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Thank you all for the help. I have something I think I can work with though I'm not fond of the some of the assumptions I'm making. The main one being the shear modulus of the conductor. Using the Shear Modulus for solid copper The strand should be twisting itself apart with our medium sized...

Dave you really do like your electronic graffiti. I shouldn't even respond to this. Not sure why I am. I'm not fishing for a solution. All I ever wanted was how to do determine the torsional load and if my assumptions were correct. All the information needed for that answer was in the first...

The IDES database is a good source for base properties. In general a material with a low surface energy (HDPE, PP, PTFE, Delrin etc) will have low frictional coefficients. High surface energy materials like urethane and PPO will have higher coefficients. Truth is the surface 'texture', material...

All the above suggestions will work but I doubt you will ever remove all of the plasticizer as they are designed to like the resin and diffusion laws apply. You could probably remove it to the point most couldn't tell there was any left but you could detect it analytically.

TMoose - none of this is under voltage while being made and all splices are cut out when changing reels. Yes they would fail all electrical tests so if one gets left in by error it would fail final test and be cut out.

Thank you all for the productive responses. kcj - The scrap cost ranges from $1 to $30 per foot of cable. I can easily justify a second crimper however the only crimpers with enough tonnage are 'in process' crimpers in that the conductor must run through the crimper after being crimped. There...

Those would work fantastic if the crimp didn't have to come apart at the extrusion head when going from one size to another. I can even use a steel braid between the two to accommodate the size difference. The tooling cannot be changed with the conductor in place. The crimp then has to be...

Well Dave I hope you've sufficiently boosted your ego to get you through the weekend. I'm done for today but if you need some more boosting via vain attempts to make me feel less of a human than you, feel free to stop back on Monday. I have to admit I didn't expect to find trolls of your...

Again, my problem isn't the design yet. I'm looking for how much load is applied to the cable between the capstans and I tried to simplify it to a point that it can be calculated. A 600 ft piece of cable (copper or aluminum conductor) between two points under tension is rotated once every 75...

Why don't you ask me for the information needed for the calculation? You might find I do actually have the answers or can get them. If you have no desire to help and only want to spew insults why do you even hang out in a forum like this or do you just like to sit on a pedestal thinking all...

Are you trying to formulate a compound that will swell 4-6% in EtOH or want to find something that will swell the compound 4-6%? Lower the degree of crosslinking either through the peroxide level or cure conditions to get more swell. Increasing the free volume of the base resin with more...

If it is bonded with a glue or primer to the metal you have to worry about it and not the rubber. Do you know the method of bonding? If the rubber is in fact Buna-N, acetone will be slightly better than MEK or you can go to the other end of the spectrum and try an oil. You can heat up the oil to...

Wow Dave, thanks for your help. I have the calculus and know materials better than most. Already shared that I'm not a mechanical engineer. Perhaps you could walk me through the calculation anyway. I'm pretty sure I can keep up. Who knows you may have a chemistry or materials question I can help...

You are correct. The first step to solving engineering problems is defining the problem. The first step in this case is to understand what forces will be imposed on the solution so the design will work. My original question remains how to calculate the load on the device or if it can be...

But they won't put it back together. Does anyone know how to calculate the load?

Thank you. Unfortunately I need the "connector" piece to be removable. The two ends have to be connected on one floor and then disconnected and reconnected on the 4th floor. If I didn't have to do that, the options would be much greater.

If it's the same size and type conductor, they can be welded. If the conductors are different metals or are 'filled' they are hydraulically crimped using specially designed crimps or seamless steel pipe.

Technically I'm splicing the conductors of two cables together. I can splice two of the same size easy enough. I need to splice 2 different size cables together. That's where the challenge comes in because you have a different size "splice" for each cable and something in between to connect them.

I obviously didn't explain it well. Miles and miles of this is made all over the world everyday though there isn't an off the shelf solution. Every place does it a little differently and most allow the connection to twist. This creates more scrap. I'm trying to find a better solution. Imagine...

I'm a chemist functioning as a Process/Materials engineer and have a problem that is well beyond my mechanical engineering skill set. We have a continuous production process where stranded aluminum or copper conductor is insulated. The conductor naturally twists over sheaves and a twisting...