Tensile and cut resistant performance of high-performance fiber/wire composite yarns for stab resistance: Experimental study and simulation analysis

Composite structured yarn materials are essential in the stab-resistant field. However, the microscopic and complex nature of the material presents a challenge in investigating the puncture performance and mechanism of diverse composite yarns (CY). This study investigates four types of CY materials, which are integrated with high-performance fibers and metal wires (H/MCY). The preparation process was adjusted to produce these materials with five distinct twist lengths (h₁–h₅), progressively increasing from small to large. Then, the research evaluates their tensile properties, cut resistance, and corresponding finite element simulation outcomes. The braided structure (B-H/MCY) significantly improves mechanical performance, with a 25.9 % increase in maximum tensile stress and a 44.2 % enhancement in cut resistance, compared to the UHMWPE with similar thickness. Nevertheless, at smaller twist lengths (h₁), all H/MCY structures exhibit excessive structural distortion, which compromises stress transfer efficiency. Conversely, excessively large twist lengths (h₅) increase yarn thickness and fluffiness, thereby degrading structural integrity and ultimately reducing the tensile and cutting performance of materials. Notably, the bearing stress of the B-H/MCY material is distributed into multiple segments, exhibiting superior stress propagation and energy dissipation. In contrast, the wrapped, double-wrapped, and core-wrapped structures generate single-segment stress. Moreover, the interlocking layered design of B-H/MCY materials provides multi-tiered protective capabilities. This approach provides some insights into studying the influence of the H/MCY structure on the mechanical properties of stab-resistant materials.