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IRJET-Ballistic Performance of Bi-Layer Alumina/Aluminium and Honeycomb Sandwich Armours
1.
International Research Journal
of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 05 Issue: 06 | June -2018 www.irjet.net p-ISSN: 2395-0072 © 2018, IRJET | Impact Factor value: 6.171 | ISO 9001:2008 Certified Journal | Page 1514 Ballistic performance of Bi-layer Alumina/aluminium and Honeycomb sandwich Armours I.R. Pavan Kumar Varma1, L. Venkata Ramaraju2 1Asst. professor, Department of Mechanical Engineering, S.R.K.R Engineering College, Bhimavaram, India. 2M. Tech Scholar, Department of Mechanical Engineering, S.R.K.R Engineering College, Bhimavaram, India. ---------------------------------------------------------------------***--------------------------------------------------------------------- Abstract - This work presents numerical simulations on ballistic response of Aluminium honeycomb sandwich with ceramic(alumina) faced laminates of total 12 mm thick against 7.56mm blunt shape projectile. All numerical simulations are performed for an impact velocity of 712 m/s. Performance evaluation is done based on residual velocity of the projectile. This work is focused to study the effect on residual velocity of projectile for changes in foil thickness of Aluminium honeycomb, thickness of honeycomb. Process is simulated by using a finite element code HyperWorks-Radioss. To ensure the set-up procedure a bilayer Alumina/aluminium armour is taken from reference and is validated with an error percentage of 2.5 which is allowed. Results from the simulation showed that decrease in thickness of honeycomb foil caused decrease in residual velocity and also increasing thickness of honeycomb with total thickness as constant, reduces ballistic performance. Key Words: Ballistic response, Honeycomb Sandwich, Armour, Hyperworks, Radioss. 1.INTRODUCTION At present light weight armours are made of composite materials but these stand alone cannot withstand to high velocity impacts. So ceramic faced armours backed by low density metal or composite laminates are being used for armour design. Tools based on finite elementapproachesare widely spread and as well as they are appropriate and cost effective, numerical simulations are being used to represent the behaviour in impact problemsalso.Hyperworks-Radioss solver is used for the current simulation. A Bilayer Al2O3/Al armour from J. Venkatesan et al. [1] work is considered for validation and current solver could approximate the results with an error percentage of 2.5. An aluminium honeycomb sandwich with alumina face plates is considered for armour application and simulated against the same projectile configuration as in the validation case. 1.1 Literature Review Godrej [3] present the NIJ level III steel plate behaviour against the dynamic loading of 7.62 x 39mm steel core AK47 ammunition using Radiossexplicit non-linear analysis and it was found that the steel plate behaviour in Radioss explicit non-linear analysis is very much similar with actual test results. J. Venkatesan et al. [1] simulatedtheballisticperformance of two bilayerSiC/Al andAl2O3/Al armoursagainstbluntand ogive nose projectiles and concluded that the ballistic performance of SiC/Al armour is superior than that of Al2O3/Al armour irrespective of the projectile nose shape. There are somany researchesregardingbi-layerarmours and optimum thickness of front layer etc., But there are very few researchesconsidering honeycomb sandwichstructures for impact applications. Recep Gunes et al. [2] investigates damage mechanism and deformation of honeycomb sandwich structuresreinforced by functionallygradedplates under ballistic impact effect by means of explicit dynamic analysis using ANSYS LS-DYNA. Materials data used in the current simulation is referenced from J. Venkatesan et al. [1] work. Failure criteria for ceramics (Al2O3) is taken from report [4]. An attempt has been made in this work to compare the performance among bi-layer armour and honeycomb sandwich structures based on residual velocity of the projectile for a total armour thickness of 12mm. 1.2 Objectives of Current Work To ensure the setup procedure in Radioss, primary objective is considered to be the validation of Bi-layer Al2O3/Al armour performance with the referencevaluefrom J. Venkatesan et al. [1] work. Second objective is to Setup the problem of interest, Al honeycomb with ceramic(Al2O3)face plates as a sandwich panel of 12mm thick and simulate the ballistic performance against the same projectile configuration. Third objective is to check how the honeycomb foil thickness, thickness of honeycomb affects residual velocity of projectile. 2. FINITE ELEMENT MODELING For all the numerical analysis,Lagrangianapproachisusedto simulate the projectile impact on armour plates to assess their energy absorption through Hyperworks-Radioss software. The details of geometry, meshing, boundary conditions and material models are mentioned below. 2.1 Modeling of Bi-layer Al2O3/Al armour Numerical simulation with the yaw angle of -9.9 degree about y axis and +1.1 about x axis of blunt nose steel projectile impacting Al2O3/Al is shown in figure 1 for the purpose of validation
2.
