Numerical and experimental investigations into ballistic performance of hybrid fabric panels

Strong, low density fibres have been favoured materials for ballistic protection, but the choice of fibres is limited for making body armour that is both protective and lightweight. In addition to developments of improved fibres, alternative approaches are required for creating more protective and lighter body armour. This paper reports on a study on hybrid fabric panels for ballistic protection. The Finite Element (FE) method was used to predict the response of different layers of fabric in a twelve-layer fabric model upon impact. It was found that the front layers of fabric are more likely to be broken in shear, and the rear layers of fabric tend to fail in tension. This suggested that using shear resistant materials for the front layer and tensile resistant materials for the rear layer may improve the ballistic performance of fabric panels. Two types of structure, ultra-high-molecular-weight polyethylene (UHMWPE) woven and unidirectional (UD) materials, were analyzed for their failure mode and response upon ballistic impact by using both FE and experimental methods. It was found that woven structures exhibit better shear resistance and UD structures gives better tensile resistance and wider transverse deflection upon ballistic impact. Two types of hybrid ballistic panels were designed from the fabrics. The experimental results showed that placing woven fabrics close to the impact face and UD material as the rear layers led to better ballistic performance than the panel constructed in the reverse sequence. It has also been found that the optimum ratio of woven to UD materials in the hybrid ballistic panel was 1:3. The improvement in ballistic protection of the hybrid fabric panels allows less material to be used, leading to lighter weight body armour.     

Multiscale modeling of the impact of textile fabrics based on hybrid element analysis

In this work, a multi scale modeling approach has been developed to simulate the impact of woven fabrics using a finite element (FE) analysis. A yarn level of resolution is used in the model. This approach, referred to as the hybrid element analysis (HEA) is based on decreasing the complexity of the finite element model with distance away from the impact zone based on the multiscale nature of the fabric architecture and the physics of the impact event. Solid elements are used to discretize the yarns around the impact region, which transition to shell elements in the surrounding region. A new method for modeling the shell yarns is incorporated that more accurately represents the contours of the yarn cross section. Impedances have been matched across the solid–shell interface to prevent interfacial reflections of the longitudinal strain wave. The HEA method is validated by first applying it to the FE model of a single yarn for which an analytical solution is known. The HEA method is then applied to a woven fabric model and validated by comparing it against a baseline model consisting of yarns discretized using only solid elements.     

A numerical investigation into the influence of fabric construction on ballistic performance

The use of high-performance fibres has made it possible to produce lightweight and strong personal body armour. Parallel to the creation and use of new fibres, fabric construction also plays an essential role for performance improvement. In this research, finite element (FE) models were built up and used to predict the response of woven fabrics with different structural parameters, including fabric structure, thread density of the fabric and yarn linear density. The research confirmed that the plain woven fabric exhibits superior energy absorption over other structures in a ballistic event by absorbing 34% more impact energy than the fabric made from 7-end satin weave. This could be explained that the maximum interlacing points in this fabric which help transmit stress to a larger fabric area, enabling more secondary yarns to be involved for energy dissipation. It was found that fabric energy absorption decreases as fabric is made denser, and this phenomenon becomes more pronounced in a multi-ply ballistic system than in a single-ply system. The research results also indicated that the level of yarn crimp in a woven fabric is an effective parameter in influencing the ballistic performance of the fabrics. A low level of yarn crimp would lead to the increase of the fabric tensile modulus and consequently influencing the propagation of the transverse wave. In addition, it was found that for fabrics with the same level of yarn crimp, low yarn linear density and high fabric tightness were desirable for ballistic performance improvement.     

