My understanding for cocoon hatch times is between 14-21 days. If they pass 21 days, I'll open them up, and there s usually something wrong that explains it such as a shrivelled pupa or a moth that couldn't break through the cocoon and died trapped inside.
Once they are in the potential hatch range, I try to check for wet spots on unhatched cocoons because that could indicate that its trapped. Also, I listen for light scratching sounds. Both of those have helped me rescue trapped moths.
Remember that they were bred for thousands of years to produce strong, quality silk....which means sometimes that can't get through it, or so I've read.
When I cut open a cocoon, I try to slice the very tip to avoid cutting the moth, although I am ashamed to admit that I did cut too low once by mistake.
I read that sometimes two silkworms will build one big cocoon together and share it, and I was lucky enough to witness this event in gen 3!
I also had one pupate without making a cocoon.
Here's a pic: