The main causes of wire rope breakage can be classified into three categories: inherent material and manufacturing defects, damage and fatigue during use, and corrosion from the external environment. The details are as follows: 

Material and manufacturing issues 

The raw materials contain impurities and cracks, which result in the insufficient strength of the steel wire rope itself. 

During the manufacturing process, the twisting technique was improper, resulting in uneven arrangement of the steel wires and stress concentration. After being subjected to long-term force, it is prone to breaking at the weak points. 

Damage and fatigue during use 

Overloading: Exceeding the rated load capacity of the wire rope, the instantaneous tension exceeds the material's strength limit, and it breaks directly. 

Repeated bending fatigue: The steel wire rope repeatedly bends on the pulley and drum, causing the internal steel wires to undergo metal fatigue, gradually developing micro-cracks, and eventually breaking. 

External damage: During use, if it rubs or collides with sharp objects, it will cause the steel wire to wear and break. If not replaced in time, the damaged area will become the starting point of the fracture. 

Environmental corrosion impact 

Damp, acidic or alkaline environments can cause steel wire ropes to rust and corrode. The cross-section of the steel wire becomes thinner due to rusting, and the strength significantly decreases. Even under slight force, the rope may break.