An indispensable component, wire rope finds application in a variety of fields, such as building, shipping, agriculture, and amusement parks. Although wire rope is incredibly durable and long-lasting, when you want to cut to a specific length or when a worn-out wire rope needs to be replaced. Because wire rope is rather stiff and fibrous, cutting it is quite challenging. However, cutting wire rope is not difficult if the proper equipment and techniques are used, which will also guarantee safety. In order to prevent sharp edges that could injure people, this article will go into detail on the proper technique for cutting wire rope.
Understanding Wire Rope
Whenever you proceed to cut the wire rope, there are several important aspects that you need to know about the structure. Wire rope is a flexible elongated metal product made up of several bands of metal wire or strands wound around a core. The first one is named the “outer strand”, and the second one is designated as “lay strands”. The core can be made up of a number of fibers or steel, thus determining the flexibility or the strength of rope.
Safety First
You should be very cautions while sawing wire ropes because they may pose a serious hazard to the people operating them. Eye protection such as goggles, hand protection such as gloves and ear protection in cases where there’ll be usage of power tools. Make sure that your work area is to some extent free from obstruction and fasten the wire rope to minimize shifting whilst cutting. Also, if you are working close to an electrical line or equipment, one must also consider electrical risks involved therein.
Tools You’ll Need
To get it right when cutting wire rope, it is important that one acquires the correct tool.
Some of the most frequently used tools for this task as follows:
- Bolt Cutters
Best for: Small to medium diameter ropes.
Advantages: The learning process is easy to follow and it is quite cheap.
Limitations: May struggle with larger or high-tensile wire ropes.
- Chain Saws
Best for: Medium to large diameter ropes.
Advantages: Quick and efficient for thick ropes.
Limitations: Requires safety precautions due to sharp teeth and high-speed operation.
- Disc Saws
Best for: Larger diameter ropes.
Benefits: Cuts angled and can cut through thin and thick material.
Disadvantages: Suitable in a stable environment and requires protective measures because of revolutions of blades.
- Hydraulic Shears
Best for: Large diameter ropes and high-tensile wire ropes.
Advantage: It has many advantages, one of which is that it can make deep and fast cuts in the hardest of materials.
Limitations: The system contains high cost and is costly to maintain.
- Abrasive Cut-Off Wheels
Purpose: Useful for cutting ropes that are challenging to cut with various other tools.
Advantages: It will suit various type of works since they will be used with angle grinders.
Limitations: It has a feature of arc and how it must be handle.
Step-by-Step Guide to Cutting Wire Rope
Step 1: Measure and Mark
First of all, determine the length to be cut. Alternatively, you can use a piece of chalk or marker to encircle the rope and come up with a line in cross section. This will help in achieving a straight cut. It is also important to verify any written measurement to avoid any kind of mistakes.
Step 2: Secure the Wire Rope
Secure the wire rope into a position such as to avoid any movement when cutting it. When fixing the rope, you can lock it in clamps, vise grips or any suitable equipment to enable it not to move. Saw that it is tight enough so that it does not move freely but not too tight so as to distort the shape of the rope to be used in the shop.
Step 3: Choose the Right Tool
The cutting capacity of the tool should be matched to that to the diameter of the wire rope. Smaller ropes can be cut using just bolt cutters while thicker ropes call for the use of the disc saws or hydraulic shears.
Step 4: Cutting the Rope
Using Bolt Cutters
Position the Rope: When pulling the rope through the pipe, the marked section should be positioned between the jaws of the bolt cutters.
Hazardous Movement: Pull the trigger to apply pressure on the handles by squeezing them from both ends and ensuring that it is firm and constant. It might require more pressure several times particularly, for thicker ropes.
Using a Chain Saw
Stake the Rope: Ensure that the chain saw is aligned with the rope in this fashion to cut on the rope’s marked line.
Cut Slowly and Smoothly: One should allow the saw to complete as much of the work as possible, minimizing ‘bark carving’. It should not be forced in order to avoid kickback.
Using a Disc Saw
Assemble the Ropes: Ensure that the marked part of the rope is placed under the disc saw blade.
Sever Delicately: Switch on the power button of the saw and allow it to rift through the rope. It is also important not to have any contact with the blade too as this might lead to severe injuries.
Using Hydraulic Shears
The wire rope needs to be positioned in the shears such that it adheres to the following steps:
Double Block and Tackle: Use the crank to turn over the shears provided by the hydraulic mechanism in order to cut through the rope easily with minimum force.
Using an Abrasive Cut-Off Wheel
Prevention from Accidental Movement: This can be done by positioning the rope in the following ways.
Angle Grinder: Cut the rope through slicing mechanism. Stay focused and be calm and composed while running the rehearsal at a steady pace.
Step 5: Clean Up the Ends
The two cut ends of the rope are likely to have sharp edges, or worn wires on their outer surface. Metal file or deburring tool should be used to refine the edges of the copper surface. This will eliminate instances of people getting injuries during periods of moving the rope and equally make sure that the rope serves its intended purpose as expected.
Step 6: Inspect the Cut
After cutting, one should check the cut ends to ascertain that they are neat and the dimensions are accurate. Ensure that there are no remaining burrs that should ideally be trimmed or loose wires that require tucking.