International Research Journal
of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 05 Issue: 06 | June -2018 www.irjet.net p-ISSN: 2395-0072 © 2018, IRJET | Impact Factor value: 6.171 | ISO 9001:2008 Certified Journal | Page 1515 Fig-1: Modelling of bilayer armour against 7.56mm blunt shape projectile Geometric description [1] Dimensions of plates: 100mm x 100mm Front plate (Al2O3) thickness: 6.1mm Back plate (Al) thickness: 5.87 mm Projectile (steel) diameter: 7.56 mm Projectile length: 30.54 mm Meshing A Three dimensional 8 noded hex element is used for meshing both the plates and projectile. Two-way biasing is used to have a dense mesh at central portion of the plates where the impact is going to happen. Solid element formulation used in this work is Isolid =24; HEPH8-nodesolid element, Co-rotational, under-integrated (1 Gauss point) with physical stabilization 2.2 Modeling of Honeycomb Sandwich Structure Fig-2: Modeling of Honeycomb Sandwich Structure Dimensions of plates are 100mm x 100mm. Honeycomb thickness is 4mm and it is varied further, considered as different cases. Different cases are considered for honeycomb foil thickness like 0.04mm, 0.1mm and 0.5mm. Plates and projectile are idealized with solid elements and metal honeycomb is meshed with 2D shell elements as shown in figure 2. Unit system used in the simulation consists length in mm, force N, pressureMpa,densityg/mm3, time in ms. Table-1: Material properties of ceramics (Al2O3 95%) [1] Material law Johnson Holmquist-2 Density 0.003741 Shear modulus, G 120340 Intact strength constant, a 0.589 Fracture strength constant, b 0.29 Fracture strength exponent, m 0.53 Intact strength exponent, n 0.764 Strain rate constant, c 0.0045 Reference strain rate, Epsilon_0 0.001 Normalized Max. fracture strength, Sigma_fmax 1 Hydro tensile limit, T 300 HEL 6000 P_HEL 1460 Damage constant, D1 0.005 Damage exponent, D2 1 Bulk modulus, K1 184560 Pressure constant, K2 185870 Pressure constant, K3 157540 Beta 1 Table-2: Material propertiesof aluminium (Al 2024-T3)[1] Material law Plas_Johns_zeril Density 0.002785 Young’s modulus, E 71607.2 Poison ratio, nu 0.33 Static yield strength, a 167 Strain hardening constant, b 596 Strain hardening exponent, n 0.551 EPS_max 0.75 Strain rate constant, c 0.001 Reference strain rate 0.001 Table-3: Material properties of steel (steel 4340) [1] Material law Plas_Johns_zeril Density 0.0079 Young’s modulus, E 200200 Poison ratio, nu 0.3 Static yield strength, a 950 Strain hardening constant, b 725 Strain hardening exponent, n 0.375 Strain rate constant, c 0.015 Reference strain rate 0.001 Failure criteria for ceramics [4] Failure criteria forsteel[1] Criteria Tensile strain Eps_t1 0.5 Eps_t2 0.6 criteria Johnson cook D1 -0.8 D2 2.1 D3 -0.5 D4 0.002 D5 0.61
3.
