Full text
Nume ical s udy on he op imized
hickness o laye configu a ion
agains he 7.62 APM2 p ojec ile
Di yanshu S. Mo ghode
1
, D. G. Thaku
1
*, Sachin Salunkhe
2
,
3
,
Lenka Cepo a
4
and Emad Abouel Nas
5
1
Depa men o Mechanical Enginee ing, De ense Ins i u e o Ad anced Technology, Pune, India,
2
Depa men o Biosciences, Sa ee ha School o Enginee ing, Sa ee ha Ins i u e o Medical and
Technical Sciences, Chennai, India,
3
Depa men o Mechanical Enginee ing, Gazi Uni e si y Facul y o
Enginee ing, Anka a, Tü kiye,
4
Depa men o Machining, Assembly and Enginee ing Me ology, Facul y
o Mechanical Enginee ing, VSB—Technical Uni e si y o Os a a, Os a a, Czechia,
5
Depa men o
Indus ial Enginee ing, College o Enginee ing, King Saud Uni e si y, Riyadh, Saudi A abia
This s udy aimed o selec sui able ma e ials and op imize he hickness o hese
ma e ials so ha hey could p e en he pe o a ion o 7.62-mm AP bulle s a
830 m/s impac eloci y. A nume ical me hod is used o analyze he impac on
laye ed configu a ions o Al
2
O
3
and Al 7075-T651 o ulfill his aim. In o de o
op imize he hickness o he a mo , no mal impac and angula impac
condi ions we e conside ed. Ini ially, a 20-mm Al
2
O
3
on pla e wi h a 20-
mm Al 7075-T651 back pla e is analyzed o laye ed configu a ion. Back pla e
hickness is educed in s eps o 10 mm such ha no plas ic de o ma ion is
obse ed on he ea side o he a ge . Fo u he op imiza ion o weigh , he
hickness o he Al
2
O
3
pla e is educed o 18 mm. The weigh o his configu a ion
is 1.77 kg, and he a eal densi y is 97.22 kg/m2. This configu a ion is analyzed o
a ge o ien a ions such as 80°,70
°, and 60°. In his analysis, he p ojec ile
de o med in a mush oom shape o 90°and 80° a ge o ien a ions, while o
70°and 60° a ge o ien a ions, he p ojec ile expe ienced mo e damage on he
shank pa . The mos e ec i e configu a ion wi h he highes deg ee o ballis ic
pe o mance is a laye ed combina ion o he 18-mm Al
2
O
3
on pla e and 10-mm
Al 7075-T651 back pla e a 70° a ge o ien a ion.
KEYWORDS
7.62 AP p ojec iles, Al
2
O
3
, Al 7075-T651, laye ed configu a ion, no mal and oblique
impac , hickness op imiza ion
1 In oduc ion
Secu i y o ces mus ope a e in highly dange ous a eas whe e e o is a acks a e always
una oidable. Ideally, secu i y o ces mus ha e only bulle p oo ehicles in such high- isk
a eas o p o ide necessa y p o ec ion om such a acks. Howe e , due o a lack o esou ces,
i is no possible o ha e bulle p oo ehicles in such la ge numbe s. Hence, non-bulle p oo
ehicles a e used o he ou ine mo emen o oops. Howe e , such ehicles a e ulne able
o a acks and canno p o ide he equi ed p o ec ion o he oops. So, he only solu ion
a ailable is o con e a non-bulle p oo ehicle in o a bulle p oo ehicle using add-on
a mo . Howe e , add-on a mo inc eases he weigh o he ehicle. Hence, ma e ials used
o he add-on a mo need o be ca e ully selec ed, conside ing hei densi y and op imizing
hei hickness o minimize he e ec o hei weigh on he ehicle. So, he ques ion ha
needs o be answe ed is “which ma e ials and o wha hickness, when fixed on o dina y
OPEN ACCESS
EDITED BY
Mohamed A. El ahe ,
King Abdulaziz Uni e si y, Saudi A abia
REVIEWED BY
Kadi Gunaydin,
Gene al Elec ic, Uni ed S a es
Chang Yan,
Xi’an Uni e si y o Technology, China
*CORRESPONDENCE
D. G. Thaku ,
[email p o ec ed]
RECEIVED 16 Oc obe 2023
ACCEPTED 18 Ma ch 2024
PUBLISHED 04 Ap il 2024
CITATION
Mo ghode DS, Thaku DG, Salunkhe S, Cepo a L
and Abouel Nas E (2024), Nume ical s udy on
he op imized hickness o laye configu a ion
agains he 7.62 APM2 p ojec ile.
