STM Journals Peer-reviewed research from Consortium e-Learning Network

Journal of Polymer & Composites Original Research Open Access

Design and Ballistic Performance Assessment of Pattern-Optimized Lightweight Composite Armor Using ANSYS Explicit Dynamic and AUTODYN

  1. Shah Nusrat Jahan Shanta Department of Nuclear Science and Engineering, Military Institute of Science and Technology (MIST), Mirpur Cantonment, Mirpur, Dhaka-1216
  2. Abdus Sattar Mollah Department of Nuclear Science and Engineering, Military Institute of Science and Technology (MIST), Mirpur Cantonment, Mirpur, Dhaka-1216

Abstract

This study investigates the ballistic performance of lightweight composite armor panels designed to defeat 9 mm full-metal-jacket (FMJ) threats using high-fidelity numerical simulations. Four different composite materials were arranged into panels of identical overall dimensions; only the internal segment pattern was varied to explore geometric resistance effects while keeping mass and material type controlled. Ballistic impact simulations were performed using ANSYS Explicit Dynamics and AUTODYN to capture high-strain-rate behavior, local perforation, delamination, and energy dissipation mechanisms. A systematic pattern screening identified a resisting layout that maximizes projectile energy absorption and minimizes rear face deformation. Based on that layout, an additional design iteration produced a lowest mass sample targeted at the BR2 class threat conditions for 9 mm projectiles (GOST BR series). Simulation outputs evaluated included residual projectile velocity, back-face deformation, strain, and damage maps, and component-wise energy absorption. Results demonstrate that pattern optimization without changing base material or panel footprint can substantially improve ballistic performance and enable significant mass reduction while maintaining protection against the specified 9 mm FMJ threat. The combined use of ANSYS Explicit Dynamics and AUTODYN provided complementary insight into early perforation events and later-stage structural fragmentation, informing practical design recommendations for lightweight composite armor. Future work will validate the numerical findings with controlled ballistic testing and refine manufacturing approaches for the optimal pattern identified.

Keywords

References (25)

