Multi-objective optimization design of tungsten alloy long-rod armor-piercing projectile penetrating ceramic-rubber composite armor

PurposeThis study aims to elucidate the penetration mechanism of tungsten alloy long-rod armor-piercing projectiles impacting ceramic-rubber composite armor under oblique angles. The objective is to understand how varying attack angles influence projectile failure behavior, energy dissipation within armor materials, and overall protection performance. Additionally, the study seeks to explore the potential of structural optimization to enhance armor efficiency, either by reducing weight or improving resistance, thereby providing design guidance for advanced composite armor systems subjected to angled threats.Design/methodology/approachA finite element model was developed in LS-DYNA to simulate the oblique impact of tungsten alloy long-rod projectiles on ceramic-rubber composite armor. The study analyzed projectile velocity evolution, failure modes, and stress distribution under different impact angles. Mass erosion, ceramic fragmentation, and energy dissipation mechanisms were examined in detail. Furthermore, a multi-objective optimization approach was applied to minimize areal density or maximize residual velocity without compromising ballistic performance. The combined numerical simulation and optimization framework provides insights into armor response and structural improvements under asymmetric loading conditions.FindingsMulti-objective optimization demonstrates that through angle-dependent structural adjustments, either a 4.89% areal density reduction or 14.77% residual velocity increase can be achieved without compromising ballistic protection.Originality/valueThis study reveals the coupled influence of oblique impact angles on the failure mechanisms of long-rod penetrators and the energy absorption characteristics of ceramic-rubber composite armor. It provides new insights into asymmetric stress-induced shear localization and projectile erosion under high obliquity. The integration of viscoelastic effects, ceramic fragmentation, and frictional interactions enhances understanding of composite armor performance. Moreover, the application of multi-objective structural optimization demonstrates that significant weight reduction or improved resistance can be achieved without compromising protection, offering valuable guidance for the lightweight design and efficiency enhancement of advanced armor systems.