A filament-level analysis on failure mechanism and ballistic limit of real-size multi-layer 2D woven fabrics under FSP impact

Abstract

This paper investigates the failure mechanism and fabric ballistic performance of real-size multi-layer 2D woven fabrics impacted by sharp-edge fragment simulating projectile (FSP). First, the relations between digital fiber shear force and bending rigidity are established under the modified digital element approach (DEA) framework. Then, a systematic parametric study was carried out on the ballistic impact of a 4-inch-long single yarn and 4-inch by 4-inch 2D woven fabric at near fiber level to solve for the relations of digital fiber moment of inertia and ballistic limit. The results show that for the same number of digital fibers per yarn model, the simulated ballistic limits are in direct proportion to digital fiber moment of inertia. The increase of the number of digital fibers per yarn, however, decreases the digital fiber moment of inertia effect on ballistic limits. Second, the 1- to 28-layer real-size 2D woven Kevlar KM2 fabrics are simulated at filament level against FSP on the cluster to estimate the V50 zone. The perforation process and failure mechanism of 4-layer fabric is investigated and analyzed in detail. The simulation results demonstrate the deformed fabric shape with respect to time and the damage modes at the impact area. Numerical results are compared with standard ballistic test results.

A dynamic weaving simulator for filament-level 3D woven fabric modelling

“…Periodic boundary condition : During the fabric manufacturing process, a boundary effect exists near the edges and demonstrates properties different from that of the remaining fabric piece. Hence, a periodic boundary condition similar to that utilised in the dynamic relaxation approach 28 was implemented only in the weft direction. As shown in Figure 4, the simulation domain includes a primary region (in green) and two image regions (in grey).…”

“…The fibre tensile force, 25 inter-fibre contact force, 26 frictional force, 31 damping force, 27 and shear force 28,32 have been considered and presented in previous studies. In this section, we discuss the weft yarn tension and periodic boundary conditions.…”

“…In this study, a dynamic weaving simulator that fully models loom kinetics and kinematics is proposed to simulate the entire textile weaving process. It employs the DEA 27,28,30,31 to simulate weaving actions, boundary conditions, inter-fibre forces (contact and friction), and fibre forces (tensile, bending, shear, and damping). The work presented in this paper is organised as follows: (1) the necessary components of a Jacquard loom to perform all weaving functions are explicitly modelled and illustrated; (2) the mechanisms of all principal weaving actions, especially the relation between yarn interlacing motion and fabric pattern, are explained; (3) the weft yarn tension and periodic boundary conditions in the warp direction are established; and (4) the weaving process of a 3D orthogonal woven fabric is simulated step by step and compared to micrographs of an actual fabric.…”

“…27 In this approach, one virtual fibre is composed of short-rod elements connected by a torsional spring. 28 Fibre bending is not preserved by the element itself but by elements with joints. In addition, a homemade software package Digital Fabric and Composite Analyser (DFCA), 29 with yarn discretisation, which splits yarns into a user-defined number of virtual fibres with equal cross-sectional areas, and fibre discretisation, which divides virtual fibres into several rod elements, has been implemented to adjust fabric resolution.…”

“…In this study, a dynamic weaving simulator that fully models loom kinetics and kinematics is proposed to simulate the entire textile weaving process. It employs the DEA 27,28,30,31 to simulate weaving actions, boundary conditions, inter-fibre forces (contact and friction), and fibre forces (tensile, bending, shear, and damping). The work presented in this paper is organised as follows: (1) the necessary components of a Jacquard loom to perform all weaving functions are explicitly modelled and illustrated;…”