1. Bending Fatigue from Tight Routing
What happens:
Repeated bending under tight radii weakens outer strands in wire rope cores, especially in 7x7 or 7x19 configurations.
Prevention:
• Follow minimum bend radius guidelines (D/d ≥ 15:1 recommended)
• Use pulley-guided routing where possible
• Select more flexible cores for dynamic paths; avoid sharp corners
Reference: Cablecraft Design Guide – Flexible Cable Routing Section
2. Compression Deformation from Overload
What happens:
Push-type actuation with excessive compressive force can cause core buckling or kinking, especially in 1x7 and 1x19 cores.
Prevention:
• Choose solid core or larger-diameter 1x19 for long push distances
• Match stroke distance with routing design
• Add inner liner to reduce core friction
Use proof-loading methods per CMA Safety Guide to validate cable stiffness
3. Core Loosening or Unraveling
What happens:
Poorly tensioned or overflexed wire cores can twist, creating strand separation or "birdcaging."
Prevention:
• Use preformed strand constructions (e.g. 7x7 preformed)
• Follow correct proof-load tensioning procedures
• Avoid field trimming without re-terminating
4. Friction-Induced Overheating
What happens:
Uncoated wire cores in long housings with frequent actuation may generate heat from friction, damaging liners or seizing the system.
Prevention:
• Use PTFE-coated inner wires (e.g. 1x19 or 7x7)
• Lubricate periodically or select lubricant-embedded liners
• Avoid over-tight housing paths
Phidix offers factory-lubricated options and PTFE extrusion for core surfaces.
5. Corrosion & Rust-Based Locking
What happens:
Stainless steel cores exposed to marine or chemical environments may still corrode without proper material grade or coatings.
Prevention:
• Use SUS 316L or marine-grade stainless cores
• Avoid removing protective PTFE jacket during installation
• Store cables in dry, sealed containers prior to assembly
Design Insights from the Experts
According to CMA’s Safety Guide and Cablecraft’s Motion Control Design Guide, ensuring that the wire rope is never loaded beyond 80% of its minimum break strength is critical to preventing core failures.
At Phidix, our inner wire core products are manufactured under the IATF 16949 quality management system, which ensures strict process control, consistent tensile properties, and traceability from material to final inspection. This guarantees not just technical compliance—but real-world safety and performance in demanding mechanical control applications.
Related Pages
• Inner Wire Core Structure Guide
• Manufacturing & Quality Capabilities
Need Help Troubleshooting?
Send us photos or system specs, and our engineers will diagnose the failure mode and recommend a compatible inner core configuration—along with drawings or samples if needed.
