FROM FILAMENTS TO FABRIC PACKS – SIMULATING THE PERFORMANCE

OF TEXTILE PROTECTION SYSTEMS

1 1 1 2 2
B.A. Cheeseman , C.F. Yen , B.R. Scott , B. Powers and T.A. Bogetti
U.S. Army Research Laboratory, Aberdeen Proving Ground, MD 21005-5069
1 2
AMSRD-ARL-WM-MD, AMSRD-ARL-WM-MB

B. LaMattina*
U.S. Army Research Office, Research Triangle Park, NC 27709

Y. Duan and M. Keefe

Center for Composite Materials, University of Delaware, Newark, DE 19716

Y. Miao and Y. Wang

Department of Mechanical and Nuclear Engineering, Kansas State University, Manhattan, KS 66506

ABSTRACT samurai. The advent of high velocity firearms made

protective textiles less effective, even with more recent
Enhancements in lightweight and compliant textile commercial glass fibers and nylons, until the development
based protection systems require the use of advanced of higher stiffness and strength filaments in the late 1960s.
materials as well as innovative reinforcement and The aramid material, Kevlar, ushered in a new era of
hybridization schemes. To date, the majority of the textile armor that continues to progress towards more
ballistic textile development has relied on experiments mass efficient systems that offer the soldier exceptional
and experience. While both analytical and computational protection. Yet as material advances continue, from
methods for this class of materials, specifically fabrics improved aramids to high molecular weight polyethylenes
and compliant composite laminates, has yielded insight, (Dyneema, Spectra) and beyond (PBZ, M5), the
advanced material models and modeling capabilities with development of textile armor systems that contain these
the resolution to accurately describe the interactions advanced materials are driven primarily by experiments
between the fibers, yarns and impacting projectile have and experience. Although there have been a number of
only recently become available. Scientists at the U.S. analytical models developed [Vinson and Zukas, 1975;
Army Research Laboratory and the U.S. Army Research Parga-Landa et al., 1995; Cunniff, 1999; Walker, 1999;
Office are collaborating with researchers in academia to Billon and Robinson, 2001; Phoenix, 2003] these models
develop and utilize advanced modeling capabilities for typically aren’t used to design armor systems as they
fabrics and armor grade composites used in body armor don’t directly relate the structure of the as-manufactured
designs. The technology being developed will ultimately textile to its corresponding ballistic performance. Rather,
relate the constituent material – the filament – to its the models serve as a first level screening tool and provide
incorporation into a textile architecture through its insight into the relative importance of specific material
manufacturing processes to a ballistic performance parameters that influence performance. Although, how a
prediction of the corresponding textile and will allow a ballistic textile is manufactured and its resulting
true materials-by-design approach to textile based configuration directly influences its behavior, details
protection systems. The current paper describes efforts about its manufacture such as yarn denier, end count, etc.,
associated with utilizing numerical analysis towards are much too detailed to be accurately accounted for in
gaining a fundamental understanding of the projectile- analytical techniques. Ballistic impacts into textile fabrics
textile interaction, the development of numerical present a challenging modeling environment involving
techniques relating textile manufacture to ballistic contact, complex stress and strain states with severe
prediction and hybridized systems currently being gradients, and friction between filaments and yarns. The
developed that can benefit from this detailed analysis. sensitivity of ballistic performance to these and other
mechanisms is not well understood. Highly detailed
1. INTRODUCTION numerical simulations, however, can be developed that
capture these complexities and provide insights into how
Compliant textile garments developed for protection the manufactured textile microstructure affects its
have been produced for thousands of years - from the performance. Ultimately, accurate simulations covering
layers of linen utilized by the ancient Greeks through multiple-scales (from a filament-to-fabric level) will be
medieval Japan, where layers of silk were worn by required to understand how manufacturing effects relate
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1. REPORT DATE 2. REPORT TYPE 3. DATES COVERED

01 NOV 2006 N/A -
4. TITLE AND SUBTITLE 5a. CONTRACT NUMBER
From Filaments To Fabric Packs Simulating The Performance Of Textile 5b. GRANT NUMBER
Protection Systems
5c. PROGRAM ELEMENT NUMBER

