Ansys Paper
Ansys Paper
Results in Materials
journal homepage: www.sciencedirect.com/journal/results-in-materials
A R T I C L E I N F O A B S T R A C T
Keywords: This research explores the effectiveness of two hybrid composites, pattern-1 (K-M-G-K-M-G-G-M-K) and pattern-2
Bombyx mori (K-M-G-K-M-G-K-M-G), in experimental and simulation tests to create a cost-efficient hybrid composite. The
Mulberry silk composite includes Mulberry (M) silk (Bombyx mori) fibers reinforcing an epoxy resin-matrix hybrid with Kevlar
Kevlar
(K) and Glass fiber (G). Both pattern-1 and pattern-2 are evaluated through experimental tests, and simulation
Glass fiber
tests are conducted to validate the findings. ANSYS Workbench is used for simulation tests to determine the best
Hybrid composite
ANSYS workbench stacking sequence for protective gears, aerospace components, automotive parts, sport equipment and marine
Simulation applications. The structural morphology of the hybrid composites is examined using scanning electron micro
scope (SEM). The results show that pattern-1 performs better than pattern-2 in various experimental and
simulation tests, with a wider plastic zone in the tensile test stress-strain curve, greater tensile strength (73 MPa
and 67.923 MPa), higher load-bearing capacity, and enhanced ductility. Pattern-1 also demonstrates improved
performance in flexural strength (45.35 MPa and 71.474 MPa) and impact strength (6 J and 5.4898 J). Simu
lation results confirm that pattern-1 is superior to pattern-2 in terms of energy absorption and resistance to bullet
penetration.
1. Introduction Herein (MS-Kevlar) composite, made of Kevlar fiber, shear stiffening gel
(SSG), and two-dimensional MXene, aims to create a fabric-based heater
Hybrid engineering involves blending two or more distinct fiber with sensitive monitoring, efficient thermal management, and impact
materials to improve reinforcing components and reduce unwanted protection. This innovative material offers sensing capabilities, thermal
qualities. It is a crucial material design principle in composite engi management, and enhanced bullet-shooting protection, making it suit
neering, focusing on positive effects rather than negative ones[1–3]. able for bulletproof curtains and wearable sensors [7]. Jana Katia et al.
Wang et al. found that symmetric intercalation structures perform better studied composites impact and residual strength using two 11-layer
under high energy impact, with lower impact damage volume compared laminates: bidirectional glass fiber woven and a hybrid laminate with
to asymmetric specimens [4]. Recent experiments aim to create Kevlar three layers of bidirectional aramid fiber. The research revealed a
for body armor applications, optimizing mechanical qualities and relationship between damage area and residual properties of glass fiber
weight reduction. However, environmental, ecological, high cost and material [8]. It does not investigate the environmental endurance,
limited synthetic fiber supply hinder their widespread use [5]. Susmita long-term implications of repetitive hits, or the optimization of repair
Naik et al. investigated failure mechanisms after ballistic impact and procedures for Kevlar-based composites. The development of composite
analyzed methods for Kevlar fiber-reinforced composites. They aimed to materials would be boosted by more research into multi-impact
understand structural features and characterize these composites for behavior, sustained mechanical qualities, and improved repair
ballistic applications. Generalized models are needed to predict complex methods. Anand Narayana et al. investigated Kevlar, an advanced ma
anisotropic materials properties and post-impact behavior [6]. The terial with exceptional strength and durability, for defense applications.
* Corresponding author.
E-mail addresses: rajesh1saha1@gmail.com (R. Saha), abrarnafis609@gmail.com (S.A.N. Uddin Ahmed), saquibjamil7@gmail.com (S. Jamil), rknayeem.mpe@
aust.edu (Md.R. Karim), adib@me.mist.ac.bd (A. Bin Rashid).
https://doi.org/10.1016/j.rinma.2024.100588
Received 22 January 2024; Received in revised form 26 April 2024; Accepted 4 June 2024
Available online 5 June 2024
2590-048X/© 2024 The Author(s). Published by Elsevier B.V. This is an open access article under the CC BY license (http://creativecommons.org/licenses/by/4.0/).