  1. Nayak N, Banerjee A, Sivaraman P. Ballistic Impact Response of Ceramic-Faced Aramid Laminated Composites Against 7.62 mm Armour Piercing Projectiles. Defence Science Journal. 2013;63(4):369-375. doi:10.14429/dsj.63.2616
  2. Alkhatib F, Mahdi E, Dean A. Design and Evaluation of Hybrid Composite Plates for Ballistic Protection: Experimental and Numerical Investigations. Polymers. 2021;13(9):1450. doi:10.3390/polym13091450
  3. David NV, Gao XL, Zheng JQ. Ballistic Resistant Body Armor: Contemporary and Prospective Materials and Related Protection Mechanisms. Applied Mechanics Reviews. 2009;62(5). doi:10.1115/1.3124644
  4. Lopes Martins Marques C, Kumar SR, Goswami C, Verma R. Numerical simulation of armor materials and optimization using gray relational analysis. Materials Today: Proceedings. 2021;44:4717-4730. doi:10.1016/j.matpr.2020.10.942
  5. Saleem I, Abed M, Ahmed P. Numerical and Experimental Study of Hybrid Composite Body Armor. Engineering and Technology Journal. 2021;39(11):1681-1687. doi:10.30684/etj.v39i11.2274
  6. Bandaru AK, Chavan VV, Ahmad S, Alagirusamy R, Bhatnagar N. Ballistic impact response of Kevlar® reinforced thermoplastic composite armors. International Journal of Impact Engineering. 2016;89:1-13. doi:10.1016/j.ijimpeng.2015.10.014
  7. Gower HL, Cronin DS, Plumtree A. Ballistic impact response of laminated composite panels. International Journal of Impact Engineering. 2008;35(9):1000-1008. doi:10.1016/j.ijimpeng.2007.07.007
  8. Sarhan AAR, Franklyn M, Lee PVS. The use of finite element models for backface deformation and body armour design: a systematic review. Computer Methods in Biomechanics and Biomedical Engineering. 2023;28(1):121-143. doi:10.1080/10255842.2023.2281275
  9. Mishra V, Kukshal V. Numerical analysis for estimating ballistic performance of armour material. Materials Today: Proceedings. 2021;44:4731-4737. doi:10.1016/j.matpr.2020.11.221
  10. Mishra V, Kukshal V. Numerical analysis for estimating ballistic performance of armour material. Materials Today: Proceedings. 2021;44:4731-4737. doi:10.1016/j.matpr.2020.11.221
  11. Li D, Huang F, Ren B, Zhang W, Xiong J, Zhou B, et al. Ballistic analysis of high-performance armor steel by numerical simulation. Scientific Reports. 2024;14(1). doi:10.1038/s41598-024-62482-5
  12. Shanta SNJ, Mollah AS. Structural and Thermal Analysis of Fuel Rod of VVER-1200 Nuclear Reactor Using ANSYS Software. MIST INTERNATIONAL JOURNAL OF SCIENCE AND TECHNOLOGY. 2025;13:65-71. doi:10.47981/j.mijst.13(01)2025.510(65-71)
  13. Bandaru AK, Vetiyatil L, Ahmad S. The effect of hybridization on the ballistic impact behavior of hybrid composite armors. Composites Part B: Engineering. 2015;76:300-319. doi:10.1016/j.compositesb.2015.03.012
  14. Soydan AM, Tunaboylu B, Elsabagh AG, Sarı AK, Akdeniz R. Simulation and Experimental Tests of Ballistic Impact on Composite Laminate Armor. Advances in Materials Science and Engineering. 2018;2018(1). doi:10.1155/2018/4696143
  15. Santos LSFD. Bernoulli’s equation, energy and enthalpy. Revista Brasileira de Ensino de Física. 2024;46. doi:10.1590/1806-9126-rbef-2023-0253
  16. Adam NM, Attia OH, Al-Sulttani AO, Mahmood HA, As’arry A, Md Rezali KA. Numerical Analysis for Solar Panel Subjected with an External Force to Overcome Adhesive Force in Desert Areas. CFD Letters. 2020;12(9):60-75. doi:10.37934/cfdl.12.9.6075
  17. ANSYS Inc. ANSYS Fluent Meshing User’s Guide. Section: Mesh Quality Metrics. [Internet]. 2024. Available from: https://www.afs.enea.it/project/neptunius/docs/fluent/html/ug/node167.htm.
  18. Shanta SNJ, Mollah AS. Numerical investigation of hybrid composite armors: cost-effective solutions for ballistic protection using ANSYS. International Journal of Structural Mechanics and Finite Elements. 2025;11(02):1–11. Available from: https://journalspub.com/publication/uncategorized/article=21939.
  19. Ghosh M. Construction and simulation of a novel high altitude versatile armor comprising of X-Aerogel and Carbon fiber composite with Ansys 2020 R2. Materials Today: Proceedings. 2021;44:3045-3049. doi:10.1016/j.matpr.2021.02.441
  20. Saleem I, Abed M, Ahmed P. Numerical and Experimental Study of Hybrid Composite Body Armor. Engineering and Technology Journal. 2021;39(11):1681-1687. doi:10.30684/etj.v39i11.2274
  21. Alkhatib F, Mahdi E, Dean A. Design and Evaluation of Hybrid Composite Plates for Ballistic Protection: Experimental and Numerical Investigations. Polymers. 2021;13(9):1450. doi:10.3390/polym13091450
  22. Li D, Huang F, Ren B, Zhang W, Xiong J, Zhou B, et al. Ballistic analysis of high-performance armor steel by numerical simulation. Scientific Reports. 2024;14(1). doi:10.1038/s41598-024-62482-5
  23. Muritala AO, Adio SA, Onibi OA, Adebiyi AI, Azeez RO, Idowu AO. Simulation of Multi-Layered Ballistic-Resistant Armour with Enhanced Energy Absorption Properties. FUOYE Journal of Engineering and Technology. 2023;8(4). doi:10.46792/fuoyejet.v8i4.1100
  24. Islam, Kamrul M. The dynamic response of additively manufactured bioinspired structures. 2023. doi:10.26190/unsworks/25262.
  25. Agbo S, Sumaila M, Umaru S. Modelling of composite from 3-D carbon fibre and particulates reinforced ultra-high density polyethylene for human hard body armour protection. Nigerian Journal of Engineering Science and Technology Research. 2022;8(1):106–118.
Support