6. AUTHOR(S) 5d. PROJECT NUMBER

5e. TASK NUMBER

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U.S. Army Research Laboratory, Aberdeen Proving Ground, MD
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to the interaction between the material and the projectile. of constraining the backsurface of multiple plies of fabric,
The current effort will detail efforts that are Roylance et al., 1995. This technique was solved using
accomplishing this and providing insight on the important the method of characteristics by Leech and Adeyafa,
mechanisms that affect performance. 1982, and has since been utilized and extended by a
. number of other researchers to include additional
projectile geometries and edge conditions, Cunniff, 1992,
2. BACKGROUND nonlinear viscoelastic effects, Roylance and Wang, 1978,
multiple plies, Ting et al., 1993, yarn crimp, Shim et al.,
As textiles are comprised of many filaments, 1995, and slip at the yarn crossover points, Ting et al.,
arranged in bundles (yarns), which are subsequently 1999. Yet, the representation of the textile with this
assembled in some repeating (or, in the case of nonwoven approach does not truly represent the complex topology of
textiles - random) format, defining the continuum an actual woven or braided fabric and as noted by
perspective at which to model the material will dictate the Roylance, 1973, “the ballistic response of the textile
resolution of the results attained. If fabric is considered as structure depends on the response of the fiber with which
a continuum, the details of the projectile interaction with it is woven as well as the structural geometry itself.”
the yarns (and, by default, the filaments) will not be
attained. However, if fabric is considered a dense .
structure composed of individual yarns, and ultimately,
fibers, the complexity of this definition makes analytical
solutions to the problem intractable, but not numerical
ones.

Impact
Numerous researchers have taken the former
approach, whereby the fabric is defined to be the
continuum and represented as: a homogenous, isotropic
plate which deformed into a straight sided conical shell
when impacted by a projectile, Vinson and Zukas, 1975,
and Taylor and Vinson, 1990; a two dimensional isotropic
membrane, Phoenix and Porwal, 2002, an anisotropic
membrane, Simons and Shockey, 2001, with a
constitutive behavior represented as a system of linear
springs, Walker, 1999; or viscoelastic with rate dependent
failure, Lim, Shim, and Ng, 2003. While all of these Fig. 1. Graphical representation of impact into a pin-
efforts report reasonable success when compared with jointed representation of a textile.
experiment results, these approaches are inherently
limited as they cannot account for important details such
as yarn-yarn and projectile yarn interaction, which has 3. YARN LEVEL SIMULATIONS
been shown to influence the ballistic performance of the
system, Briscoe and Motamedi, 1992 and Bhatnagar, As detailed above, numerical simulations of textile
2006. However, recent efforts by Tabiei et al., King et al., protection systems are not new, but the resolution that can
2005, and Boljen and Hiermaier, 2006, have developed be attained has been greatly enhanced as computational
multiscale formulations that endeavor to account for the power has progressed. Cunniff, 1992, stated that at that
microstructural aspects of a textile within a membrane time, the cost of performing numerical simulations of a 50
formulation. layers of fabric modeled at the detail of the yarn
crossovers would be far in excess of building and testing
The latter approach was taken in the pioneering work the system. However, since this time, computational
of Roylance et al., 1973, who developed the simulation power has increased dramatically and numerical
techniques that advanced the analysis from impact into an simulations of textiles comprised of discrete yarns and
individual yarn to impact into a single ply of fabric. To multiple layers has become possible. Shockey et al.1997,
accomplish this, these researchers represented the yarns of were among the first researchers to perform finite element
a fabric as a system of pin-jointed bars, depicted in Figure simulations of impact into a fabric with each individual
1, and with this they were able to provide important yarn represented with solid finite elements. These
insights into the behavior of a fabric as it was struck with researchers analyzed the impact of a turbine fan blade,
a projectile. The technique allowed insight into the traveling approximately 80 m/s, on woven containment
importance of material parameters, such as fiber modulus shrouds. Using this same level of resolution, Duan et al,
and failure strain, Roylance and Wang, 1981, and system 2005, 2006, investigated the impact of steel spheres and
effects such as fiber slippage and the detrimental effects right circular cylinders of a single ply of Kevlar.
Thorough studies of the influence of friction between
yarns and between the yarn and projectiles gave insight 2006. In this study, individual yarns are modeled with
into the importance of friction in the projectile-textile multiple continuous membrane elements across the woven
interactions. Shown in Figure 2, a steel sphere impacts a yarn’s lateral surface. Note that the 8-node membrane
34x34 plain weave fabric having a) no friction between elements provide much improved computational
any of the interacting surfaces and b) having friction. The efficiency for the dynamic fabric analysis over the
boundary conditions are 2 sides clamped, 2 sides free. In commonly used 3D brick elements. Figure 3 shows the
the case with no friction, it is seen that the steel sphere deformed mesh of a layer of Kevlar® KM2 fabric
can wedge through the distended fabric. With friction, the subjected to normal impact of a steel cylindrical projectile
projectile has to break more yarns before it can penetrate at 249 m/sec. The frictional coupling and the density of
the fabric. In the simulations, friction, in general, does cross-overs was studied and shown to influence the timing
not act as a large energy dissipation mechanism. It is and extent of axial strains developed in the principally
apparent that the friction allows more of the yarns to stay loaded yarns. Figure 4 shows a typical result that
in contact with the projectile throughout the penetration compares the strain distributions in a yarn for various
event; thus allowing more energy to be lost as strain friction coefficients. It shows that the peak yarn strain,
energy and kinetic energy in the yarn. The simulations which is directly related to yarn failure, is significantly
allow the total energy to be partioned between strain increased as the friction coefficient reduced from 0.25 to
energy, kinetic energy, and energy dissipated by friction. 0. Real armor design variables include fabric construction
For the case with friction, 89% of the total kinetic energy and surface finish. It’s quite possible that the
the projectile lost was before yarn failure. 72% of the performance of fabric based body armor or fabric
energy went into strain energy, while 7% was dissipated reinforced composite armor could be improved following
by friction, and the kinetic energy of the fabric accounted application of lessons learned from these ongoing
10%. After the yarns started failing, the projectile lost an computational studies.
additional 11% of the energy, with the energy going into
kinetic and frictional energy.