F on . Mech. Eng 10:1322640.
doi: 10.3389/ mech.2024.1322640
COPYRIGHT
© 2024 Mo ghode, Thaku , Salunkhe, Cepo a
and Abouel Nas . This is an open-access a icle
dis ibu ed unde he e ms o he C ea i e
Commons A ibu ion License (CC BY). The use,
dis ibu ion o ep oduc ion in o he o ums is
pe mi ed, p o ided he o iginal au ho (s) and
he copy igh owne (s) a e c edi ed and ha he
o iginal publica ion in his jou nal is ci ed, in
acco dance wi h accep ed academic p ac ice.
No use, dis ibu ion o ep oduc ion is
pe mi ed which does no comply wi h hese
e ms.
F on ie s in Mechanical Enginee ing on ie sin.o g01
TYPE O iginal Resea ch
PUBLISHED 04 Ap il 2024
DOI 10.3389/ mech.2024.1322640
ehicles, will p o ide p o ec ion agains 7.62-mm APM2 bulle s and
make he ehicle bulle p oo ?”.
P e ious s udies e eal ha unde he e ec o high- eloci y
impac , ma e ials show non-linea and dynamic beha io , including
he mal so ening, ac u e, and s ain a e ha dening o me al
(Fo es al e al., 1992;Fo es al and Wa en, 2008;2009;Bø ik
e al., 2009;2010;Pede sen e al., 2011;Holmen e al., 2017), conc e e
(Rajpu e al., 2017;2018;Rajpu and Iqbal, 2017), and ce amic (Den,
1991;Fellows and Ba on, 1999) a ge s. The fini e elemen analysis
o bulle s’impac on a ious ypes o a mo is done using explici
dynamic FE analysis. Du ing such an analysis, di e en con ac
algo i hms and ma e ial models a e used. Flo es-Johnson e al.
(2011) pe o med nume ical impac simula ions on single-laye
and mul ilaye configu a ions o s eel and aluminum using a
7.62-mm AP bulle wi h an impac eloci y o 770–950 m/s. LS-
DYNA so wa e was used. The esul s show ha mul i-laye ed pla es
wi h di e en ma e ials show g ea e esis ance a he same a ea
densi y. Rahman e al. (2016) conduc ed simila simula ions using
high-s eng h s eel and Al 7075-T6 as a ge s, in which hey s udied
he ballis ic limi , he p ocess o pene a ion, and de o ma ion. The
esul s showed ha he iple-laye ed configu a ion achie es
maximum weigh educ ion wi hou comp omising pe o mance.
Ce amic ma e ials a e widely used as a mo ma e ials because o
hei excellen ballis ic esis ance p ope ies. Den (1991) s udied ha
he p ojec ile’s beha io du ing impac , iden i ying h ee phases:
e osion o mass, mush ooming, and igidi y. Fellows and Ba on
(1999) de eloped impac models o semi-fini e ce amic a ge s.
Ande son and Walke (2005) p esen ed he dwell phenomenon
model o p ojec ile impac on ce amic a ge s. An app op ia e
ma e ial model o s eel co e bulle s, Al 2024-T351, and Al
2
O
3
was gi en by Tu han e al. (2008), in which he plas ic kinema ic
ha dening model was used o s eel co e p ojec iles and Al 2024-
T351, and he Johnson–Holmquis model was used o Al
2
O
3
.