Effect of Frictions on the Ballistic Performance of a 3D Warp Interlock Fabric: Numerical Analysis

3D interlock woven fabrics are promising materials to replace the 2D structures in the field of ballistic protection. The structural complexity of this material caused many difficulties in numerical modeling. This paper presents a new tool that permits to generate a geometry model of any woven fabric, then, mesh this model in shell or solid elements, and apply the mechanical properties of yarns to them. The tool shows many advantages over existing software. It is very handy in use with an organization of the functions in menu and using a graphic interface. It can describe correctly the geometry of all textile woven fabrics. With this tool, the orientation of the local axes of finite elements following the yarn direction facilitates defining the yarn mechanical properties in a numerical model. This tool can be largely applied because it is compatible with popular finite element codes such as Abaqus, Ansys, Radioss etc. Thanks to this tool, a finite element model was carried out to describe a ballistic impact on a 3D warp interlock Kevlar KM2? fabric. This work focuses on studying the effect of friction onto the ballistic impact behavior of this textile interlock structure. Results showed that the friction among yarns affects considerably on the impact behavior of this fabric. The effect of the friction between projectile and yarn is less important. The friction plays an important role in keeping the fabric structural stability during the impact event. This phenomenon explained why the projectile is easier to penetrate this 3D warp interlock fabric in the no-friction case. This result also indicates that the ballistic performance of the interlock woven fabrics can be improved by using fibers with great friction coefficients.     

A combined experimental and numerical approach to study ballistic impact response of S2-glass fiber/toughened epoxy composite beams

A combined experimental and 3D dynamic nonlinear finite element (FE) approach was adopted to study damage in composite beams subject to ballistic impact using a high-speed gas gun. The time-histories of dynamic strains induced during impact were recorded using strain gages mounted on the front of the composite beam specimen. During ballistic impact tests, the impact velocity was also measured. The commercially available 3D dynamic nonlinear FE code, LS-DYNA, modified with a proposed user-defined nonlinear-orthotropic damage model, was then used to simulate the experimental results. In addition, LS-DYNA with the Chang–Chang linear-orthotropic damage model was also used for comparison. Good agreement between experimental and FE results was found from the comparisons of dynamic strain and damage patterns. Once the proposed nonlinear-orthotropic damage model was verified by experimental results, further FE simulations were conducted to predict the ballistic limit velocity (V₅₀) using either the number of damaged layer approach or a numerically established relation between the projectile impact velocity versus residual velocity or energy similar to the classical Lambert–Jonas equation for metals.     

Development of reliable modeling methodologies for engine fan blade out containment analysis. Part II: Finite element analysis

In the first part of the paper [Naik D, Sankaran S, Mobasher B, Rajan SD, Pereira M. Development of reliable modeling methodologies for fan blade-out containment analysis. Part I: experimental studies. Int J Impact Eng, in press], details of the experiments to characterize the behavior of dry fabrics including Kevlar^®49, and ballistic tests involving the fabric were presented. In this second part of the paper, we discuss the development and verification of a constitutive model for dry fabrics for use in an explicit finite element program. The developed constitutive model is implemented as a user-defined subroutine in LS-DYNA, a commercial finite element program. It is then used to simulate a suite of ballistic tests [Naik D, Sankaran S, Mobasher B, Rajan SD, Pereira M. Development of reliable modeling methodologies for fan blade-out containment analysis. Part I: experimental studies. Int J Impact Eng, in press] that replicate conditions seen in an engine fan blade out (FBO) event. A qualitative and quantitative comparison of the deformation shape of the fabric containment system and a quantitative comparison of the absorbed energy are carried out. Results indicate that the developed constitutive model provides a very encouraging start in modeling these high-speed events and could provide as Federal Aviation Administration (FAA) desires, an attractive complement to full-scale engine FBO tests.     

