Effect of Lode angle incorporation into a fracture criterion in predicting the ballistic resistance of 2024-T351 aluminum alloy plates struck by cylindrical projectiles with different nose shapes

The aim of the present paper is to evaluate the effect of Lode angle incorporation into a fracture criterion when predicting the ballistic resistance of 2024-T351 aluminum alloy plates struck by cylindrical projectiles with different nose shapes through finite element (FE) simulations. To this end ballistic tests in the sub-ordnance impact velocity range were firstly conducted on 9.94 mm thick 2024-T351 aluminum alloy plates using cylindrical projectiles with blunt, hemispherical and ogival nose shapes, a nominal diameter of 12.66 mm, and a nominal mass of 50 g. Ballistic limit velocities (BLVs) for different projectile-target pairs considered were calculated using initial vs. residual velocity data obtained in the experiments. Subsequently FE simulations of the conducted experiments were performed with SIMULIA Abaqus software. In those simulations Johnson–Cook yield criterion with a modified strain hardening law was accompanied with either the Lode-independent Johnson–Cook (JC) fracture criterion or the Lode-dependent modified Mohr–Coulomb (MMC) fracture criterion to describe target material properties. Finally, the predicted ballistic resistance and fracture patterns of the targets were compared with those observed in the experiments. It was found that in the simulations with the Lode-independent JC fracture criterion the BLVs of the targets were overestimated by 18.0–35.1% depending on the projectile nose shape. In the simulations with MMC fracture criterion the BLVs predictions were substantially improved, so that the difference with the experimental results did not exceed 9.0%. Targets failure mechanisms obtained in the simulations with MMC fracture criterion also better match the experiments than those predicted with JC fracture criterion. In the simulations with MMC fracture criterion the targets impacted by the projectiles with blunt and hemispherical noses failed through shear plugging, whereas ogive-nosed projectiles caused ductile hole enlargement and target fragmentation due to its rear side radial fracture and bending of formed short petals with their eventual shear fracture. At the same time the simulations with JC fracture criterion predicted shear plugging for the blunt-nosed projectiles, very small conical plug ejection and target fragmentation due to discing for the hemispherical-nosed projectiles, and ductile hole enlargement for the ogive-nosed projectiles. A detailed analysis of the failure process revealed that in the case of the ogive-nosed and hemispherical-nosed projectiles, respectively, the ductile hole enlargement occurs during the initial stage of the impact and subsequent through-thickness fracture develops causing either fragmentation of the target or its shear plugging failure. The Lode-independent JC fracture criterion overestimates a material fracture strain under shear, thus leading to poor prediction of 2024-T351 aluminum alloy targets ballistic performance in the numerical simulations.