Finite element modeling of ballistic impact of inserts containing titanium structures were presented in the article. The inserts containing an additional layer made using additive manufacturing technology were analyzed. The layer was created from repetitive elements made without connections (adjacent cells were inseparable). Four variants of printed titanium structures were placed between layers of Twaron CT 750 aramid fabric to create ballistic inserts. In order to assess the ballistic resistance of the inserts, numerical simulations of ballistic impact phenomenon were carried out using LS-Dyna software. In the simulations the inserts were placed on a steel box filled with ballistic clay and were fired at with the 9 × 19 mm full metal jacket (FMJ) Parabellum projectile. The main aim of the work was to check the effectiveness of such solutions in soft ballistic protection applications and to select the most effective variant of 3D printed structure. Results of the numerical analysis showed a high potential for 3D printed structures made of titanium alloys to be used for bulletproof vest inserts. In all analyzed cases the projectile was stopped by the armor. In addition, thanks to the cooperation of adjacent cells, the projectile energy density was distributed over a large area, as evidenced by large volumes of hollows in the ballistic clay. The indentations in the ballistic clay obtained in the simulations were significantly lower than the acceptable value for the back face deformation (BFD) parameter required by international body armor standards.

This article presents an analysis of the effectiveness of available numerical techniques in mapping the characteristic behavior of ballistic ceramics under projectile impact conditions. As part of the work, the ballistic tests were performed on the layered ceramic/steel composite armor and tested with the 7.62 × 39 mm, armor-piercing incendiary (API) BZ projectile. The experimental tests were then mapped using computer simulations. In numerical analyses, four different techniques were used to describe cubic ceramic tiles Al₂O₃ placed on the ARMOX 500T steel backing plate, i.e.,: the Finite Element Method without Erosion (FEM), Finite Element with erosion (FEM + Erosion), Smoothed Particles Hydrodynamics (SPH) and a hybrid method that converts finite elements to SPH particles after exceeding the defined failure criteria (FEM to SPH conversion). The effectiveness of the individual methods was compared in terms of quality (mapping of characteristic phenomena occurring during the penetration process), quantity (bulge height of the backing plate) and time needed to complete the calculations. On the basis of the results of the experiments and numerical simulations, it was noticed that the most accurate reproduction of the phenomenon of ballistic impact of AP projectiles on ceramic/steel composite armor can be obtained by using a hybrid method, incorporating the conversion of finite elements into SPH particles. This method should be used in cases where accuracy of the results is more important than the time required to complete the calculations. In other situations where the purpose of the calculation is not to determine, for example, the exact value of penetration depth but only to observe a certain trend, the FEM method with defined erosion criteria (variant 2), which is more than 10 times faster, can be successfully used.

Analyses presented in the article were carried out in order to characterize the main parameters of the shaped charge jet formed due to detonation of the PG-7VM warhead. As opposed to the previously published studies in which rolled homogeneous armored steel was mainly used as a target, in the current work the warhead penetration capability was determined against more contemporary high-hardness (500 HB) ARMSTAL 30PM steel armor with precisely determined mechanical properties. The research included experimental depth of penetration tests and their numerical reproduction in the LS-Dyna software. Special attention was paid to factors that could perturbate the shaped charge jet formation process and under- or overestimate its penetration capability. For this reason, warheads were X-ray inspected for structural discrepancies (voids or air inclusions in explosive, misalignment between the body, explosive, and liner, or lack of contact between the explosive and the liner) and properties of materials (explosive, targets, and most important warhead components) were analyzed before the experiments. The numerical model of the warhead was defined more accurately than in previously published studies, since it was based on the real grenade dimensions and its technical documentation. Thanks to this, the depth of penetration of the target made of ARMSTAL 30PM armored steel plates by the shaped charge jet formed from the PG-7VM warhead obtained by numerical simulation was consistent with the experimental results and equaled 278 mm and 280 mm, respectively. The difference between the experimental and numerical value was smaller than 1%, which confirms that the developed methodology of modeling allows users to properly reproduce the PG-7VM shaped charge jet formation and target penetration processes. A verified numerical model of the shaped charge jet penetration into a steel target was used to determine depth of penetration in function of stand-off distance for the PG-7VM warhead. A maximum depth of penetration of about 317 mm was obtained for the stand-off distance of 360 mm, which may indicate the potential direction of modernization of warheads.

The main aim of the work was the experimental and numerical analysis of the energy absorption/dissipation capabilities and failure mechanisms of novel hyper-elastic target material intended for ballistic applications including layers of composite armors, projectile catching systems and anti-ricochet layers covering walls of shooting ranges, ballistic tunnels, etc. Static and dynamic mechanical properties of the material were analyzed at both room and elevated temperatures ( $$40\div 80\,^{\circ }\hbox {C}$$40 ÷ 80 ∘ C ). Numerical models of the material and $$7.62\times 25$$7.62 × 25 mm FMJ projectile were defined. Simulations of the hyper-elastic target penetration with the projectile were carried out. The differences between the results obtained numerically and experimentally were determined (measured as a relative error) and were lower than 15% what testified about proper definition of the numerical models of the analyzed phenomenon components.