López-Puen e e al. (2005) p esen ed he op imum hickness o
he oughened epoxy esin adhesi e laye o alumina–aluminum
a mo s. Mazahe i e al. (2017) s udied he e ec on ballis ic limi
eloci y and ene gy abso p ion a e w apping Al oil on he impac
ace o Al
2
O
3
iles. The s udy shows a 13% inc ease in ballis ic limi
eloci y and an 11% inc ease in ene gy abso p ion wi h jus a 2.4%
inc ease in weigh . Gál ez e al. (2005) P anay and Panig ahi
(2022a),P anay and Panig ahi (2022b), and P anay and
Panig ahi (2022c) conduc ed a nume ical s udy o he
de elopmen o p ojec iles and a emp ed e ec i e pene a ion o
a ge s using ANSYS Explici Dynamics/AUTODYN so wa e. In
Gál ez e al. (2005) , he e ec o p ojec ile umbling has been
s udied o ce amic and aluminum a mo . Wei and Zhang (2014)
expe imen ally s udied he p ojec ile de o ma ion modes o so -
co e and ha d-co e p ojec iles impac ing ce amic a ge s a di e en
impac eloci ies.
In p e ious s udies, di e en in es iga o s ha e s udied di e en
pa ame e s in ol ed in he ballis ic impac o he bulle on he a ge :
esidual eloci y pos -impac , he eloci y o he ballis ic limi , he
pa e n o pe o a ion, mechanisms o ac u e, e c. Fu he mo e,
a ious ma e ials ha can be used as a mo , along wi h di e en
combina ions and configu a ions o hese ma e ials, we e
highligh ed in p e ious s udies.
F om he li e a u e e iew, i was obse ed ha e y ew
s udies ha e been conduc ed on he op imiza ion o a mo pla e
hickness o p oposing hickness o a mo ab ica ion agains
7.62-mm APM2 p ojec iles. Mos o he wo k on ballis ic impac
in he open li e a u e deals wi h me allic and non-me allic a ge
ma e ials wi h ela i ely low hicknesses and p ojec iles mo ing
wi h sub-o dnance eloci ies. The pene a ion o mul i-laye ed
a mo pla es is a complex p oblem. In o de o design p o ec i e
s uc u es, hickness and laye configu a ions a e ac o s ha
mus be conside ed ca e ully o ensu e no pene a ion. I mus
also be ensu ed ha no deb is is p ojec ed o he ea o he
a mo and ha he e is no panel deflec ion. Thus, a sys ema ic
s udy emains needed o op imize he s eng h- o-weigh a io o
a mo ma e ials while p o ec ing agains 7.62-mm
APM2 bulle s.
The pu pose o his s udy was o selec sui able ma e ials in he
laye ed configu a ion wi h an op imized hickness o each laye such
ha hey can be used as add-on a mo on he body o a ehicle. The
conside ed ma e ials a e Al
2
O
3
and Al 7075-T651. Al
2
O
3
ma e ial
has cha ac e is ics o high s eng h and low densi y, while Al 7075-
T651 has cha ac e is ics o high s eng h and high duc ili y.
The e o e, Al
2
O
3
is conside ed he on pla e so ha i can
abso b he ini ial impac ene gy, unde go b i le ac u e, and
cause high p ojec ile de o ma ion. Al 7075-T651 is conside ed
he back pla e so ha i can abso b he esidual ene gy om he
impac and agmen s o Al
2
O
3
c ea ed due o i s ac u e. Mos o
he laye ed configu a ion s udies do no consis o specific
hicknesses o add-on a mo o p o ec ion agains p ojec iles. So,
in his s udy, he op imum hickness is conside ed based on wo
c i e ia: fi s , he a mo mus success ully s op he p ojec ile, and
second, he e mus be no plas ic de o ma ion on he ea su ace o
he a mo .
This wo k p esen s a nume ical s udy o he impac on he
laye ed combina ion o Al
2
O
3
and Al 7075-T651 by a 7.62-mm
APM2 bulle fi ed a 830 m/s. Fu he mo e, o op imize he
hickness o he a mo , no mal impac and angula impac
condi ions we e conside ed. The ollowing sec ions explain in
de ail he nume ical app oach ollowed by he esul s obse ed.
2 Resea ch me hodology
Ini ially, esidual eloci y is compu ed by nume ical simula ions
while conside ing he no mal impac a a gi en impac eloci y on an
Al 7075-T651 pla e ha ing a 20 mm hickness. The model is
alida ed using he expe imen esul s om he li e a u e
(Fo es al e al., 2010). A alida ed model is ex ended o s udy
he laye ed a mo consis ing o Al 7075-T651 and Al
2
O
3
a no mal
and oblique impac condi ions. Figu e 1 ep esen s a de ailed
esea ch me hodology flow cha .
