Reason analysis

As the carrier of beads, the life of the wire rope restricts the life of the wire saw. According to the calculation of 14.85m profiled wire saw, from the beginning of use to the scrapping of the wire saw, the use time is more than 600h, and its linear speed is 22m/s. Under the premise of the wire rope being subjected to alternating loads during the use period, it must cycle more than 3x106 times, which is very easy to cause fatigue fracture of the wire rope. After the joint is buckled and pressed, it will cause certain damage to the wire rope, which will cause premature fracture of the wire rope at the joint. Therefore, we must choose extremely excellent wire rope materials.

 

In addition, the following situations during use will cause the wire rope to break prematurely: 

① Due to machine reasons, the wire saw runs unsteadily and shakes frequently, which will easily lead to broken ropes in the middle and frequent fractures of the joints; 

② The customer unilaterally pursues cutting efficiency and forces the cutter, resulting in a large arc of the wire saw and excessive tension, which in turn causes the wire rope to break; 

③After the injection molding wire saw has been used for a certain period of time, some cooling water and chips will be injected between the plastic and the wire rope. If it is parked for too long, the wire rope will become brittle and break in the middle of the wire rope in advance; 

④Due to the manufacturer's reasons, the beads are not fixed firmly, and the beads rotate or move. After the beads rotate, the wire rope will be worn off in a short time; and after the movement, the broken wire rope will be exposed and lose protection, which will also cause the wire rope to break in advance; 

⑤ If the joint is buckled too tightly, it will increase the damage to the wire rope, causing the wire rope to break in advance at the joint,

 

 

Solution

According to the above reasons, the manufacturer and the user should jointly adopt the following measures to solve the problem of premature breakage of wire rope

① Choose high-precision machines and maintain them well during use to ensure machine performance, increase the smoothness of the wire saw and reduce vibration; 

② Reduce the amount of cutting and adjust it to a moderate level; 

③ Do not park the used wire saw for too long, such as more than half a year; 

④ Stabilize the injection molding quality to ensure that there is no bead rotation and honey movement. Check the wire saw in time after cutting for a period of time. If the bead rotates occasionally, it should be broken by hammering. 

⑤ Appropriately buckle to reduce the damage of the wire rope