A B S T R A C T Shear thickening fluids (STFs) are a special class of field responsive non-Newton... more A B S T R A C T Shear thickening fluids (STFs) are a special class of field responsive non-Newtonian fluids which exhibit transition from low viscosity to high viscosity state when these are subjected to shear deformation, particularly when the shear rate exceeds a critical value termed as the critical shear rate (CSR). Due to this unique characteristic of STFs, these are generally used for vibration mitigation or shock absorbance such as in vibration dampeners, hip protection pads, in protective gear for athletes etc. From the last two decades, STFs have found application in the field of ballistics, particularly in the development of special class of STF-intercalated armours called Liquid Body Armours (LBAs). These new age armours are lighter in weight and more flexible as compared to conventional heavy armours, which, infact seriously affect the mobility and agility of the soldier, especially in combat situations. Although, exhaustive studies are available which show the improvement in impact resistance of STF-treated high performance fabrics, but there are limited studies which explore the efficacy of STF treatment method. In this study, an attempt is made to understand this aspect. The low velocity impact studies were conducted on drop tower machine, while high velocity impact studies were accomplished on in-house designed and fabricated Split Hopkinson Pressure Bar (SHPB) experimental setup. It was observed that when STF was kept in liquid form between layers of ballistic fabrics, the composite exhibited reduced performance, whereas, STF-treated ballisic composites exhibited enhanced impact toughness at high strain rates in SHPB testing.
In the present work, dynamic compression response of polypropylene (PP) based composites reinforc... more In the present work, dynamic compression response of polypropylene (PP) based composites reinforced with Kevlar/Basalt fabrics was investigated. Two homogeneous fabrics with Kevlar (K3D) and Basalt (B3D) yarns and one hybrid (H3D) fabric with a combination of Kevlar/Basalt yarns were produced. The architecture of the fabrics was three-dimensional angle-interlock (3D-A). Three different composite laminates were manufactured using vacuum-assisted compression molding technique. The high strain rate compression loading was applied using a Split-Hopkinson Pressure Bar (SHPB) setup at a strain rate regime of 3633e5235/s. The results indicated that the dynamic compression properties of thermoplastic 3D-A composites are strain rate sensitive. In all the composites, the peak stress, toughness and modulus were increased with strain rate. However, the strain at peak stress of Basalt reinforced composites (B3D, H3D) decreased approximately by 25%, while for K3D specimens it increased approximately by 15%. The K3D composites had a higher strain rate as compared to the B3D and H3D composites. In the case of K3D composite, except strain at peak stress, remaining dynamic properties were lower than the B3D composite , however, hybridization increased these properties. The failure mechanisms of 3D-A composites were characterized through macroscopic and scanning electron microscopy (SEM).
Shear thickening is a non-Newtonian flow behavior characterized by the increase in apparent visco... more Shear thickening is a non-Newtonian flow behavior characterized by the increase in apparent viscosity with the increase in applied shear rate, particularly when the shear rate exceeds a critical value termed as the critical shear rate (CSR). Due to this remarkable property of shear-thickening fluids (STFs), they are extensively used in hip protection pads, protective gear for athletes, and more recently in body armor. The use of STFs in body armor has led to the development of the concept of liquid body armor. In this study, the effect of particle size is explored on the low and high strain rate behavior of nanosilica dispersions, so as to predict the efficacy of STF-aided personal protection systems (PPS), specifically for ballistic applications. The low strain rate study was conducted on cone and plate rhe-ometer, whereas the high strain rate characterization of STF was conducted on in-house fabricated split Hop-kinson pressure bar (SHPB) system. Spherical nanosilica particles of three different sizes (100, 300, and 500 nm) as well as fumed silica particles of four different specific surface areas (Aerosil A-90, A-130, A-150, and A-200), respectively, were used in this study. The test samples were prepared by dispersing nanosilica particles in polypropylene glycol (PPG) using ultrasonic homogenization method. The low strain rate studies aided in determining the CSR of the synthesized STF dispersions, whereas the high strain rate studies explored the impact-resisting ability of STFs in terms of the impact toughness and the peak stress attained during the impact loading of STF in SHPB testing.