2.1 Fini e elemen modeling
2.1.1 P ojec ile
Mos esea che s wo king wi h s anda d NATO ammuni ion
use 7.62-mm s eel-co e bulle s o analyze a ious a ge ma e ial
impac s (Flo es-Johnson e al., 2011). These bulle s consis o an
inne s eel co e and a p o ec i e ou e jacke . This jacke is gene ally
made o b ass and is used o engage wi h he ba el’s lands so ha
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spin can be p o ided o he bulle du ing i s a el inside he ba el.
Howe e , his b ass jacke does no a ec he collision be ween he
a ge ma e ial and bulle (Chen e al., 2013). The e o e, he jacke is
no conside ed du ing he simula ions o educe he ime equi ed
o compu a ion. Sen hil and Iqbal (2021) also used only he s eel
co e, as shown in Figu e 2, and compa ed he esul s wi h
expe imen al da a ob ained using a p ojec ile. The esul s
ma ched he expe imen esul s (Sen hil and Iqbal, 2021).
SolidWo ks was used o design he bulle , and he design was
impo ed in o LS-DYNA o simula ions.
2.1.2 Ta ge
LS-DYNA so wa e was used o designing a model o he
a ge . The a ge was designed as a ci cula pla e wi h a diame e
FIGURE 1
Resea ch me hodology flow cha .
FIGURE 2
7.62-mm AP p ojec ile (all dimensions a e in mm) (Sen hil and Iqbal, 2021).
F on ie s in Mechanical Enginee ing on ie sin.o g03
Mo ghode e al. 10.3389/ mech.2024.1322640
o 152 mm. This ci cula pla e was u he seg ega ed in o h ee
egions. The impac egion a he cen e o he ci cula a ge was
designed as a squa e wi h each side measu ing 10 mm. The
second and hi d egions a e ci cula and designed o ha e
30 mm and 50 mm diame e s, espec i ely. Figu e 3 shows he
dimensions o he ci cula pla e used as he a ge .
FIGURE 3
Ta ge disc e iza ions.
FIGURE 4
Mesh (A) p ojec ile and (B) a ge .
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2.1.3 Meshing
I is well-known ha he mos accu a e esul s a e ob ained
when wo condi ions a e sa isfied: fi s , when he densi y o he
mesh and numbe o elemen s a e highe , and second, when
elemen s a e closes o he sys em’s bounda y. To co e he
maximum olume and cu a u e o he bulle and a ge pla e,
hexahed al solid elemen s wi h eigh nodes, educed in eg a ion,
and he Hou glass e ec ’s s i ness con ol a e used o meshing.
The meshing o he bulle was done in ABAQUS, and he
meshing o he a ge pla e was done in LS DYNA. The
duplica e nodes we e ei he emo ed o me ged, depending
on hei dimensions.
A comp ehensi e mesh con e gence s udy was conduc ed
o minimize he compu a ion ime and selec he op imized
elemen size o he p ojec ile and impac egion o he a ge .
The esul s ob ained by changing he elemen size we e
compa ed wi h esul s gi en in he li e a u e (Fo es al
e al., 2010). I was concluded ha he size o elemen s in
hesqua e egiona hecen e o he a ge pla ewouldbe
0.25 mm. Simila ly, he size o he elemen s in he ci cula
po ion, ha ing diame e s o 30 and 50 mm, will be 0.5 and
1 mm, espec i ely. The size o an elemen beyond 50 mm in
diame e will be 2 mm. Figu e 4 ep esen s he final mesh o he
bulle and a ge pla e.
2.2 Cons i u i e ma e ial models
2.2.1 S eng h model by Johnson–Cook
The s eng h model gi en by Johnson and Cook (1983) and
Johnson and Cook (1985) defines he beha io o he s eng h o
ma e ials subjec ed o impac wi h high eloci ies. The model gi es
yield s ess, i.e., Y, as a unc ion o s ain ha dening, s ain a e
ha dening, and empe a u e so ening, and he equa ion o he
same is shown below.
