Andrzej Morka

NUMERICAL ANALYSES OF CERAMIC/METAL BALLISTIC PANELS SUBJECTED TO PROJECTILE IMPACT

The paper concerns research and development on modern, ceramic-based, protective layers used in the armour of tanks, combat vehicles and aeroplanes. A task of ceramic panels is reduction and dispersion of localized kinetic energy before a projectile or its fragment approaches the interior of protected object. The numerical investigations have been performed to determine the ballistic resistance of ceramic/metal panels subjected to projectile impact. The impact of the 7.62mm armour-piercing projectile on the ceramic elements backed by a metal plate was analyzed. The tested panels were composed of a ceramic layer (Al 2O3, SiC or B4C) and a metal layer (7017 aluminium alloy, Armox 500T steel or Ti6Al-4 titanium alloy). Different shapes of ceramic elements were analyzed, including hemispheres and pyramids, with respect to standard flat tiles. The influence of the impact point location was also taken into considerations. The computer simulations were performed with the Finite Element Method implemented in LS-DYNA code. Full 3D models of the projectile and targets were developed with strain rate and temperature dependent material constitutive relations. The conclusions presented in the paper can be applied to develop modern impact protection panels in which the appropriate balance between the mass and protection level must be accomplished.

EVALUATION OF TRUE STRESS IN ENGINEERING MATERIALS USING OPTICAL DEFORMATION MEASUREMENT METHODS

The aim of the paper is to evaluate a method of determining true stress in the steel sample subjected to static axial tensile on a universal testing machine. The tensile specimens were made of steel ST3, which was chosen because of its relatively high plastic deformations. Strain measurement was performed using traditional extensometers and additionally a non-contact optical deformation measuring system. Material properties were obtain by the extensometer measurements. The optical equipment registered the investigated sample through the optical system composed of two cameras and calculated a three-dimensional model of the material deformation in time. Displacement fields in axial and radial directions were determined with Digital Image Correlation method (DIC). Then the logarithmic axial strain map and radius shrinkage map in the area of the neck were obtained. Characteristic dimensions of the neck: curvature and width were also measured. It allowed determination of cross-section area changes in the real time, and in the result, calculation of actual true stress in the material during failure process. In this case Bridgman’s and other scientists’ formulas of stress distribution in the neck were applied. A numerical model, where material properties of finite elements were described by the Johnson-Cooke material model, was developed in LS-PrePost software. The FEM model was computed in LS-DYNA solver. The output tensile curve and neck curvature radius were compared with relevant data obtained from the optical measuring system.

NUMERICAL MODELLING AND DESIGN OF ALFC SHIELD LOADED BY 20 MM FSP FRAGMENT

The study develops numerical modelling and design of the ALFC shield loaded by the 20 mm 54 g FSP fragment moving at impact velocity of 1800 m/s (fragmentation simulation of IED devices), used to protect 5 mm-thick Armox 500T steel plate. The ALFC shield is composed of the ALF energy-absorbing subsystem and a 99.7% Al 2O3 alumina ceramic layer. The ALF subsystem is designed to absorb blast wave impact energy induced by explosive materials up to 10 kg TNT. The ceramic layer is aimed at stopping FSP fragments. The 5 mm-thick Armox 500T steel plate reflects the body bottom segment of a light armoured vehicle. The main purpose of the study is to determine the minimum thickness of the ceramic layer at which the 5 mm-thick Armox 500T steel plate is fully protected from perforation. The ALF subsystem has the following layered structure: Al2024 aluminium alloy plate, SCACS hybrid laminate plate, ALPORAS aluminium foam, SCACS hybrid laminate plate. The layers are joined with Soudaseal 2K chemoset glue. SCACS hybrid laminate contains the following components: VE 11-M modified vinylester resin (matrix), SWR800 glass S plain weave fabric, Tenax HTA40 6K carbon plain weave fabric, Kevlar 49 T 968 aramid plain weave fabric. The total thickness of the ALF shield amounts to 76 mm. In the numerical modelling, the aluminium alloy plate and Armox 500T steel plate are working in the elasto-plastic range according to Johnson–Cook model. The 99.7% Al 2O3 alumina ceramic is working in elasto-short range according to JH-2 Johnson–Holmquist model. The simulations correspond to large displacements, large deformations and contact among all the components of the system. In FE mesh, the 8-node 24 DOF hexahedral finite elements with single integration point have been used. Additional failure criteria governing ad-hoc erosion of finite elements have been applied. The FEM modelling, simulation and postprocessing have been carried out using Catia, HyperMesh, LS-DYNA and LS-PrePost systems. The simulation results are presented in the form of displacement – perforation contours and the FSP final deformation for both the FSP–shield–plate and the FSP–plate systems. It has been pointed out that 18 mm-thick ceramic layer protects the LAV body bottom plate from perforation.

