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A Computational Analysis of the High-velocity Impact Performance of Lightweight 3D Hybrid Composite Armors

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Abstract

Basalt and Kevlar materials are high-performance reinforcements used in armor systems. The present work presented that the combination of natural fiber (basalt) with synthetic fiber (Kevlar) and alumina tile composites improves ballistic performance. The partial replacement of basalt encourages the use of natural reinforcement for the development of eco-friendly armor. Continuum damage mechanics (CDM) based modeling is used with a high strain rate and implemented based on Yen’s criteria. Cohesive elements are used at inter-layers for modeling the damage evolution. The damage initiation and propagation model is created and implemented as a user-defined subroutine in the ABAQUS finite element (FE) code (VUMAT). Parametric studies are performed by varying the stacking sequence of Kevlar 3D (K3D) and basalt 3D (B3D) layers and the best stacking is used with ceramic (alumina) material. The optimum stacking sequence of composite laminate thickness is investigated to design the light weight body armour and the better results are used to reduce the thickness of the panel, which is the key factor to design any armor panel. Results revealed the panels with basalt composite (B16) impacting with FSP impactor and alumina/Kevlar/basalt composite (C1K7B8) impacting with 9 mm FMJ impactor improved the ballistic performance as compared to H16, K8H8 and K8B8 stacking sequences.

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Data Availability

The datasets generated during and/or analyzed during the current study are available from the corresponding author upon reasonable request.

Abbreviations

K3D:

3D Kevlar lamina

B3D:

3D Basalt lamina

H3D:

3D basalt/Kevlar hybrid lamina

B16:

16 Basalt laminae

H16:

16 Kevlar laminae

K8H8:

Eight 3D Kevlar laminae and eight 3D hybrid laminae

K8B8:

Eight 3D Kevlar laminae and eight 3D Basalt laminae

C1K7B8:

One ceramic tile, seven Kevlar laminae and eight basalt laminae

KPL:

2D plane Kevlar lamina

BPL:

2D plane basalt lamina

HPL:

Hybrid lamina of 2D

\(E_X, E_Y\), \(E_Z\) (GPa):

Modulus of elasticity in weft, warp, out of plane direction

\(\nu _X, \nu _Y, \nu _Z\) :

Poisson’s ratios

\(G_{XY}, G_{YZ}\), \(G_{XZ}\) (GPa):

Modulus of rigidity in xy, xy, xy direction

\(\epsilon _X\), \(\epsilon _Y\), \(\epsilon _Z\) :

Compressive strain in x,y and z direction

\(S_{XT}, S_{XC}\) (MPa):

Tensile and compressive strength in axial direction

\(S_{YT}, S_{YC}\) (MPa):

Tensile and compressive strength in transverse direction

\(S_{ZT}\) (MPa):

Tensile strength in out of plane direction

\(S_{XFS}, S_{YFS}\) (MPa):

Fiber shear strength in x and y direction

\(S_{YZO}, S_{XZO}\) (MPa):

Tensile modes corresponding shear strengths in the yz and xz directions

m:

Material constant

\(\phi ^._i\) :

Damag growth rate mode

\(\overline{\omega }_j\) :

Damage variable

\(\gamma _i\) :

Weibull distribution

\(S_{FC}\) (MPa):

Fiber crush strength

N :

Number of nodes

\(S_{XY}\) (MPa):

Matrix shear failure strength

\(\rho\) (g/cm3):

Density

\(\overline{\omega }^._j\) :

Growth rate damage variable

\(S_{SR}\) :

Residual sliding strength

\(\eta\), \(\zeta\) :

Iso-parametric coordinates

\(S_{XCR}\) :

Residual strength in x direction

\(S_{YCR}\) :

Residual strength in y direction

t (mm):

Thickness of lamina

\(\langle \rangle\) :

Macaulay brackets

\(\phi\) :

Coulomb’s friction angle

[C] :

Stiffness Matrix

[\(S^*\)]:

Compliance matrix

[q]:

Coupling matrix

\(f_i\) :

Fiber damage modes in different strains \(i = 1,2,3...\)

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Authors and Affiliations

  1. Department of Mechanical Engineering, PDPM, Indian Institute of Information Technology Design and Manufacturing, Near Dumna, Jabalpur, 482005, MP, India

    Roopendra Kumar Pathak, Shivdayal Patel & Vijay Kumar Gupta

  2. School of Engineering, University of Limerick, Limerick, State, Ireland

    Aswani Kumar Bandaru

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  1. Roopendra Kumar Pathak
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  2. Shivdayal Patel
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Pathak, R.K., Patel, S., Gupta, V.K. et al. A Computational Analysis of the High-velocity Impact Performance of Lightweight 3D Hybrid Composite Armors. Appl Compos Mater 30, 727–751 (2023). https://doi.org/10.1007/s10443-023-10112-0

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