YA+Bεn
p
1+Clogε*
p
1−Tm
H
,(1)
whe e ε
p
is he e ec i e plas ic s ain, ε
p
* is he no malized
e ec i e plas ic s ain a e, and T
H
is he homologous empe a u e
[T
H
=(T–T
oom
)/(T
mel
–T
oom
)].
A, B, C, n, and m a e ma e ial cons an s. The fi s b acke in Eq. 1
gi es s ess as he unc ion o s ain, which is de e mined by quasi-s a ic
ensile es ing (ε
p
p
=1.0sec
−1
and T
H
=0).Ais heyields essa lowe
alues o s ains; B and n define s ain ha dening. The o he wo b acke s
ep esen he e ec s o ha dening due o he s ain a e and so ening due
o empe a u e. Wi h so ening due o he mal e ec s, yield s eng h is
educed o ze o a mel ing empe a u es T
mel
. The cons an s o ma e ials
a e de e mined using he dynamic ensile es using a spli Hopkinson
Ba o e a wide ange o s ain a es and empe a u es.
TABLE 1 Ma e ial p ope y o Al 7075-T651 and bulle .
Pa ame e Uni Al 7075-T651 (Jø gensen K. C. and Swan V., 2014) Bulle (Sen hil and Iqbal, 2021)
Young’s modulus E GPa 71.7 202
Poisson’s a io υ- 0.33 0.32
Densi y ρkg
m32810 7,850
Johnson–Cook s eng h model
Yield s eng h A MPa 520 2,700
S ain ha dening pa ame e B MPa 477 211
S ain ha dening pa ame e n - 0.52 0.065
Re e ences s ain a e _
ϵ0s−15e-4 1e-4
S ain a e cons an C - 0.0025 0.005
Re e ences empe a u e K 293 293
Mel ing empe a u e K 893 1,800
The mal so ening pa ame e m - 1.61 1.17
Specific hea capaci y CPJ
kg.K910 452
The mal expansion coe ficien α1/K 2.3e-5 1.2e-5
Johnson Cook ailu e model
Failu e pa ame e D1- 0.096 0.4
Failu e pa ame e D2- 0.049 0
Failu e pa ame e D3- 3.465 0
Failu e pa ame e D4- 0.016 0
Failu e pa ame e D5- 1.099 0
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2.2.2 Johnson–Cook ailu e model
The ailu e model gi en by Johnson–Cook was used o model
ma e ial ailu es. Simila ly, in he p e ious model, ac u e s ain, a
ma e ial p ope y, is gi en as an explici unc ion o empe a u e,
s ain a e, and p essu e. The equa ion o he same is gi en as Eq. 2.
ε D1+D2exp D3σ*
1+D4ln ε*
()
1+D5TH
.(2)
The dimensionless a io o p essu e and s ess is ep esen ed as σ*=
σ
m
/σ,whe eσ
m
is p ima y s ess, (σ
1
+σ
2
+σ
3
)/3, and σis e ec i e s ess
o Von Mises s ess (3J
2
), whe e J
2
is he second in a ian o he s ess
de ia o . Dimensionless s ain a e ε
p
is ε/ε
0
,whe eε
0
is he uni s ain
a e. T
H
is he homologous empe a u e, p oduced by in e nal hea ing.
D
1
,D
2
,D
3
,D
4
,andD
5
a e pa ame e s o he model o ac u e, and hese
can be ob ained om expe imen s done in he labo a o y.
TABLE 2 Ma e ial p ope ies o Al
2
O
3
(Zochowski e al., 2021).
Pa ame e Uni Al
2
O
3
Densi y ρg/cm
3
3.84
Shea modulus G GPa 93
In ac s eng h coe ficien A - 0.93
F ac u ed s eng h coe ficien B - 0.31
S ain a e cons an C - 0.007
F ac u e s eng h exponen M - 0.6
In ac s eng h exponen N - 0.64
EPSI - 1
Max ensile hyd os a ic p essu e MPa 262
SFMAX - 1
Hugonio elas ic limi (HEL) MPa 8,000
P essu e a HEL MPa 1,460
Bulking ac o β-1
Damage coe ficien D
1
0.01
Damage coe ficien D
2
0.7
P essu e cons an K
1
GPa 131
P essu e cons an K
2
GPa 0
P essu e cons an K
3
GPa 0
*MAT_ADD_EROSION VOLEPS 0.05
FIGURE 5
Assembly and bounda y condi ions o he model.