(a) (a)

(b)

Fig. 2. Deformed mesh of a 34x34 Kevlar Fabric Layer

impacted by a spherical projectile (a) without friction)
(b)
and (b) with friction.
Fig. 3. (a) Deformed mesh of a 5x5 Kevlar fabric layer
Additional insight has also been gained from the
impacted by a cylindrical projectile and (b) close-up view
recent detailed simulations performed by Scott and Yen,
of impacted area.
 readily simulated unless techniques are developed that can
0.01
first simulate textile manufacturing processes and then the
0.008 perform impact and penetration calculations. This
0.006
capability is being developed and is described below.
0
0.004 0.25 4. DIGITAL ELEMENT ANALYSIS: SIMULATING
0.51
TEXTILE MANUFACTURING AND PREDICTING
Strain, cm/cm

0.002

0
BALLISTIC PERFORMANCE
0 0.5 1 1.5 2 2.5

-0.002
The Digital Element Analysis (DEA) was initially
-0.004 developed by Wang and Sun, 2000, Sun and Wang, 2001,
and Zhou, Sun and Wang, 2004 to simulate textile
-0.006
manufacturing processes. Depicted in Figure 5 are the
-0.008 three concepts that define the DEA approach to textile
-0.01
manufacturing simulations: namely, the digital chain, the
Distance Along Yarn From Impact Center, cm contact of digital chains and yarn assembly. As depicted
0.025
in Fig. 5(a), a digital chain is composed of many rod-
elements, defined here as “digital elements”. Frictionless
0.02 pins connect the rod elements. As the length of rod
0
0.25
elements approaches zero, the digital chain becomes fully
0.015 0.51 flexible and can be taken to be the physical representation
Strain, cm/cm

of the fiber or filament. Fig. 5(b) illustrates the contact

0.01 between two digital chains. When the element length
approaches zero, contact between two digital chains can
0.005
be represented by contact between nodes from two
neighboring chains. If the distance between two nodes is
0
smaller than the diameter of the digital chain, a contact
0 0.5 1 1.5 2 2.5 element is added between them. The contact element can
support both compressive and shear (friction) forces. In
-0.005

