs. 3 and 4) and three cords
provided with a core strand and made according to the invention (as
shown in Figs. 1 and 2) were compared with each other.
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The structure of the cords used in said set of tests is shown in Table
1. The three conventional cords, identified by the
numbers 1, 2 and 3,
have a 1+6+12 configuration, while the three cords according to the
invention, identified by the
numbers 4, 5 and 6, have a 3+6+12
configuration.
Cord | Configuration | Pitch/Direction |
1 | 0.20+6x0.175+12x0.175 | 12.5 mm/Z |
2 | 0.25+6x0.22+12x0.22 | 16 mm/Z |
3 | 0.25+6x0.23+12x0.23 | 16 mm/Z |
4 | 3x0.10+6x0.175+12x0.175 | 12.5 mm/Z |
5 | 3x0.12+6x0.22+12x0.22 | 1 6 mm/Z |
6 | 3x0.12+6x0.23+12x0.23 | 16 mm/Z |
Test No.1
Pure bending
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The test, consisting in winding a cord with a length of 1000 mm over
a 100 mm diameter pulley, with no traction or torsion applied to the
threads, and measuring the tensile and bending forces acting in the
threads, was simulated in advance on a computer.
-
The test parameters were as follows:
Dp = pulley diameter | 100 mm |
Mt = torque applied to the ends of the cord | 0 N*mm |
F = tension applied to the ends of the cord | 0 N |
-
The results of the test are shown in Table II below, where
sigma 1 is
the tension acting in the core thread of cords 1-3 or in the threads of
the core strand in cords 4-6;
sigma 2 and
sigma 3 are, respectively, the
tensions acting in the threads of the inner shell and in the threads of
the outer shell of the aforesaid cords; Mb is the bending moment; and
A* is the bending rigidity of the cords.
Cord | sigma 1 [MPa] | sigma 2 [MPa] | sigma 3 [MPa] | Mb [N*mm] | A* [N*mm2] |
1 | 416 | 362 | 357 | 3.7 | 187.78 |
2 | 519 | 454 | 448 | 9.3 | 468.35 |
3 | 519 | 475 | 467 | 10.9 | 551.16 |
4 | 208 | 362 | 356 | 3.5 | 174.25 |
5 | 249 | 454 | 448 | 8.6 | 434.36 |
6 | 249 | 475 | 467 | 10.2 | 517.14 |
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The data in Table II show that the tensions acting in the core strand
(sigma 1) of cords 4-6 according to the invention were practically half of
the tensions acting in the core thread (sigma 1) of the corresponding
conventional cords 1-3, for an essentially identical bending moment.
Additionally, the bending rigidity A* of cords 4-6 according to the
invention was reduced by approximately 10% with respect to the
bending rigidity of the corresponding conventional cords 1-3.
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The tensions sigma 2 and sigma 3 remained essentially unchanged.
-
The experimental tests carried out subsequently in the laboratory
confirmed the results obtained by the simulation. These tests were
conducted on specimens of cord with a length of 1000 mm, fixed at
both ends with a pair of clamps. At a point approximately halfway along
its length, each specimen was fixed by winding on a 100 mm diameter
pulley, which was subjected in a suitable way to cycles of vertical stress
such that bending cycles were caused in the specimen.
-
Similar results were obtained when the test specimen was fixed to
the pulley by contact only.
-
The above results therefore show that the cords according to the
invention are capable of improving the resistance of the tyre to the
cyclic bending stresses to which it is subjected when in use.
Test 2
Applied bending
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The test consisted in subjecting the cord (having a length of 1000
mm) to an applied bending moment, of approximately 10 N mm, in the
absence of traction and torsion, and measuring the tensile forces acting
in the threads and the radius of curvature assumed by the cord. This
radius of curvature corresponds to the diameter of the pulley which
would cause a bending moment essentially equal to the applied
bending moment to appear in the cord wound on this pulley under the
same conditions. The test was simulated in advance on a computer.
-
The test parameters were as follows:
Mb = bending moment applied to the cord | 10 N*mm |
Mt = torque applied to the ends of the cord | 0 N*mm |
F = tension applied to the ends of the cord | 0 N |
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The results of the test are shown in Table III below.