A Composite Consisting of a Set of Hexagonal Ceramic Bars - The Numerical Study of the Ballistic Resistance

The paper presents a numerical study of a double layer composite panels impacted by a AP (Armor Piercing) 51WC projectile. The standard panel is built with aluminum and Al2O3 ceramic continuum layers while the studied model consists of the same aluminum plate but the front one is built with a set of hexagonal ceramic bars. The bar width and the impact position influence on the ballistic resistance are analyzed and compared with the reference solution. The problem has been solved with the usage of the modeling and simulation methods as well as finite elements method implemented in LS-DYNA software. Space discretization for each option was built by three dimension elements guarantying satisfying accuracy of the calculations. For material behavior simulation specific models including the influence of the strain rate and temperature changes were considered. Projectile Tungsten Curbide and aluminum plate material were described by Johnson-Cook model and ceramic target by Johnson-Holmquist model. In the studied panels the area surrounding back edges was supported by a rigid wall. The obtained results show interesting properties of the examined structures considering their ballistic resistance. All tests has given clear results about ballistic protection panel response under WC projectile impact. Panels consisting of sets of hexagonal ceramic bars are slightly easier to penetrate, reference model is stronger by 19% for smaller bars and by only 7% for bigger rods. Despite this fact, the ceramic layer is much less susceptible to overall destruction what makes it more applicable for the armor usage. Furthermore, little influence of the projectile impact point and consequently a part of the bar which is first destroyed is proved.

Experimental and numerical investigation of energy absorption elastomer panel with honeycomb structure

The paper presents a prototype design of elastomer energy absorbing panel made in a shape of honeycomb structure. The proposed panel was installed in a protected plate and tested on a specially designed test stand, where a shock wave from a small explosive charge was applied. The elastomer honeycomb structure was compared with a version of the panel made of solid elastomer materials, the same as used in the honeycomb structure and also with a protected plate without any panels. During the research, acceleration in the middle part of each investigated protected plate was recorded. The protected plates were scanned after the tests in order to measure their maximum deformation. Acceleration graphs and maximum deflections of all three considered structures were compared. The obtained results were used to validate numerical models of the designed structures and the test stand. A discreet model of the test stand and models of elastomer panels were developed with HyperMesh FEM software using shell and solid elements. The materials were described using a tabulated Johnson-Cook model and constitutive model for the rubber parts; all available in the material library of Ls-Dyna software. The blast loading was simulated using the CONWEP method. This model generates a boundary condition, based on the experimental data and TNT equivalent mass, which substitutes the wave propagation with a pressure. Finally, the experimental results of acceleration and deformation of the plates were compared with the corresponding results of the numerical analyses carried out using finite element method. The numerical models can be utilised in the future research as a virtual range stand. The developed elastomer honeycomb structure can be modified to meet various requirements of ballistic protection levels, by applying elastomer of different stiffness or optimizing shape and dimensions of the honeycomb structure.

Multisphere Ceramic Composite Concept and its Numerical Study of the Ballistic Response

Numerical investigations were performed to determine the influence of the spherical convex shape ceramic - alumina composite in reference to the standard double layer panel. All versions of the target were verified in an impact test including influence upon the position of the AP (Armor Piercing) 7,62x51HHS impact. The crucial parameter which was used for this verification was change in time of the PROJECTILE kinetic energy. The problem has been solved with the usage of the modeling and simulation methods as well as finite elements method implemented in LS-DYNA software. Space discretization for each option was built by three dimension elements guarantying satisfying accuracy of the calculations. For material behavior simulation specific models including the influence of the strain rate and temperature changes were considered. Projectile’s core made of HHS and aluminum plate material were described by Johnson-Cook model and ceramic target with Johnson-Holmquist model. In the studied panels the area surrounding back edges was supported by rigid wall. The obtained results show interesting properties of the new structures considering their ballistic resistance. However only certain places were chosen for tests, the protection ability against projectile attack is in general higher than the reference model. What is particularly interesting during the 6.6mm from the sphere center impact the sphere surface trajectory deviation effect is present. A projectile is not stopped here by material strength but the front layer shape. Moreover it can be assumed that this phenomenon will take place on majority of points on the sphere surface. Despite this fact, a ceramic multi sphere layer is less susceptible to overall destruction, depending on the impact point. The results of those numerical simulations can be used for designing of modern armor protection systems against hard kinetic projectiles.