Design and Ballistic Performance Assessment of Pattern-Optimized Lightweight Composite Armor Using ANSYS Explicit Dynamic and AUTODYN

Open Access

Year : 2026 | Volume : 14 | Issue : 01 | Page : 174 190
    By

    Shah Nusrat Jahan Shanta,

  • Abdus Sattar Mollah,

  1. Research Assistant, Department of Nuclear Science and Engineering, Military Institute of Science and Technology (MIST), Mirpur Cantonment, Mirpur, Dhaka-1216, , Bangladesh
  2. Professor, Department of Nuclear Science and Engineering, Military Institute of Science and Technology (MIST), Mirpur Cantonment, Mirpur, Dhaka-1216, , Bangladesh

Abstract

This study investigates the ballistic performance of lightweight composite armor panels designed to defeat 9 mm full-metal-jacket (FMJ) threats using high-fidelity numerical simulations. Four different composite materials were arranged into panels of identical overall dimensions; only the internal segment pattern was varied to explore geometric resistance effects while keeping mass and material type controlled. Ballistic impact simulations were performed using ANSYS Explicit Dynamics and AUTODYN to capture high-strain-rate behavior, local perforation, delamination, and energy dissipation mechanisms. A systematic pattern screening identified a resisting layout that maximizes projectile energy absorption and minimizes rear face deformation. Based on that layout, an additional design iteration produced a lowest mass sample targeted at the BR2 class threat conditions for 9 mm projectiles (GOST BR series). Simulation outputs evaluated included residual projectile velocity, back-face deformation, strain, and damage maps, and component-wise energy absorption. Results demonstrate that pattern optimization without changing base material or panel footprint can substantially improve ballistic performance and enable significant mass reduction while maintaining protection against the specified 9 mm FMJ threat. The combined use of ANSYS Explicit Dynamics and AUTODYN provided complementary insight into early perforation events and later-stage structural fragmentation, informing practical design recommendations for lightweight composite armor. Future work will validate the numerical findings with controlled ballistic testing and refine manufacturing approaches for the optimal pattern identified.

Keywords: ANSYS explicit dynamics, AUTODYN simulation, ballistic performance, failure analysis, lightweight composite, pattern-optimized armor

[This article belongs to Journal of Polymer & Composites ]

How to cite this article:
Shah Nusrat Jahan Shanta, Abdus Sattar Mollah. Design and Ballistic Performance Assessment of Pattern-Optimized Lightweight Composite Armor Using ANSYS Explicit Dynamic and AUTODYN. Journal of Polymer & Composites. 2026; 14(01):174-190.
How to cite this URL:
Shah Nusrat Jahan Shanta, Abdus Sattar Mollah. Design and Ballistic Performance Assessment of Pattern-Optimized Lightweight Composite Armor Using ANSYS Explicit Dynamic and AUTODYN. Journal of Polymer & Composites. 2026; 14(01):174-190. Available from: https://journals.stmjournals.com/jopc/article=2026/view=236673


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Regular Issue Open Access Original Research
Volume 14
Issue 01
Received 04/12/2025
Accepted 15/12/2025
Published 14/01/2026
Publication Time 41 Days
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