Where does breakage of control cable wires occur most frequently?

Breakage of control cable wires most frequently occurs where cables pass over pulleys and through fairleads due to the mechanical wear and stress these areas experience. As cables navigate around pulleys or through fairleads, they are subject to bending and friction, which can cause the wires to weaken over time. The sharp edges of the pulleys and fairleads can also contribute to localized stress concentrations, leading to fatigue failure in the wires.

In contrast, while terminals of the cables are critical points, they typically involve fewer dynamic stresses compared to the continuous motion and bending that occurs around pulleys. Additionally, breakage along the length of cables might occur but is less common than at these high-stress points. Connection points with control surfaces can experience wear as well, but they are generally less prone to failure than the points where cables change direction or are subjected to significant bending forces.