An investigation is reported on the breakage of the diamond wire saw during stone processing. A Lot of breaken wire samples were collected from factories and observed macroscopically and microscopically. The results indicate that the breakages were mainly fatigue failure. And statistic of results show that all the breakage sites centralize on two sections. Reasons for the two break sections are also discussed in detail. Furthermore, sawing experiment was conducted to study the effect of the process parameters and the results reveal that the breakage of the wire saw is sensitive to the processing parameters. Finally, some proposals for manufacture and application were presented.