Modern and sophisticated ammunition systems have necessitated the development of advanced ballist... more Modern and sophisticated ammunition systems have necessitated the development of advanced ballistic protection personal armour systems that are damage resistant, flexible, lightweight and possess high energy absorbing/dissipating capacity. Although, exhaustive studies are available which show the improvement in impact resistance of STF-treated high performance fabrics, but there are limited studies which explore the efficacy of STF impregnation method. In this study, an attempt is made to understand this aspect. The low velocity impact studies were conducted on drop tower machine, while high velocity impact studies were accomplished on Split Hopkinson Pressure Bar (SHPB). High impact Poly Propylene Co-polymer (CO15EG) and UHMWPE variants Gold Shield ® and Spectra Shield were chosen for this study. It was observed that when STF was kept in liquid form between layers of ballistic fabrics, the composite exhibited reduced performance, whereas, when STF was impregnated in a ballistic fabric it had a synergistic effect to enhance the impact toughness of ballistic composite.
The high strain rate impact performance of STF-treated Gold shield UHMWPE composite is experi... more The high strain rate impact performance of STF-treated Gold shield UHMWPE composite is experimentally investigated on in-house designed and fabricated SHPB apparatus.
Characterization of Kevlar-Polypropylene based composite material system under high strain rate l... more Characterization of Kevlar-Polypropylene based composite material system under high strain rate loading has been investigated using Split Hopkinson Pressure Bar (SHPB) test for varying specimen aspect ratios. Flat laminates of 16, 24 and 30 layered Kevlar composite were compression molded and laser machining to get cylindrical specimens of desired aspect ratios. Based on SHPB experiments, stress-strain plots were obtained and analysed to reveal compressive material behaviour as function of growing strain rate. The peak stress, strain and toughness exhibited considerable increase with growing strain rate of loading. With increasing strain rates peak specimen stress increased by 90%, for lowest thickness composite. The aspect ratio studies suggests application of thin laminates for better performance of composite laminates.
The high strain rate impact performance of STF is experimentally investigated on inhouse design... more The high strain rate impact performance of STF is experimentally investigated on inhouse designed and fabricated SHPB apparatus.
In order to face the grand challenge of characterizing soft and light armour material system shav... more In order to face the grand challenge of characterizing soft and light armour material system shaving polymers and shear thickening fluids under impacts at high strain rates lead to design and development of this particular SHPB set up. The developed set up is designed for a maximum firing pressure of 300 bar of nitrogen gas and it comprises automated gas filling and firing, striker bar velocity recording and data acquisition system. Pressure bars are made of titanium alloy due to its high yield strength and reasonably lower density which could protect plastic deformation, wave dispersion and reduces impedance mismatch with the intended soft specimens, unlike maraging steel bars. The maximum stresses on the critical parts of the setup are crosschecked with simulation results and compared with corresponding yield strengths. Velocity-pressure calibration of the developed setup shows higher velocities can be achieved at any particular pressure, when it is compared with the existing public domain velocity calibration of SHPB setup.
Kevlar ® fabric reinforced plastics (KFRPs) are specialized composites with multiple layers of fa... more Kevlar ® fabric reinforced plastics (KFRPs) are specialized composites with multiple layers of fabrics (~ranging from 20 to 50 layers) designed for high impact applications. In this work, Kevlar-129 fiber was reinforced with polyetherimide (PEI) and polypropylene (PP) to obtain two groups of laminates in three configurations i.e. 16, 24 and 30 layers. Holes of diameter 11.6 mm were profile cut using fiber laser machining system operating at 1070 nm wavelength. Effects of polymeric matrix on the failure of the Kevlar e polyetherimide (K-PEI) and Kevlar e polypropylene (K-PP) laminates were characterized by studying the following: (i) threshold laser power required to make the holes (ii) surface morphology using scanning electron microscopy (iii) damage zone along the laser cut path using scanning acoustic microscopy and optical microscopy. K-PEI laminates underwent material separation at much lesser line energy (ratio of laser power to velocity) than K-PP laminates during laser machining. Scanning electron microscopy (SEM) was used to further analyze the laser cut surfaces. A prominent observation on the laser-irradiated surface was: less recast/resolidified polymer covered the Kevlar fabric in K-PEI as compared to a thicker polymeric layer in K-PP. Heat affected zone and damage factors were evaluated using scanning acoustic microscopy (SAM). Surface roughness and kerf width were also analyzed to understand the effect of laser machining of Kevlar laminates.