R. Saha et al. Results in Materials 22 (2024) 100588
The paper explores its uses and properties, highlighting its significance investigated: Type I (aloe vera and bamboo blend), Type II (bamboo and
in polymer matrix composites and its potential in defense and ballistic palm combination), and Type III (palm and aloe vera blend). Their study
applications [9]. However, there is a dearth of thorough investigation investigates how to change Kevlar’s characteristics within epoxy com
into the creation of body armor through the impregnation of Kevlar posites. Vacuum-assisted resin transfer molding results reveal that these
between composite plates, the investigation of various bullet impacts, natural composites have potential applications that reduce dependency
and the optimization of Kevlar-fiber ratios. Determining bullet types, on chemicals. Notably, Type I had the highest impact strength at 10 J,
evaluating weight ratios, and extending uses beyond of the defense in followed by Type II at 8.3 J (sample 2) and Type III at 9.66 (sample 3),
dustry to other industries like aerospace and medicine require more demonstrating the influence of fiber arrangement on impact strength
research. Hu et al. investigated the impact of ambient temperature on [17]. Natural fibers are becoming increasingly popular due to their
hybrid Polytetrafluoroethylene (PTFE)/Kevlar fabric tribological prop availability, low density, and renewable nature as compared to synthetic
erties through reciprocating wear tests. They found that high tempera fibers, Investigation of hybrid composites carried out by Karthik et al.
tures increased wear rates, indicating a decline in wear resistance [10]. where the hybrid composite laminates were created by combining
Wu et al. investigate thermal damage in Kevlar composites using 1064 Basalt/Kevlar fibers and sawdust particles with epoxy LY556 resin in a
nm continuous lasers. Results show lower laser powers reduce heat fixed 50:50 proportion. Post-curing investigations, as well as surface
accumulation, heat-affected areas, and morphological changes [11]. S. analysis and microstructure examinations, were carried out in accor
Samaneh Asemani et al. investigated high-velocity impacts on Kevlar dance with ASTM mechanical property requirements. As a result, the
fabric and elastomer composites using experimental tests and numerical laminates had high tensile strength (328 MPa), flexural strength (380
simulations. They found high energy absorption rates due to the com MPa), and impact value (13 J), making them suitable replacements for
bined properties of the materials [12]. To test numerical models, look interior automobile parts [18]. V Ramesh et al. investigated the me
into long-term durability, and improve composite designs for wider in chanical properties of basalt, ramie, and polyester hybrid composite
dustrial uses beyond high-velocity collisions, more research is necessary. laminates. A 45 % polyester matrix was chosen because of its strong
Ramesh Velumayil et al. studied the mechanical properties of Kevlar/ adhesion with the fibers. While natural fibers are environmentally
epoxy and basalt/epoxy composite laminates and hybrid laminates friendly and cost effective, their lower strength and higher water ab
combining Kevlar, basalt, and epoxy. They found that fiber volume sorption limit their use. Combining natural and synthetic fibers has the
fractions and stacking sequences affect composite laminate properties potential to successfully address these challenges. Consequently, their
[13]. However, it does not examine failure patterns or conduct a thor research shows that the developed composites had maximum tensile
ough investigation of laminates that outperform neat composite strength of 120 MPa, impact energy 8 J, and flexural strength 115 MPa.
strengths. To further improve composite performance and application in Natural fiber-reinforced composites are increasingly being employed in
a variety of sectors, more study should concentrate on comprehending automotive applications, such as electric cars [19]. Despite substantial
anomalies, refining hybrid designs, and investigating failure study into strengthening fiber metal laminates (FMLS) with nano-fillers,
mechanisms. the effect of reduced graphene oxide (r-GO) on fiber intermetallic lam
Karthik et al. have discovered that synthetic fibers are important in inates is unknown. D. Rajamani et al. investigated the impacts of varying
the composite sector because of their superior mechanical qualities. The r-GO concentrations on the mechanical, microstructural, and
stacking order of fiber mats in HPMCs (Hybrid Polymer Matrix Com high-velocity impact properties of new fiber intermetallic laminates
posites) has a considerable impact on their thermomechanical behavior. (FILS) made of Nitinol foils and carbon/aramid fibers. The results of the
S5 (Kevlar- K, Glass Fiber- G, Carbon Fiber- C Stacking Sequence- study demonstrate that FILS infused with r-GO have higher tensile,
CGKKGC) composite specimens exhibit superior mechanical properties, flexural, and impact strength [20].
including increased tensile, flexural, impact, and hardness such as 19.19 Hybrid-reinforced composites are increasingly used in various in
%, 21.6 %, 23.55 %, and 26.41 % compared to S1 (GGCCKK) composite dustries, including aviation, armored vehicles, and ballistic applications,
specimens. However, delamination, fiber-matrix de-bonding, fiber with researchers exploring hybridization processes for novel properties
pullouts, and voids owing to SiC nanoparticles release all contribute to [21–23]. Additional research is required to evaluate the stability of the
tensile and flexural failures. Scanning electron microscope (SEM) pic composites over time, particularly their resilience in different environ
tures indicate failure processes, highlighting the stacking sequences ef mental settings, in order to fully establish their industrial relevance.
