Study on cut-protective performance of composite yarn-based knitted UHMWPE fabrics for industrial safety applications: influence of stitch density, repeated rubbing, washing, and fabric stretchability

Cut-resistant knitted fabrics are extensively used in industrial safety applications due to their flexibility, wearer comfort, and protective functionality. However, their performance can deteriorate under practical conditions such as repeated abrasion, washing, and mechanical stretching. This study evaluated the cut-resistance behavior of knitted fabrics developed using stainless-steel-reinforced UHMWPE, glass fiber-reinforced UHMWPE, and 100% UHMWPE yarns. In the first stage, three yarn systems were knitted at five glove knitting machine gauges (7, 10, 13, 15, and 18 gauge), resulting in fifteen fabric variants with different stitch densities. A consistent non-linear trend in cut performance was observed across all variants, with maximum cut resistance achieved at 384 loops/inch2 on 13-gauge, corresponding to the optimal balance between yarn compactness and loop mobility. Based on this preliminary stitch-density optimization study, the three fabrics produced at 13-gauge—13 SU (stainless-steel reinforced UHMWPE), 13 GU (glass fiber reinforced UHMWPE), and 13 U (100% UHMWPE)—were selected for detailed durability evaluation under repeated abrasion, laundering, and tensile loading conditions. Under repeated rubbing, 13 SU demonstrated the highest durability (withstanding up to 1120 cycles), while 13 GU and 13 U failed after 750 and 500 cycles, respectively, due to brittle fracture and structural collapse. Washing cycles led to gradual fiber degradation and core exposure, with 13 SU retaining the best cut resistance post-wash. Pre-tension during testing significantly reduced cut performance in all fabrics, especially at 90° blade orientation, where axial alignment limited energy absorption mechanisms. For instance, 13 GU showed a drop in cut load from 32.43 to 17.76 N as tension increased from 0 to 40 N. Among the investigated fabrics, 13 SU consistently exhibited the highest cut resistance and durability under abrasion, laundering, and stretching conditions owing to the superior ductility and toughness of the stainless-steel reinforcement. In contrast, the glass fiber reinforced fabric (13 GU) showed accelerated degradation due to brittle fracture of the reinforcing filaments, while the 100% UHMWPE fabric (13 U) exhibited the lowest resistance because of the absence of a reinforcing core. The findings further demonstrate that an optimum stitch density is essential for maximizing cut resistance by balancing fabric compactness and loop mobility. This study establishes the combined influence of stitch density, reinforcement type, and service-induced degradation on the long-term cut-protective performance of knitted fabrics, providing practical design guidelines for the development of durable, lightweight, and high-performance protective textiles for industrial safety applications.