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<p>Three-dimensional angle-interlock woven fabrics (3DAWF) offer superior delamination resistance for soft armor, yet their ballistic response involves complex multi-scale interactions often oversimplified by continuum-based modeling. This study introduces a high-fidelity multi-scale finite element framework to bridge the gap between micro-mechanical behavior and macroscale deformation. By explicitly discretizing yarns into distinct fiber bundles within the primary impact zone, the model captures critical phenomena—specifically yarn spreading and fibrillation—that homogenized mesoscale approaches fail to reproduce. Validated against ballistic impact using 9&#xa0;mm projectiles, the proposed framework demonstrates superior predictive accuracy regarding residual velocity and damage morphology. A critical energy audit reveals that ballistic performance is governed less by tensile strength and predominantly by frictional dissipation, which constitutes approximately 76% of the total absorbed energy. Crucially, the multi-scale approach elucidates the role of intra-yarn friction—sliding between individual fiber bundles—as a primary energy sink, a mechanism invisible to traditional models. Furthermore, the analysis uncovers significant stress heterogeneity across the yarn cross section, challenging conventional uniform loading assumptions. These findings underscore the necessity of fiber-level discretization for accurate ballistic prediction, providing a robust theoretical tool for the mechanism-driven optimization of next-generation protective textiles.</p>

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Multi-scale finite element modeling of ballistic impact onto 3D angle-interlock woven fabric involving fiber bundles

  • 期刊论文

  • 发表日期：

    2026年7月4日

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  • Xianyan Wu,
  • Qingsong Wei,
  • Yanan Ke,
  • Xi Liu,
  • Lvtao Zhu,
  • Mingling Wang,
  • Yan Ma

摘要

Three-dimensional angle-interlock woven fabrics (3DAWF) offer superior delamination resistance for soft armor, yet their ballistic response involves complex multi-scale interactions often oversimplified by continuum-based modeling. This study introduces a high-fidelity multi-scale finite element framework to bridge the gap between micro-mechanical behavior and macroscale deformation. By explicitly discretizing yarns into distinct fiber bundles within the primary impact zone, the model captures critical phenomena—specifically yarn spreading and fibrillation—that homogenized mesoscale approaches fail to reproduce. Validated against ballistic impact using 9 mm projectiles, the proposed framework demonstrates superior predictive accuracy regarding residual velocity and damage morphology. A critical energy audit reveals that ballistic performance is governed less by tensile strength and predominantly by frictional dissipation, which constitutes approximately 76% of the total absorbed energy. Crucially, the multi-scale approach elucidates the role of intra-yarn friction—sliding between individual fiber bundles—as a primary energy sink, a mechanism invisible to traditional models. Furthermore, the analysis uncovers significant stress heterogeneity across the yarn cross section, challenging conventional uniform loading assumptions. These findings underscore the necessity of fiber-level discretization for accurate ballistic prediction, providing a robust theoretical tool for the mechanism-driven optimization of next-generation protective textiles.