fect on the thermomechanical characteristics. Consequently, their work Kevlar fibrillation and hydrothermal treatments show potential rein
focuses on the effect of the stacking sequence on the thermomechanical forcing agents with acceptable mechanical performance [24]. Natural
properties of created HPMC specimens and investigates its potential for silk fibers, spun by silkworms, possess exceptional mechanical qualities
a variety of applications [14]. H. Fayaz et al. researched about the like strength, elongation, and energy absorption [25,26]. Global
poly-aramid, an aromatic polyamide derivative, improves material awareness for environmentally friendly products drives the exploration
properties by providing superior thermal stability. Its reinforcing of natural animal-based fibers, like silkworm silk, for protecting larvae
properties are derived from interfacial hydrogen bonding and aromatic [27]. Shaoyong Chen et al. found that silk brin exhibits fewer mechan
stacking interactions between chains. Furthermore, using natural fiber ical qualities and diameter variance than above. They also determined
polymer composites provides a sustainable method of recycling waste the mechanical characteristics of sericin using the mixing law for com
materials and adding value. As a result, their study shows at how posite materials. The study contributes to understanding silk fibers’
introducing 2 wt% nano-titanium oxide and 5 % poly aramid fibers into mechanical characteristics and potential uses [28]. Lalit Ranakoti et al.
an epoxy matrix composite reinforced with three types of natural fibers explore the processing and use of silk fibers in various industries,
(jute, bagasse, and coir fibers) affects the composites structure and including textiles, engineering, and medicine. They address
qualities [15]. In automotive and building insulation, lightweight non-biodegradability issues and emphasize the need for improved sur
composite materials with outstanding mechanical and thermal qualities face adhesion qualities through chemical treatment. Selecting biode
are essential. V Ramesh et al. studied using ASTM standards to analyze gradable polymers for silk fibers is challenging, but poly-lactic acid
the thermal characteristics of a hybrid composite made up of various composites bonded with silk fiber have numerous applications in the
reinforcement fibers and an epoxy matrix. Notably, a hybrid composite medical field [29]. Mulberry branch-derived biochar CuO (MBC/CuO)
with basalt fiber outer layers has a high coefficient of linear thermal composite was successfully used as a catalyst for reducing bisphenol-A
expansion, whereas utilizing Kevlar as the outer layer increases heat (BPA) degradation. The system demonstrated high degradation effi
deflection, indicating better insulation [16]. The study by B Murali et al. ciency (93 %), with free radicals and non-radicals. This environmentally
sought to assess composite materials reinforced using aloe vera, friendly and cost-effective treatment system has gained interest in
bamboo, palm, and Kevlar fibers. Three fabrication styles were treating wastewater contaminants. The composite’s toxicity is lower
2
R. Saha et al. Results in Materials 22 (2024) 100588
than the original BPA solution, making it a practical and environmen behavior of commercial Bombyx mori silk and medium toughness
tally friendly alternative to recycling discarded mulberry branches [30]. nylon. Mulberry silks nanoscale structure allows for efficient energy
However, provide a thorough investigation into scaling up the process dissipation at different deformation rates. Consequently, high rate
for real-world applications, a long-term stability evaluation of the stress-strain curves for silk revealed greater impact energy absorption
catalyst, or thorough toxicity tests that go beyond silkworm larvae to compared to nylon, implying that millions of years of natural selection
determine the influence on the environment and take wider safety have optimized silk for toughness at various speeds [38]. H.A. Tuan et al.
concerns into account. Silkworms are used in surgical meshes, textiles, researched silk resins as alternatives to tortoiseshell for eyeglass frames
medical research, wound healing, tissue engineering, medicinal uses, and ornaments, focusing on their mechanical qualities and structure.
commercial materials, electricity, and optical equipment. They have Their study reveals that silk resins have desirable mechanical charac
potential applications in medicine, cosmetics, and pharmaceuticals. teristics for a variety of applications. Specifically, Bombyx mori silk
Raising silkworms offers economic efficiency, reproducibility, and resins have greater apparent densities, flexural strengths, and
biohazard-free production benefits [31]. The immunogenic component micro-vickers hardness values than Eri silk resins from Samia Cynthia
of (silk sericin-silk fibroin) SS-SF composites is not well understood, but ricini [39].