Cord | sigma 1 [MPa] | sigma 2 [MPa] | sigma 3 [MPa] | Dp [mm] | Mb [N*mm] |
1 | 1119 | 973 | 958 | 36.35 | 10.002 |
2 | 561 | 491 | 484 | 92.50 | 10.004 |
3 | 302 | 436 | 429 | 109.05 | 10.001 |
4 | 602 | 1048 | 1032 | 33.93 | 10.001 |
5 | 290 | 529 | 521 | 85.72 | 10.001 |
6 | 244 | 464 | 457 | 102.24 | 10.001 |
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The test demonstrated that, for an essentially identical bending
moment, cords 4-6 according to the invention could be wound on
pulleys whose diameter Dp was smaller than that of pulleys on which
the corresponding conventional cords 1-3 could be wound.
-
The experimental tests carried out subsequently in the laboratory
confirmed the results obtained with the simulation. These tests were
conducted with the use of a test apparatus similar to that described in
test 1, with the difference that, in this case, a vertical load of 10 N was
applied to the pulley mentioned above.
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Therefore, according to the above data, cords 4-6 according to the
invention were shown to be more flexible than the conventional cords
1-3.
Test 3
Pure tensile test
-
The test consisted in the application of a tension of 100 N to the cord
while the torque and the bending moment at its ends were kept at zero.
The test was simulated in advance on a computer.
-
In practice, the test was carried out by applying a tensile force to the
cord and leaving it free to rotate about its own axis to dissipate the
torque generated by said tension.
-
The test parameters were as follows:
Mb = bending moment applied to the cord | 0 N*mm |
Mt = torque applied to the cord | 0 N*mm |
F = tension applied to one end of the cord | 100 N |
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The results of the test are shown in Table IV below.
Cord | sigma 1 [MPa] | sigma 2 [MPa] | sigma 3 [MPa] | epsilon [mm] | beta [rad] |
1 | 523 | 499 | 365 | 0.002044 | -0.009506 |
2 | 326 | 313 | 230 | 0.001277 | -0.005971 |
3 | 302 | 294 | 215 | 0.001199 | -0.005528 |
4 | 513 | 551 | 396 | 0.002264 | -0.011 |
5 | 314 | 342 | 250 | 0.001393 | -0.006722 |
6 | 291 | 319 | 231 | 0.001298 | -0.006145 |
where "epsilon" and "beta" are, respectively, the axial deformation
(tensile elongation) and the torsional deformation of the cord.
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Also this test shows that the structure of cords 4-6 according to the
invention is more effective than that of the corresponding conventional
cords 1-3. The tensions in the core are reduced, although only by a
small amount, while the tensions in the shell threads increase. The
axial and torsional deformations increase, and this is an indication of
increased flexibility of the cords according to the invention. Moreover,
the tensions (sigma 1-3) are more uniform among the various layers of
threads of the cords according to the invention than among those of the
conventional ones.
-
The experimental tests carried out subsequently in the laboratory
confirmed the results obtained with the simulation. These tests were
conducted on specimens of cord, each having a length of 1000 mm and
fixed by a clamp at one end. A tension of 100 N was applied to the free
end of each specimen, said end being associated with a 100 mm
diameter pulley.
Test 4
Combined tensile test
-
The test consisted in the application of a tension of 100 N to the cord
while the bending moment at its ends was kept at zero and the cord
was prevented from rotating about its own axis. The test was simulated
in advance on a computer.
-
The experimental tests carried out subsequently in the laboratory
confirmed the results obtained with the simulation.
-
The test parameters were as follows:
Mb = bending moment applied to the cord | 0 N*mm |
F = tension applied to the ends of the cord | 100 N |
beta = angle of rotation between two axially opposed sections of the cord | 0° |
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The results of the test are shown in Table V below.
Cord | sigma 1 [MPa] | sigma 2 [MPa] | sigma 3 [MPa] | epsilon [mm] | Mt [N*mm] |
1 | 224 | 224 | 219 | 0.001068 | 4.524 |
2 | 142 | 142 | 139 | 0.000676 | 5.573 |
3 | 131 | 131 | 128 | 0.000623 | 5.957 |
4 | 229 | 228 | 223 | 0.00109 | 4.837 |
5 | 145 | 145 | 142 | 0.000691 | 5.825 |
6 | 134 | 133 | 130 | 0.000637 | 6.211 |
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The test demonstrated that the cords 4-6 according to the invention
withstood a torque greater than that withstood by the corresponding
conventional cords 1-3. This means that they have a better resistance
to the applied torsion.
-
The experimental tests carried out subsequently in the laboratory,
using a test method similar to that of Test 3, confirmed the results
obtained with the simulation.
-
To summarize, Tests 1-4 described above showed that the cords
according to the invention had half of the tensions due to bending, as
well as a lower bending rigidity (in other words a higher torque) with
respect to the conventional cords which were considered.
