Finite element analysis of ballistic impact on Kevlar-29/epoxy composites with varying layer configurations

Abstract

This study presents a numerical investigation of the ballistic impact response of Kevlar-29/epoxy resin composites sandwiched between two aluminum layers with an air gap using the Finite Element Method (FEM). The simulation results were validated through comparison with experimental data and numerical benchmarks from the literature. Four composite structures—woven, unidirectional, short fiber, and random particle — were analyzed to evaluate residual velocity, yield stress, displacement, and energy absorption. The results indicate that dividing a 1.29 mm aluminum alloy 2024-O plate into three identical layers, with the middle layer composed of Kevlar-29/epoxy resin woven composite, exhibits the highest resistance to perforation. This configuration achieves significant energy absorption and reduction in projectile velocity while decreasing the total weight of the structure by approximately 18% compared to neat aluminum plate. Further parametric analysis demonstrated that a fiber volume fraction of 0.4, twill weave type, high-volume-fraction fiber geometry, and 1% nanoparticle reinforcement increased central displacement by 19%, and reduced the projectile velocity by approximately 88%. These findings provide insights into optimizing composite structures for enhanced ballistic protection, contributing to the development of high-performance impact-resistant structures.