Computational simulation of fabric armour subjected to ballistic impacts

In computational simulations of ballistic impacts on woven polymeric fabric armour, specialized fabric models are normally used. Attempts have also been made to use commercial finite element packages for such purposes. However, such attempts normally result in either overly simplified models or prohibitively detailed finite element discretization of the fabric to capture the unique properties of woven fabric. This paper presents an FE model of woven fabric that reflects the orthotropic properties of the fabric, the viscoelastic nature of the yarns, the crimping of the yarns, the sliding contact between yarns and yarn breakage using an assembly of viscoelastic bar elements. Excellent agreement between simulation and ballistic test data is obtained in terms of the deformation of the fabric during impact, residual velocity of the projectile and the energy absorbed by the fabric. This is achieved despite the modest number of degrees of freedom employed by the model.     

Evaluation of head response to ballistic helmet impacts using the finite element method

Injuries to the head caused by ballistic impacts are not well understood. Ballistic helmets provide good protection, but still, injuries to both the skull and brain occur. Today there is a lack of relevant test procedure to evaluate the efficiency of a ballistic helmet. The purpose of this project was (1) to study how different helmet shell stiffness affects the load levels in the human head during an impact, and (2) to study how different impact angles affects the load levels in the human head. A detailed finite element (FE) model of the human head, in combination with an FE model of a ballistic helmet (the US Personal Armour System Ground Troops’ (PASGT) geometry) was used. The head model has previously been validated against several impact tests on cadavers. The helmet model was validated against data from shooting tests. Focus was aimed on getting a realistic response of the coupling between the helmet and the head and not on modeling the helmet in detail. The studied data from the FE simulations were stress in the cranial bone, strain in the brain tissue, pressure in the brain, change in rotational velocity and translational and rotational acceleration. A parametric study was performed to see the influence of a variation in helmet shell stiffness on the outputs from the model. The effect of different impact angles was also studied. Dynamic helmet shell deflections larger than the initial distance between the shell and the skull should be avoided in order to protect the head from the most injurious threat levels. It is more likely that a fracture of the skull bone occurs if the inside of the helmet shell strikes the skull. Oblique ballistic impacts may in some cases cause higher strains in the brain tissue than pure radial ones.     

织物弹道贯穿性能分析计算

纤维织物增强复合材料由于轻质和高冲击损伤容限而在防弹装甲设计及制造中逐渐得到应用,如人体防弹衣和车辆防护装甲。但是尚无较好的方法直接计算复合材料防弹特性,其中困难在于复合材料弹道冲击过程中的应变率效应和冲击破坏机理至今没有被揭示。解决问题的第一步是建立复合材料增强相(即织物)防弹特性计算方法。提出基于纤维力学性质应变率效应的织物弹道冲击破坏分析模型,计算不同面密度织物靶体在弹道贯穿过程中的弹体剩余速度,由此反映靶体防弹特性。用本文中提出的简单算法预测的结果与实测结果在靶体厚度不大时极为接近,而且也有可能将其扩展到纤维织物增强复合材料防弹性质的计算。     

Motorcyclist helmet composite outer shell characterisation and modelling

In this study a new finite element model of composite outer shell of motorcyclist helmet is proposed, by modelling each layer of the composite material that builds the laminated structure of the outer shell of the helmet. Elastic and rupture properties of the laminate are taken into account for developing the finite element (FE) model and are extracted experimentally. A coupled experimental–numerical method combined with experimental modal analysis on beam samples is used to obtain the elastic characteristics of each layer of the outer shell. The rupture properties for each layer are extracted by experimental impact tests. The FE model of the outer shell is then validated with experimental data for elastic and rupture behaviour.     

Finite element modeling of impact, damage evolution and penetration of thick-section composites

Impact, damage evolution and penetration of thick-section composites are investigated using explicit finite element (FE) analysis. A full 3D FE model of impact on thick-section composites is developed. The analysis includes initiation and progressive damage of the composite during impact and penetration over a wide range of impact velocities, i.e., from 50 m/s to 1000 m/s. Low velocity impact damage is modeled using a set of computational parameters determined through parametric simulation of quasi-static punch shear experiments. At intermediate and high impact velocities, complete penetration of the composite plate is predicted with higher residual velocities than experiments. This observation revealed that the penetration-erosion phenomenology is a function of post-damage material softening parameters, strain rate dependent parameters and erosion strain parameters. With the correct choice of these parameters, the finite element model accurately correlates with ballistic impact experiments. The validated FE model is then used to generate the time history of projectile velocity, displacement and penetration resistance force. Based on the experimental and computational results, the impact and penetration process is divided into two phases, i.e., short time Phase I - shock compression, and long time Phase II - penetration. Detailed damage and penetration mechanisms during these phases are presented.     

