Steel Wire Rope Cutting Methods: Tools, Techniques, and Safety Guidelines

Steel wire rope cutting methods must be selected based on rope material, diameter, and application requirements. Improper cutting can lead to broken strands, burrs, internal core damage, and serious safety risks. Below is a practical overview of common steel wire rope cutting methods, key operating techniques, and safety considerations widely used in industrial applications.

Mechanical Cutting Method

Applicable Scenarios

Mechanical cutting is suitable for small- to medium-diameter steel wire ropes (≤20 mm) or applications where extremely high cut-face precision is not required.

Operating Procedure

1. Secure the wire rope
Fix the steel wire rope vertically using a dedicated clamp or bench vise to prevent movement during cutting.

2. Select the appropriate cutting tool

• Abrasive wheel cutter:
  Recommended for carbon steel wire rope. Use a diamond or reinforced cutting disc (diameter ≥300 mm) with a rotation speed of 1500–2000 rpm.

• Hydraulic cutter:
  Suitable for wire ropes up to 16 mm diameter. Required cutting force increases with diameter (e.g., ≥50 tons for 16 mm wire rope).

3. Cutting technique

• When using an abrasive wheel, apply steady downward pressure perpendicular to the rope strands. Avoid lateral force to prevent strand separation.

• Hydraulic cutters must complete the cut in a single action. Repeated compression may deform the rope core.

Notes

• Mechanical cutting generates high temperatures. Apply coolant (water-based or oil-based) during cutting to prevent annealing of the wire rope.

• After cutting, deburr the cut surface using sandpaper or a grinder to avoid operator injury.

Flame Cutting Method

Applicable Scenarios

Flame cutting is typically used for large-diameter wire ropes (>20 mm) where rapid cutting is required, especially for galvanized or stainless steel wire ropes.

Operating Procedure

1. Preheating
Heat the cutting area using an oxygen–acetylene flame until it reaches an orange-red color (approximately 800°C).
Preheating length should be at least 50 mm.

2. Cutting parameters

• Oxygen pressure: 0.5–0.7 MPa

• Acetylene pressure: 0.05–0.1 MPa

• Cutting speed: Reduce speed by 0.5 m/min for every additional 5 mm of rope diameter
  (e.g., approx. 0.3 m/min for a 25 mm wire rope)

3. Post-treatment
Immediately quench the cut end with water to limit oxidation, then remove oxide scale using an angle grinder.

Notes

• Flame cutting of galvanized wire rope produces toxic zinc oxide fumes. Always operate in a well-ventilated area.

• After cutting, apply anti-corrosion oil or zinc-rich coating to protect exposed steel.

Electric Wire Saw Cutting Method

Applicable Scenarios

This method is ideal for high-precision cutting, such as construction embedded components, marine applications, or situations where rope core integrity must be preserved.

Operating Procedure

1. Install guide wheels
Fix guide wheels on both sides of the rope. Wheel diameter should be at least three times the rope diameter to ensure perpendicular cutting.

2. Select the wire saw
Choose a diamond wire saw based on rope size (e.g., Ø8 mm saw for a 20 mm wire rope).
Recommended wire tension: 80–100 N.

3. Cutting parameters

• Feed speed: 0.2–0.5 m/min

• Cooling fluid flow rate: ≥5 L/min, using specialized cutting fluid

Notes

• Use a frequency inverter to prevent excessive startup current and wire breakage.

• Monitor saw wear continuously. Replace the wire immediately if wear exceeds 30%.

Special Wire Rope Cutting Considerations

Coated Wire Ropes

• Polyethylene-coated wire rope:
  Remove the coating using a utility knife (minimum stripping length: 50 mm) before mechanical cutting.

• Nylon-coated wire rope:
  Freeze to –20°C before cutting to prevent coating adhesion and tearing.

Multi-Strand Wire Ropes

• Wrap the cutting area tightly with tape (minimum length: 30 mm) before cutting to prevent strand unraveling.

• Hydraulic cutting is recommended over abrasive cutting to ensure uniform strand loading.

Industry Standards and Safety Requirements

According to GB/T 8918-2006 – Steel Wire Ropes for Important Uses:

• Cut-face inclination must not exceed 3°

• Broken strand rate must be ≤5%

Operators must wear safety goggles, cut-resistant gloves, and dust masks. Flammable materials must be kept at least 5 meters away from the cutting area.

Steel Wire Rope Supply & Support

We supply a full range of steel wire ropes with excellent flexibility and high tensile strength, suitable for automotive, marine, construction, lifting, and industrial applications.
If you need professional advice on wire rope selection, cutting solutions, or custom requirements, feel free to contact us for more information.