Poor wire feeding can have many causes. Cutting a liner too short is particularly problematic when robotic welding with smaller diameter wires, which have less column strength. Extreme articulation of the robotic MIG gun can also lead to poor wire feeding.
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Roll Length Calculator Formula
Roll Length Calculator Formula
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If the welding specifiions allow, decrease the drive roll tension, use a larger diameter wire and/or reduce the distance the wire feeds (use shorter cables) to minimize the chance of nesting. If the wire melts back and fuses with the contact tip, as shown, the tip should be replaced and the drive rolls checked for a nest before continuing to weld.
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