In this study, microcellular Acrylonitrile-Butadiene-Styrene foams with high cell density and exp... more In this study, microcellular Acrylonitrile-Butadiene-Styrene foams with high cell density and expansion ratio has been manufactured using ultrasound-induced nucleation technique in solid-state batch foaming process. Influence of sonication time, sonication frequency, and ultrasound power were found very crucial in designing of cellular morphology. The initial 10 s of ultrasound exposure was found to influence the foam morphology critically. Longer periods of ultrasound exposure developed foams with lower average cell size as compared to foams developed with lesser ultrasound exposure time. Higher sonication power resulted in foams with uniform morphology and higher cell densities as compared to foams developed with lower sonication intensities. Finally, the ultrasonic frequency was also found to influence the morphology intensely. Low frequency sonication resulted in foams with uniform cell distribution, whereas high frequency sonication developed bimodal microcellular type of microstructure. The results coherently demonstrate that with the advent of ultrasonic waves, the energy barrier for cell nucleation swiftly decreases which enhances the cell density in the final foamed product.
Machining of fiber reinforced plastic (FRP) components is often needed in spite of the fact that ... more Machining of fiber reinforced plastic (FRP) components is often needed in spite of the fact that most FRP structures can be made to near net shape. The material removal mechanism of FRP is very difficult as compared with metals due to their inherent inhomogeneity and anisotropy. This results in frequent fiber pullout, delamination, matrix burning, and other damages leading to poor cut surface quality. A finite element model is proposed to quantify the material damage, which has been experimentally validated by means of nondestructive dyepenetrant testing. Good agreement is observed for laminates with fiber orientations up to 60 . Divergence is noticed for higher fiber orientations, and the discrepancies increase with increasing fiber orientation. Proper interfacial properties vis-a`-vis machining of FRP materials are considered to be the main reasons for the divergence.
A B S T R A C T Shear thickening fluids (STFs) are a special class of field responsive non-Newton... more A B S T R A C T Shear thickening fluids (STFs) are a special class of field responsive non-Newtonian fluids which exhibit transition from low viscosity to high viscosity state when these are subjected to shear deformation, particularly when the shear rate exceeds a critical value termed as the critical shear rate (CSR). Due to this unique characteristic of STFs, these are generally used for vibration mitigation or shock absorbance such as in vibration dampeners, hip protection pads, in protective gear for athletes etc. From the last two decades, STFs have found application in the field of ballistics, particularly in the development of special class of STF-intercalated armours called Liquid Body Armours (LBAs). These new age armours are lighter in weight and more flexible as compared to conventional heavy armours, which, infact seriously affect the mobility and agility of the soldier, especially in combat situations. Although, exhaustive studies are available which show the improvement in impact resistance of STF-treated high performance fabrics, but there are limited studies which explore the efficacy of STF treatment method. In this study, an attempt is made to understand this aspect. The low velocity impact studies were conducted on drop tower machine, while high velocity impact studies were accomplished on in-house designed and fabricated Split Hopkinson Pressure Bar (SHPB) experimental setup. It was observed that when STF was kept in liquid form between layers of ballistic fabrics, the composite exhibited reduced performance, whereas, STF-treated ballisic composites exhibited enhanced impact toughness at high strain rates in SHPB testing.
In the present work, dynamic compression response of polypropylene (PP) based composites reinforc... more In the present work, dynamic compression response of polypropylene (PP) based composites reinforced with Kevlar/Basalt fabrics was investigated. Two homogeneous fabrics with Kevlar (K3D) and Basalt (B3D) yarns and one hybrid (H3D) fabric with a combination of Kevlar/Basalt yarns were produced. The architecture of the fabrics was three-dimensional angle-interlock (3D-A). Three different composite laminates were manufactured using vacuum-assisted compression molding technique. The high strain rate compression loading was applied using a Split-Hopkinson Pressure Bar (SHPB) setup at a strain rate regime of 3633e5235/s. The results indicated that the dynamic compression properties of thermoplastic 3D-A composites are strain rate sensitive. In all the composites, the peak stress, toughness and modulus were increased with strain rate. However, the strain at peak stress of Basalt reinforced composites (B3D, H3D) decreased approximately by 25%, while for K3D specimens it increased approximately by 15%. The K3D composites had a higher strain rate as compared to the B3D and H3D composites. In the case of K3D composite, except strain at peak stress, remaining dynamic properties were lower than the B3D composite , however, hybridization increased these properties. The failure mechanisms of 3D-A composites were characterized through macroscopic and scanning electron microscopy (SEM).