Test 5
Wear due to rubbing (fretting)
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With reference to Table I, the test was conducted by comparing the
cord 5 (Invention), the conventional cord 2 (Comparative 1) and a
conventional cord with a core strand (of the type illustrated in Figs. 5
and 6) having the following structure: 3+9+15x0.22+0.15 (Comparative
2).
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The specimens were formed by preparing strips of rubberized and
vulcanized fabric comprising a predetermined number (generally from 3
to 5) of cords of the above types.
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Each strip of fabric was subjected to a fatigue test consisting of a
series of cyclical bendings (1500 kC in the case in question), caused
by moving each fabric strip alternately in two directions around a roller
of suitable dimensions (having a diameter of 32 mm in the case in
question), to which a suitable pre-loading was applied (this pre-loading
being chosen appropriately in relation to the dimensions of the
reinforcing cords, and being 450 N in the case in question).
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At the end of the test, the degree of wear of the individual threads
was measured according to the scale of wear shown in Fig. 7. The
degree of wear found in the individual threads of the cords is shown
below in Table VI, in which each individual value indicates the degree
of wear (measured according to the scale in Fig. 7) in one area of the
thread, while the sum of a plurality of values indicates the total degree
of wear in two or more areas of a single thread.
| | Invention | Comparative | 1 | Comparative 2 |
Cord | thread | 3x0.12+6+12x0.22 | 0.25+6+12x0.22 | 3+9+15x0.22+0.15 |
Outer shell | 1 | 1 | 1 | 3+2 |
2 | 1 | 1 | 4+2 |
3 | 1 | 1 | 3+2 |
4 | 1 | 1+1 | 3+2 |
5 | 1+1 | 1+1 | 2+2 |
6 | 1+1 | 2+1 | 3+2 |
7 | 1+1 | 1+1 | 3+3 |
8 | 1+2 | 3+1 | 2+1 |
9 | 1 | 1 | 3+2 |
10 | 1 | 1 | 3+3 |
11 | 1 | 1 | 3+2 |
12 | 1+1 | 2+2 | 4+2 |
13 | | | 3+2 |
14 | | | 3+2 |
15 | | | 2+2 |
Inner shell | 1 | 1+1 | 1+1 | 3+3 |
2 | 1 | 1+1 | 3+1 |
3 | 1 | 2+1 | 3+2 |
4 | 1 | 1+1 | 2+2 |
5 | 1 | 1+1+1 | 2+2 |
6 | 2+1 | 2+1+2 | 3+2 |
7 | | | 2+2 |
8 | | | 3+2 |
9 | | | 2+2 |
Core | 1 | 1+1 | 1+1+2+1 | 1+1+1 |
2 | 2+1 | | 1+2 |
3 | 1+1+1 | | 1+2+1 |
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For example, the value "2+1+2" relating to thread 6 of the inner shell
of the "Comparative 1" cord indicates that said thread has three
different areas of wear in the same cross section (said areas being
identifiable in the figures as flattenings of the circular section of each
thread), namely two areas with a degree of wear equal to 2 and one
area with a degree of wear equal to 1.
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The weight of the material removed (Fe) during the aforesaid wear
tests was also measured. The values found in the cords are shown in
Table VII below.
-
As shown by the above table, at the end of the test it was found that
the cord according to the invention had undergone a very low degree of
wear due to fretting, this degree of wear being less than half of the
wear of the Comparative 1 cord and about 15 times less than the wear
of the Comparative 2 cord.
-
The initial and final states of the cords subjected to Test 5 are shown
in Figs. 9-17.
-
Fig. 9 is a photographic reproduction of a cross section of the cord
according to the invention in the initial state. Figs. 10 and 11 are
photographic reproductions of two cross sections of the cord according
to the invention in the final state, after 1500 kilocycles (kC), where the
cross sections have been taken within the same pitch.
-
Fig. 12 is a photographic reproduction of a cross section of the
Comparative 1 cord in the initial state. Figs. 13 and 14 are
photographic reproductions of two cross sections of the Comparative 1
cord in the final state, after 1500 kilocycles (kC), where the cross
sections are close to each other, within the same pitch.
-
Fig. 15 is a photographic reproduction of a cross section of the
Comparative 2 cord in the initial state. Figs. 16 and 17 are
photographic reproductions of two cross sections of the Comparative 2
cord in the final state, after 1500 kilocycles (kC), where the cross
sections are close to each other, within the same pitch.
-
The comparison between the photographs of the cross sections of
the same cord before and after the fretting test illustrates in a clearly
visible way the amount of wear on the different threads of the cord, this
wear being represented by the flattening of the circular section of each
thread.