Modeling and validation of full fabric targets under ballistic impact

The impact of three different projectiles (0.357 Magnum, 9-mm FMJ and 0.30 cal FSP) onto Kevlar® was modeled using a commercial finite-element program. The focus of the research was on simulating full-scale body armor targets, which were modeled at the yarn level, by reducing to a minimum the number of solid elements per yarn. A thorough validation of the impact physics was performed at the yarn level, single-layer level, and a full body armor system. A verification was performed by checking the numerical model against analytical predictions for yarn impact. For one-layer and multiple-layer targets validation consisted on matching experimental data of pyramid formation recorded by an ultra-high-speed camera. The full-scale targets were also instrumented with nickel–chromium wires that stretch with the yarn during the penetration event. The wires provided a second validation data set since the numerical model can reproduce the signal recorded by the wires. The third and final validation of the model is provided by a comparison of the ballistic limit predicted by the model and data obtained in tests. This is a check of the failure model used in the numerical simulations. This paper shows that the main features of the impact physics are well reproduced by the finite-element model. Prediction of ballistic limits for the 9-mm FMJ and FSP projectiles were within the scatter of the tests, while for the 0.357 projectile the difference was only 15%.