Soccer ball anisotropy modelling

The work presented in this paper details the development of a finite element (FE) model of a soccer ball, allowing for a greater understanding of the performance of soccer balls under dynamic conditions that are representative of play. The model consists of composite shell elements that include a hyperelastic strain energy potential equation to define the latex bladder layer and a plane stress orthotropic elastic material model to define the anisotropic woven fabric outer panels. The model was validated through a series of experimental impact tests whereby the ball was impacted normal to a rigid plate at an inbound velocity of approximately 34 ms⁻¹ (76 mph), with each impact recorded using high speed video (HSV) techniques. It was found that the combined effects of ball design and panel material anisotropy resulted in impact properties such as coefficient of restitution, contact time, deformation and the 2D shape taken up by the ball at maximum deformation, to vary with pre-impact ball orientation. The model showed good agreement with the measurements, and its ability to represent the effects of anisotropy in ball design.     

Influences of weaving architectures on the impact resistance of multi-layer fabrics

Fabrics constructed from different weaving architectures such as plain, basket, twill and satin provide varying flexibility and durability when applied on surfaces of complex structures for protective applications. They also affect the manufacturing processes and mechanical properties of both fabrics and composite structures in various applications such as soft armours, helmets, aircraft engine cowlings or automobile monocoques. In this work, the influences of weaving architectures on the ballistic resistance and energy absorption of both single and multi-layer Twaron® fabrics are investigated. A mesoscale yarn model is constructed, validated experimentally, and analytical. Finite element fabric models of different fabric structures are then developed and their firmness is quantified using interlacing factors. Numerical models for plain weave are validated against experimental results from single-ply ballistic tests. The evolutions of kinetic, strain, and friction energy components, normalised with areal mass, are presented to demonstrate the better ballistic protection of the plain weave compared with other weaving architectures. Further investigations on multi-ply systems illustrate the energy absorption capacities for different types of woven fabrics and the associated ballistic resistances. The research results indicate that weaving architectures and fabric firmness are less influential on the overall ballistic protection of multi-ply systems compared to the single-ply cases.     

卵形弹斜冲击作用下平纹织物的动态响应分析

利用LS-DYNA有限元软件模拟了卵形弹倾斜冲击作用下平纹织物的动态响应,分析了织物的变形、纱线断裂以及能量吸收特性,讨论了边界约束条件对织物动态响应的影响。结果表明:在弹体贯穿织物过程中,纱线应变能和摩擦耗散能是弹体动能转变的主要形式。在给定的计算时间内,对于四边无约束、对边(经向和纬向)固定约束和四边固定约束的四种边界条件,两者之和占弹体动能损失量的比例不小于80.5%。模拟结果还表明,边界条件对织物的变形、纱线断裂以及能量吸收特性均有明显影响。边界条件不同,纱线断裂数目不同,弹体动能损失量转变成其它能量的比例也不同,导致织物的能量吸收特性也发生变化。     

A material point method model and ballistic limit equation for hyper velocity impact of multi-layer fabric coated aluminum plate

A multi-layer fabric coated aluminum plate is usually used in the hard upper torso of space suit to protect astronauts from getting hurt by space dust. In this paper, the protective performance of the multi-layer fabric coated aluminum plate is investigated. To establish its ballistic limit equation, thirteen hyper velocity impact tests with different impact velocities (maximum velocity is 6.19 km/s) and projectile diameters have been conducted. To provide data for impact velocity higher than 6.2 km/s which is hard to be obtained by tests due to the limitations of test equipment capacity, a material point method (MPM) model is established for the multi-layer fabric coated aluminum plate and validated/corrected using the test results. The numerical results obtained using the corrected MPM model for impact velocity higher than 6.2 km/s are used together with the test results to develop the ballistic limit equation. The corrected MPM model and the ballistic limit equation developed for the multi-layer fabric coated aluminum plate provide an effective tool for the space suit design.     

