1.Badly Wound Wire
As wire is wound on to the spool, careful adjustment of casting pulley’s ensures that a satisfactory inherent cast is put into the wire. This sounds a fairly simple operation but in practise can be very difficult as fluctuations in tension during the winding process will cause problems in maintaining a consistent cast.
b) Overlapped Wire
Caused mainly by a bad traverse setting during winding or lack of tension control. The traverse length may be underset or overset causing a barrel of diablo shaped spool.The overlapped wire will trap,and become impossible to dewind.
c) Rippled Wire
Caused by worn or defective “casting pulley’s” or loosely set wire drawing dies.The rippled wire will cause malformed stitches.