Where does breakage of control cables occur most frequently?

The breakage of control cables occurs most frequently where cables pass over pulleys and through fairleads due to the mechanical stress and friction involved in these areas. When a cable bends around a pulley or is routed through a fairlead, it experiences a change in its direction and tension. This can lead to wear over time, particularly if the surfaces of the pulleys or fairleads are not smooth, or if they lack proper lubrication. The flexing and tension changes during operation create points of weakness where fatigue can accumulate, making these locations more susceptible to failures than other areas of the cable.

While breakage can occur at the ends of the cables, and near the connection points to the control surfaces, these locations do not typically experience the same level of constant mechanical strain and abrasion as the bends or transitions over pulleys and fairleads. Additionally, breakages due to exposure to the elements, while possible, are less frequent compared to the wear and tear that occurs at pulleys and fairleads, which are critical junctions in cable systems.