Effect of Mesoscale and Multiscale Modeling on the Performance of Kevlar Woven Fabric Subjected to Ballistic Impact: A Numerical Study

In this study, an optimal finite element model of Kevlar woven fabric that is more computational efficient compared with existing models was developed to simulate ballistic impact onto fabric. Kevlar woven fabric was modeled to yarn level architecture by using the hybrid elements analysis (HEA), which uses solid elements in modeling the yarns at the impact region and uses shell elements in modeling the yarns away from the impact region. Three HEA configurations were constructed, in which the solid element region was set as about one, two, and three times that of the projectile’s diameter with impact velocities of 30 m/s (non-perforation case) and 200 m/s (perforation case) to determine the optimal ratio between the solid element region and the shell element region. To further reduce computational time and to maintain the necessary accuracy, three multiscale models were presented also. These multiscale models combine the local region with the yarn level architecture by using the HEA approach and the global region with homogenous level architecture. The effect of the varying ratios of the local and global area on the ballistic performance of fabric was discussed. The deformation and damage mechanisms of fabric were analyzed and compared among numerical models. Simulation results indicate that the multiscale model based on HEA accurately reproduces the baseline results and obviously decreases computational time.     

Loosely woven fabric model with viscoelastic crimped fibres for ballistic impact simulations

A computational micro‐mechanical material model of loosely woven fabric for non‐linear finite element impact simulations is presented in this work. The model is a mechanism incorporating the crimping of the fibres as well as the trellizing. The equilibrium of the mechanism allows the straightening of the fibres depending on the fibre tension. The contact force at the fibre crossover point determines the rotational friction dissipating a part of the impact energy. The stress–strain relationship is viscoelastic based on a three‐element model. The failure of the fibres is strain rate dependent. The model is implemented as user defined subroutine in the transient finite element code LS‐DYNA. The ballistic impact simulations with the model are in good agreement with the experimental results. Copyright © 2004 John Wiley & Sons, Ltd.     

Numerical simulation of impact tests on GFRP composite laminates

The design of advanced composite structures or components subjected to dynamic loadings requires a deep understanding of the damage and degradation mechanisms occurring within the composite material. The present paper deals with the numerical simulation of low-velocity impact tests on glass fabric/epoxy laminates through the LS-DYNA Finite Element (FE) code. Two laminates of different thickness were subjected to transverse impact at different energy levels and modeled by FE. Solid finite elements combined with orthotropic failure criteria were used to model the composite failure and stress based contact failure between plies were adopted to model the delamination mechanism. The final simulation results showed a good correlation with experimental data in terms of both force–displacement curves and material damage.     

Computational micro‐mechanical model of flexible woven fabric for finite element impact simulation

This work presents a computational material model of flexible woven fabric for finite element impact analysis and simulation. The model is implemented in the non‐linear dynamic explicit finite element code LSDYNA. The material model derivation utilizes the micro‐mechanical approach and the homogenization technique usually used in composite material models. The model accounts for reorientation of the yarns and the fabric architecture. The behaviour of the flexible fabric material is achieved by discounting the shear moduli of the material in free state, which allows the simulation of the trellis mechanism before packing the yarns. The material model is implemented into the LSDYNA code as a user defined material subroutine. The developed model and its implementation is validated using an experimental ballistic test on Kevlar woven fabric. The presented validation shows good agreement between the simulation utilizing the present material model and the experiment. Copyright © 2001 John Wiley & Sons, Ltd.