TABLE 3 Residual eloci y wi h a ia ion in he numbe o elemen s.
No. o elemen s Residual eloci y (m/s)
25 476.88
33 545.36
40 570.87
50 583
60 585.9
80 584.4
100 584.7
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Changes occu ing while loading a e depic ed in he
Johnson–Cook model using he concep o linea summa ion.
This model calcula es changes in ailu e s ain using he s ess
s a e, empe a u e, s ain a e, and damage accumula ed du ing
loading. Howe e , his model does no accoun o he
deg ada ion o he s eng h o he ma e ial o s i ness. When he
c i ical alue o damage is eached, he alues o p essu e and s ess
a e ab up ly educed o ze o. Fo his eason, i is said o be an
ins an aneous ailu e model. Damage is compu ed as he cumula i e
alue, as gi en in Eq. 3, and ailu e is fixed a a c i ical alue, which is
gene ally aken as 1.
Dε
ε ,(3)
whe e εis he equi alen plas ic s ain inc emen ha occu s
du ing ensile loading and ε
is he equi alen s ain o ac u e
co esponding o ins an aneous condi ions du ing he accumula ion
o he inc emen o s ain.
FIGURE 6
Dep h o pene a ion o 50-mm Al 7075-T651 a an impac eloci y o 830 m/s.
FIGURE 7
Impac simula ions on an independen Al
2
O
3
pla e.
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2.2.3 Johnson–Holmquis model
The Johnson–Holmquis model (Johnson and Holmquis ,
1994), ha ing an equa ion o s a e, model o s eng h, and model
o damage, was used o define he beha io o Al
2
O
3.
Polynomial
equa ion-o -s a e (EOS) calcula ed he cu en alue o p essu e as a
unc ion o olume ic change, he model o s eng h ga e equi alen
s eng h o undamaged and damaged ma e ial, and he model o
damage was used o show he ansi ion o ma e ial om
undamaged o damaged s a es.
No malized equi alen s ess is defined as ollows:
σ*σi*−Dσi*−σ *
()
,(4)
whe e σ
i
* is he no malized in ac equi alen s ess, σ
* is he
no malized ac u e s ess, and D is damage (0 ≤D≤1).
FIGURE 8
Impac on he laye ed configu a ion o he 20-mm- hick Al
2
O
3
on pla e and 20-mm- hick Al 7075-T651 back pla e.
FIGURE 9
Impac on he 20-mm- hick Al
2
O
3
on pla e and 10-mm- hick Al 7075-T651 back pla e.
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No malized in ac equi alen s ess is shown in Eq. 5, and
no malized ac u ed equi alen s ess is shown in Eq. 6.
σi*AP*+T*
()
N1+Clnε*
()
,(5)
σ *BP*
()
M1+Clnε*
()
,(6)
whe e A, B, C, M, and N a e cons an s o ma e ial and no malized
p essu e. P* = P/P
HEL
, whe e P is he ac ual p essu e and P
HEL
is he
p essu e a he Hugonio elas ic limi (HEL). The HEL is he ne
comp essi e s ess co esponding o uniaxial s ain (shock wa e)
exceeding he elas ic limi o he ma e ial. No malized maximum
ensile hyd os a ic p essu e is ep esen ed as T* = T/P
HEL
, whe e T is
he maximum ensile hyd os a ic p essu e ha ma e ial can
wi hs and, and he dimensionless s ain a e is ε*=ε/ε
0
, whe e ε
is he ac ual equi alen s ain a e and ε
0
is he e e ence s ain a e
conside ed o be 1 s
-1
.
FIGURE 10
Impac on he 18-mm- hick Al
2
O
3
on pla e and 10-mm- hick Al 7075-T651 back pla e.
FIGURE 11
Impac on 80° a ge o ien a ion.
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