Shear thickening is a non-Newtonian flow behavior characterized by the increase in apparent visco... more Shear thickening is a non-Newtonian flow behavior characterized by the increase in apparent viscosity with the increase in applied shear rate, particularly when the shear rate exceeds a critical value termed as the critical shear rate (CSR). Due to this remarkable property of shear-thickening fluids (STFs), they are extensively used in hip protection pads, protective gear for athletes, and more recently in body armor. The use of STFs in body armor has led to the development of the concept of liquid body armor. In this study, the effect of particle size is explored on the low and high strain rate behavior of nanosilica dispersions, so as to predict the efficacy of STF-aided personal protection systems (PPS), specifically for ballistic applications. The low strain rate study was conducted on cone and plate rhe-ometer, whereas the high strain rate characterization of STF was conducted on in-house fabricated split Hop-kinson pressure bar (SHPB) system. Spherical nanosilica particles of three different sizes (100, 300, and 500 nm) as well as fumed silica particles of four different specific surface areas (Aerosil A-90, A-130, A-150, and A-200), respectively, were used in this study. The test samples were prepared by dispersing nanosilica particles in polypropylene glycol (PPG) using ultrasonic homogenization method. The low strain rate studies aided in determining the CSR of the synthesized STF dispersions, whereas the high strain rate studies explored the impact-resisting ability of STFs in terms of the impact toughness and the peak stress attained during the impact loading of STF in SHPB testing.
Modern and sophisticated ammunition systems have necessitated the development of advanced ballist... more Modern and sophisticated ammunition systems have necessitated the development of advanced ballistic protection personal armour systems that are damage resistant, flexible, lightweight and possess high energy absorbing/dissipating capacity. Although, exhaustive studies are available which show the improvement in impact resistance of STF-treated high performance fabrics, but there are limited studies which explore the efficacy of STF impregnation method. In this study, an attempt is made to understand this aspect. The low velocity impact studies were conducted on drop tower machine, while high velocity impact studies were accomplished on Split Hopkinson Pressure Bar (SHPB). High impact Poly Propylene Co-polymer (CO15EG) and UHMWPE variants Gold Shield ® and Spectra Shield were chosen for this study. It was observed that when STF was kept in liquid form between layers of ballistic fabrics, the composite exhibited reduced performance, whereas, when STF was impregnated in a ballistic fabric it had a synergistic effect to enhance the impact toughness of ballistic composite.
The high strain rate impact performance of STF-treated Gold shield UHMWPE composite is experi... more The high strain rate impact performance of STF-treated Gold shield UHMWPE composite is experimentally investigated on in-house designed and fabricated SHPB apparatus.
Characterization of Kevlar-Polypropylene based composite material system under high strain rate l... more Characterization of Kevlar-Polypropylene based composite material system under high strain rate loading has been investigated using Split Hopkinson Pressure Bar (SHPB) test for varying specimen aspect ratios. Flat laminates of 16, 24 and 30 layered Kevlar composite were compression molded and laser machining to get cylindrical specimens of desired aspect ratios. Based on SHPB experiments, stress-strain plots were obtained and analysed to reveal compressive material behaviour as function of growing strain rate. The peak stress, strain and toughness exhibited considerable increase with growing strain rate of loading. With increasing strain rates peak specimen stress increased by 90%, for lowest thickness composite. The aspect ratio studies suggests application of thin laminates for better performance of composite laminates.
The high strain rate impact performance of STF is experimentally investigated on inhouse design... more The high strain rate impact performance of STF is experimentally investigated on inhouse designed and fabricated SHPB apparatus.