International Research Journal
of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 05 Issue: 06 | June -2018 www.irjet.net p-ISSN: 2395-0072 © 2018, IRJET | Impact Factor value: 6.171 | ISO 9001:2008 Certified Journal | Page 1516 Type 7 interface is defined between projectile and plates. Projectile is considered for slave nodes, ceramic plates and metal honeycomb are considered for master segments. Type 2, tied interface is used to connect the 2D shell elements to 3D elements top and bottom of the honeycomb. All degrees of freedom constrained at plate edges and translational degree of freedom in one direction is allowed for projectile movement and velocity of projectile712m/sis given as initial velocity for all the simulations. 3. RESULTS AND DISCUSSION Case 1: Validation of ballistic performance of bilayer Al2O3/Al armour against 7.56mm blunt shapeprojectilewith certain angle of inclination Fig-3: Simulation of bullet penetration into bilayer armour plates Graph-1: Kinetic Energy, Internal Energy and Total Energy for case1 Initial velocityof projectile is 712m/sandresidualvelocityof projectileobtained from kinetic energyingraph1is441m/s. Experimental value fromthereferenceis430m/s.Thissetup could approximate the impact behaviour, particularly residual velocity with an error percentage of 2.5 Case2: ballistic performanceof honeycomb sandwichpanel of total 12mm thick against same projectile configuration. Thickness of the honeycomb is 4mm and thickness of two plates is 4mm each. Al honeycomb foil thickness is 0.5mm Fig-4: Failure mode of sandwich target against 7.56mm blunt projectile Graph-2: Kinetic Energy, Internal Energy, Total Energy for case 2 Residual velocity of projectile in this case is approximately 377 m/scalculated from the graph 2, which is lesscompared to the previous case of bilayer armour. Case 3: Effect of honeycomb foil thickness on ballistic performance of honeycomb sandwich armour against the same blunt shape projectile. (Honeycomb thickness is 4mm, thickness of each ceramic plate is also 4mm) Table-4: Effect of honeycomb foil thickness S. No Foil thickness (in mm) Residual velocity (approximately in m/s) 1 0.04 356 2 0.1 366 3 0.5 377 From table 4, reduction of foil thickness results in slight decrease in residual velocity of projectile indicates energy absorption by Al honeycomb Case 4: Effect of honeycomb thickness on ballistic performance for a foil thickness of 0.04mm and of total thickness 12mm. Table-5: Effect of honeycomb thickness S. No Honeycomb thickness (in mm) Thickness of each ceramic plate (in mm) Residual velocity (approximately in m/s) 1 4 4 356 2 6 3 576 3 8 2 595
4.
International Research Journal
of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 05 Issue: 06 | June -2018 www.irjet.net p-ISSN: 2395-0072 © 2018, IRJET | Impact Factor value: 6.171 | ISO 9001:2008 Certified Journal | Page 1517 From table 5, Increase in honeycomb thickness causes considerable variation in residual velocity and reduces the ballistic performance of sandwich structure. Table-6: Performance comparison for different cases Performance comparison is based on residual velocityofthe blunt shape projectile coming with an impact velocity 712 m/sand certain inclination angle. From the table 6 it is clear that case 3.1 shows better performance with slight increase in target or armour weight. It indicateshoneycombsandwich is capable to absorb the projectile kinetic energy compared to the bilayer armour target. 4. CONCLUSION RADIOSS solver can be used to simulate the ballistic response. Reducing the foil thickness of honeycomb results in decrease of residual velocity of projectile after impact, indicates absorbing characteristics of honeycomb between the ceramic plates. Increasing the thickness of honeycomb results in slight increment in residual velocity which is not recommended. After comparing the residual velocities for different cases, case 3.1 shows better characteristics with slight increase in weight that is, honeycomb sandwichtarget with each plate 4mm thick and foil thicknessof0.04mm.This indicates honeycomb sandwich target is capable to absorb the kinetic energy of projectile compared to the bilayer armour. Scope of future work This work is done by using tied interface to connect shell elements of honeycomb and sold elements of ceramic plate. Further it is recommended to find the different modelling possibilities and to study their effects on ballistic performance. 5. REFERENCES [1] J. Venkatesan, M.A. Iqbal, V. Madhu, Ballistic performance of alumina/aluminium and silicon carbide/aluminium armours, Procedia Engineering 73 (2017) 671–678 [2] Recep Gunes, Kemal Arslan, M. Kemal Apalak, J.N. Reddy, Numerical Investigations on the Ballistic Performance of Honeycomb Sandwich Structures Reinforced by Functionally Graded Plates, Blucher Material Science Proceedings. www.proceedings.blucher.com.br/evento/mm- fgm2014 [3] Simulation of Bullet Impact on Bullet Resistant Steel Plate by Godrej Security Solution Division. [4] The Johnson-Holmquist Ceramic Model as used in LS-DYNA2D by G. McIntosh, December 1998. [5] Altair HyperWorks Radioss v13 help Manual Case No. Weight of target or armour (in grams) Residual velocity of projectile (in m/s) Case 1 391 441 Case 3.1 449 356 Case 3.2 452 366 Case 3.3 474 377 Case 4.2 338 576 Case 4.3 227 595
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