Distance Along Yarn From Impact Center, cm

reality, a yarn is composed of many fibers and therefore,
in the digital element approach, a yarn is modeled as an
Figure 4. Strain distributions along impacted yarn for assembly of digital chains, as shown in Fig. 5(c). Once
various friction coefficients at (top) 1.3 microseconds and yarns are assembled from the digital chains, a global
(bottom) 2.8 microoseconds. stiffness matrix can be determined and the fabric response
to external loads can be derived in a procedure similar to
Although the development of these detailed finite finite element analysis. Textile manufacturing processes
meshes is labor intensive, this has not dissuaded a number such as weaving, braiding, and three-dimensional weaving
of other researchers from advancing these detailed can be simulated and processing limitations, such as yarn
simulations and incorporating refinements such as jamming, can be determined, along with the
multiple layers, Gu, 2004, Barauskas and Abraitiene, corresponding microstructure and topology of the
2006, different weaves, Boljen and Hiermaier, 2006 and resultant textile. This can be extremely helpful with
recently, efforts have been made by Zohdi and Powell, braided and three-dimensionally reinforced textiles, as the
2006, to model the fabric on the filamentary scale. track of the yarns and filaments becomes extremely
difficult to visualize (and therefore, difficult to mesh).
All of these yarn-level efforts start with the as- Fig. 6(a) and (b) shows a 2D woven and 3-D braided
received textile product, where the geometry of the finite fabric, respectively, generated using the digital element
element mesh is developed from measurements and approach and Figure 7(a) and (b) show a comparison of
pictures of the textile cross-sections. For standard plain the simulated cross sections with that of actual textiles.
woven products, this is a readily feasible, albeit, time Excellent agreement is noted with both cases. With the
consuming process. However, some current optimized digital element approach, the fiber-level micro-structure
textile protective systems are not just utilizing layers of can be derived and both the yarn paths and cross-sectional
plain weave fabrics. As hybridized systems can become shapes can be defined for most any textile manufacturing
very complex (i.e. yarns can be comprised of more than process, including multilayer weaves with three
one material, weaves can consist of yarns of different dimensional reinforcement. It should also be noted that
materials or deniers, and layers could be comprised of hybridization on a filamentary and yarn level can be
different materials or even different weaves or textiles). readily accomplished.
Ultimately, such optimized, hybridized systems cannot be
 Currently, the analysis is being validated with high
resolution experimental data and is being extended to
incorporate additional details of the filament including its
shear failure, its stochastic strength and the strain rate
dependency of both the strength and failure that has been
observed in both aramids, Cheng, Chen and
(a) Weerasooriya, 2005, and high molecular weight
polyethylenes, Huang, Wang and Xia, 2004. Further
enhancements that are ongoing are the parallelization of
the code to allow for very large scale computations.
Microscopic
picture

19 chain
yarn model
(b)
37 chain
yarn model
52 chain
yarn model
67 chain
yarn model

(c) (a)

Fig. 5. (a) Digital chain is composed of many digital rod

elements connected by frictionless pins; (b) contact
between adjacent digital chains; (c) yarn can be Microscopic
represented as a multitude of digital chains, here 37 picture
chains are utilized.

19 chain
yarn model

(b)
Fig. 7. Comparison of cross-sections of DEA simulation
and actual textile for (a) weaving and (b) braiding.

