Defence Industry

• In this video, the impact of an Explosively Formed Projectile (EFP) against a 40mm Rolled Homogeneous Armor (RHA) plate with a hardness of approximately 270 (BHN) is being simulated. EFPs are a type of munition designed to penetrate armored targets by utilizing a shaped charge mechanism. The EFP in this simulation features a copper cone with a diameter of 60mm and an average thickness of 2.5mm. Through this investigation, valuable insights are gained into the effectiveness and potential applications of EFP technology, shedding light on its practical utility. 

• A typical modern shaped charge, with a metal liner on the charge cavity, can penetrate armor steel to a depth of seven or more times the diameter of the charge Contrary to a misconception the shaped charge jet does not depend in any way on heating or melting for its effectiveness; that is, the jet from a shaped charge does not melt its way through armor, as its effect is purely kinetic in nature.

• The A-10 Thunderbolt II, also known as the Warthog, is a legendary close air support aircraft that entered service in 1976. It is equipped with the GAU-8/A Avenger rotary cannon, a fearsome 30mm seven-barrel cannon. The GAU-8/A fires the PGU-14/B armor-piercing incendiary round, featuring a dense tungsten alloy core housed within a steel and light-alloy subprojectile. This powerful combination allows the A-10 to engage heavily armored targets with precision.

• In this simulation, witness the A-10 Thunderbolt II unleash its formidable firepower as it confronts the formidable T-80 main battle tank.

• Kevlar is a well-known component of personal armor such as combat helmets, ballistic face masks, and ballistic vests. As multiple sources state, approximately 21 layers of Kevlar 49 or 5mm has a good chance of stopping a 9mm bullet.

• In this demonstration, a simplified application was chosen, do simulate the behaviour of the woven fabric. As bullet velocity 100 m/s was chosen, to represent a bullet after richochet or slower fragments and only 3 layers of Kevlar 49 was applied.

• According to Literature and video references, a 1/8" mild steel plate is supposed to be barely able to stop a usual 9mm Parabellum FMJ bullet. 

• In this simulation a stronger armor piercing version of the 9mm projectile is tested on the same steel plate. 

• The penetration is clear and the 1/8" thickness was not a real challenge to the armor piercing projectile.

An EFP is capable of traveling at 2000 m/s and  penetrating even the toughest armor on the battlefield. As a simulation engineer, I have been facing the following challenges in the design process:

• Optimizing material models to accurately portray the high-strain formation of the projectile and later on the penetration.

• Choose the correct amount and quality of explosives, Optimisting every other dimensions to reach the perfect form and travel speed.

• Simulating the Explosion of a mortar shell or any ammunition can be difficult due  to the complex material models (Like Johnson & Cook failure model with Shock EOS) and sensitive solver settings. Even the slightest difference can cause incorrect splinterform, larger or smaller pieces, wrong flightangle and velocities. Out of all my Project this task provided the largest challange, but it was highly educational at the same time.