In order to face the grand challenge of characterizing soft and light armour material system shav... more In order to face the grand challenge of characterizing soft and light armour material system shaving polymers and shear thickening fluids under impacts at high strain rates lead to design and development of this particular SHPB set up. The developed set up is designed for a maximum firing pressure of 300 bar of nitrogen gas and it comprises automated gas filling and firing, striker bar velocity recording and data acquisition system. Pressure bars are made of titanium alloy due to its high yield strength and reasonably lower density which could protect plastic deformation, wave dispersion and reduces impedance mismatch with the intended soft specimens, unlike maraging steel bars. The maximum stresses on the critical parts of the setup are crosschecked with simulation results and compared with corresponding yield strengths. Velocity-pressure calibration of the developed setup shows higher velocities can be achieved at any particular pressure, when it is compared with the existing public domain velocity calibration of SHPB setup.
Kevlar ® fabric reinforced plastics (KFRPs) are specialized composites with multiple layers of fa... more Kevlar ® fabric reinforced plastics (KFRPs) are specialized composites with multiple layers of fabrics (~ranging from 20 to 50 layers) designed for high impact applications. In this work, Kevlar-129 fiber was reinforced with polyetherimide (PEI) and polypropylene (PP) to obtain two groups of laminates in three configurations i.e. 16, 24 and 30 layers. Holes of diameter 11.6 mm were profile cut using fiber laser machining system operating at 1070 nm wavelength. Effects of polymeric matrix on the failure of the Kevlar e polyetherimide (K-PEI) and Kevlar e polypropylene (K-PP) laminates were characterized by studying the following: (i) threshold laser power required to make the holes (ii) surface morphology using scanning electron microscopy (iii) damage zone along the laser cut path using scanning acoustic microscopy and optical microscopy. K-PEI laminates underwent material separation at much lesser line energy (ratio of laser power to velocity) than K-PP laminates during laser machining. Scanning electron microscopy (SEM) was used to further analyze the laser cut surfaces. A prominent observation on the laser-irradiated surface was: less recast/resolidified polymer covered the Kevlar fabric in K-PEI as compared to a thicker polymeric layer in K-PP. Heat affected zone and damage factors were evaluated using scanning acoustic microscopy (SAM). Surface roughness and kerf width were also analyzed to understand the effect of laser machining of Kevlar laminates.
In this study, microcellular Acrylonitrile-Butadiene-Styrene foams with high cell density and exp... more In this study, microcellular Acrylonitrile-Butadiene-Styrene foams with high cell density and expansion ratio has been manufactured using ultrasound-induced nucleation technique in solid-state batch foaming process. Influence of sonication time, sonication frequency, and ultrasound power were found very crucial in designing of cellular morphology. The initial 10 s of ultrasound exposure was found to influence the foam morphology critically. Longer periods of ultrasound exposure developed foams with lower average cell size as compared to foams developed with lesser ultrasound exposure time. Higher sonication power resulted in foams with uniform morphology and higher cell densities as compared to foams developed with lower sonication intensities. Finally, the ultrasonic frequency was also found to influence the morphology intensely. Low frequency sonication resulted in foams with uniform cell distribution, whereas high frequency sonication developed bimodal microcellular type of microstructure. The results coherently demonstrate that with the advent of ultrasonic waves, the energy barrier for cell nucleation swiftly decreases which enhances the cell density in the final foamed product.
Machining of fiber reinforced plastic (FRP) components is often needed in spite of the fact that ... more Machining of fiber reinforced plastic (FRP) components is often needed in spite of the fact that most FRP structures can be made to near net shape. The material removal mechanism of FRP is very difficult as compared with metals due to their inherent inhomogeneity and anisotropy. This results in frequent fiber pullout, delamination, matrix burning, and other damages leading to poor cut surface quality. A finite element model is proposed to quantify the material damage, which has been experimentally validated by means of nondestructive dyepenetrant testing. Good agreement is observed for laminates with fiber orientations up to 60 . Divergence is noticed for higher fiber orientations, and the discrepancies increase with increasing fiber orientation. Proper interfacial properties vis-a`-vis machining of FRP materials are considered to be the main reasons for the divergence.
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