This numerical simulation tool, which directly links

(a) (b) textile manufacturing from a near filament level to an end
state ballistic prediction, will truly allow a 'materials by
design' approach to textile protection systems, including
Fig. 6. (a) DEA simulation of weaving and (b) braiding.
the hybridization of yarns, weaves and layers, unusual
textile architectures and tailored through thickness
Recently, Wang, Miao and Cheeseman, 2006, have
reinforcements.
extended the capabilities of the DEA to include an explicit
formulation suitable to impact and penetration analysis.
5. HYBRIDIZATION AND NOVEL
With this capability, the DEA can first simulate the
ENHANCEMENT
manufacture of a textile and then simulate impact and
penetration of the as-manufactured textile. Figure 8
While the simulation technology is almost to the
shows a plain woven fabric generated using the DEA with
point of assisting in the design of these systems, the
yarns composed of five digital chains being impacted by a
optimization of these systems is progressing. As
rigid sphere. The phenomenology of the impact and
mentioned above, the utilization of uniform layers of plain
penetration is very similar to the analysis detailed above;
weave fabrics may not be the most mass efficient method
however, the DEA can probe the complexities of the
of achieving ballistic performance. This can be seen in
interactions occurring on a near filamentary level.
the most recent generations of the Interceptor Outer ballistic testing that produced V50 values between 9.5%
Tactical Vest (OTV), which have been hybridized, Zheng, and 13.4% higher for .22 FSP and 9mm projectiles,
2006. Hybridization can occur at the yarn level by respectively, when compared to conventional 2-D fabric
incorporating dissimilar filaments into a yarn; at the fabric of the same denier. Many factors may be involved in the
level, by weaving different materials and/or yarn deniers; optimization of these 3-D hybrid materials. Factors such
at the ply level, by layering with different weaves, as the amount of needling, type of batt, and lay-up may
nonwovens and/or other materials. Hybridized systems of prove to be extremely important. Research studying these
Kevlar and high molecular weight polyethylenes (HMPE) concepts is ongoing but it is believed that the needling and
have been shown to have superior ballistic performance felting inhibit the spreading of individual tows and
when compared to systems possessing the 100% Kevlar or increases the number of fibers that interact with the
100% HMPE, Bhatnagar, 2006, and additionally, projectile. This 3-D hybrid material may provide a
combinations of non-woven felts and other textile method to improve performance of textile based
products have been shown to be advantageous over protective clothing using currently available fibers. If
conventional textile materials for NIJ Level IIIA threats, successful, body armor designs will be able to take
Thomas, 2006. advantage of a simplified manufacturing process because
fewer layers of material will be involved in the counting
Side procedure.
View
As the potential for performance improvements from
hybridization are apparent, the textile design variables that
could be investigated are numerous in addition to human
Bottom factors such as comfort, flexibility, and heat dissipation.
View Maturing the simulation technology to assist in guiding
these efforts is warranted and prudent.
2.5 μs 9.8 μs 12.2 μs
6. CONCLUDING REMARKS
Fig. 8. DEA analysis of rigid sphere impacting a plain
weave fabric. Note the fabric was created with the DEA As computational power has increased, the detail that
with yarns comprised of five digital chains. can be achieved in simulating the impact into textile
protective systems has followed. Current efforts can
In other work being conducted by Tex Tech Industries reliably model yarn-level detail and provide insight into a
and the University of Maine an array of different weave number of mechanisms important to the penetration
styles and non-woven felts are being combined along with process. However, as hybridized systems and novel
a needling process to create a novel through thickness reinforcement schemes are being investigated, an even
reinforced (3-D) hybrid ballistic fabric, Farrell and Erb more refined multi-scale analysis is needed and is being
2006. developed. The DEA technique can simulate from a near
filament level the manufacturing of a textile and then
3
2 utilize the manufactured textile and simulate it subjected
to the impact and penetration by a projectile. Methods
such as DEA are becoming increasingly important for
several reasons: (1) our military is facing an increased
1 number of different threats that are rapidly adapted to
counter our fielded protection systems and (2) nano-
science is beginning to develop new fiber systems that
may provide a substantial leap in our protection
capabilities. These high resolution computational
methods will enhance our capability for adapting to new
threats and integrating new materials as they become
available. They may help enable us to optimize the
performance of our future protection systems at an
accelerated pace as compared to today’s development
cycle. This capability is currently being developed and
2 will allow a true materials-by-design approach to textile
Fig. 9. Hybridization concept involving traditional based protection systems.
weaves, felts and needling (furnished by TexTech
Industries)

These fabric packs have shown promise in preliminary

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