their potential in tissue engineering is explored. Modulating the immune The formation of particle-filled glass fiber-reinforced polymer com
response can be achieved by adjusting hydrophobic patches on the posite (PC) involves mixing glass fiber and mineral aggregates with a
scaffold surface. SS or other coatings can be applied to SS-SF composites resin system. Polymer composites are employed in several constructions,
to benefit from their antbiofouling qualities. Further study is needed to rehabilitation, and repair applications, such as bridges, pipelines, and
fully exploit the potential of these materials. Bombyx mori cocoons other types of structures, because of their quick setting time and great
extract offers excellent mechanical characteristics and bioactivity, strength. There are still questions, nevertheless, about the crucial stress
making it an ideal scaffold for tissue engineering applications [32]. intensity variables that are impacted by the notch-to-depth ratio, the
Researchers are exploring alternative materials for industrial applica impact of weak bonding on mechanical characteristics, and the
tions, such as silk fiber composites (SFCs) reinforced with vinyl ester threshold limits of polyester content. To improve composite design and
matrix material. Chikesh Ranjan et al. studied the potential of untreated fracture prediction, more research is required to clarify these linkages
silk fibers (SFs) and silk cloths (SCs) in producing silk fiber reinforced [40–42]. Low-velocity impacts fiber-reinforced plastic composites, as
composites (SFRCs). The study found promising mechanical character Short et al. [33] demonstrated, resulting in a pattern of damage that
istics and behavior, making them a potential substitute for mostly includes delamination, fiber breaking, and matrix cracking. They
ceramic-based goods. Mechanical, electrical impedance and tribological clarified that as such damage is unintentional and might not be recog
tests were conducted to analyze the coefficient of friction, wear nized, composites must be built assuming that impact damage exists.
behavior, and material characteristics of SFRCs. The main motivation is Aubad et al. conducted an experimental and computational analysis of
to create a new generation of smart composites with potential applica the dynamic properties of hybrid laminate-reinforced unsaturated
tions in various industries [33]. It falls short of providing a thorough polyester (UP) composites. They found that adding multi-wall carbon
investigation into issues like as long-term durability, production scal nanotubes (MWCNTs) at different weight fractions increased natural
ability, application-specificity, and a thorough grasp of processing pa frequency by 10.4 %, 13.82 %, and 5.8 % compared to laminated
rameters. To fully realize these materials’ potential and apply them to a composites. The damping ratio increase percentages were 12.23 %, 15.9
variety of industrial areas, more research is necessary. %, and 8.6 %, respectively. The results showed agreement between
Hao Xu et al. studied the CNT/LGS composite for strengthening experimental and numerical results, with maximum errors of 3.4 % and
silkworm fibers by feeding it to Bombyx mori silkworms. They found that 9.34 %, respectively [43]. The bumper beam is a crucial element in the
conventional feeding additives have excessive lignosulfonate (LGS) vehicle industry, and this project uses Kevlar and Date Palm fibers. The
coating, preventing carbon nanotubes (CNTs) from penetrating silk fi hand lay-up technique was used to create Kevlar and Date Palm rein
bers. Purification increased carbon nanotube (CNT) content and b-sheet forced epoxy composite specimens. Tensile tests showed improvements
nanocrystals, improving buffering behavior at fracture [34]. Yuzhou in tensile strength and modulus. CATIA created a model, and R.
Yang et al. developed silk fiber-based scaffolds with silk fiber-based Muthalagu et al. examined the design using FEA software. The Kev
scaffolds co-reinforced with Poly-L-lactic acid porous microspheres lar/date palm epoxy composite material was compared to the current
(PLLA PMs) and Bombyx mori or Antheraea pernyi (Ap) silk fibers for vehicle bumper glass mat thermoplastics (GMT) material, and Finite
auricular cartilage tissue engineering. They found that Antheraea pernyi Element Analysis was used to compare the results [44]. Verma et al.
silk fiber-based scaffolds had superior mechanical properties and examined three armor types, carbon fiber reinforced polymer (CFRP),
chondrogenic potential, with superior cell adhesion, viability, prolifer kevlar, and steel, using ANSYS software to test their impact on brass
ation [35]. However, in order to fully comprehend their potential and bullets. They focused on four performance attributes: maximum direc
effectiveness in therapeutic applications, there are gaps in the areas of tional deformation, maximum stress, energy absorption, and weight.
long-term stability evaluation, in vivo integration, and comparison in Kevlar ranked second in maximum deformation, cost, and weight and
vestigations with Bombyx mori silk equivalents. Shailendra Singh et al. best in usability due to energy efficiency. The Gray relational analysis
found that preparing bio-composites through mixing is a promising revealed that Kevlar was the most desirable material, followed by car
option for customizing material properties. Bio-composites made from bon fiber-reinforced plastic (CFRP) and steel [45]. There are still gaps in
renewable resources are crucial for biomedical engineering applications the understanding of non-mechanical factors like as resistance to cli
as resources become scarce. High porosity scaffolds, mechanical matic changes, wear over time, and ballistic performance in a range of
strength, biocompatibility, and biodegradability are essential for tissue scenarios. For a thorough material selection process in armor design,
development, wound dressing, drug delivery, and controlled degrad further research on multifaceted qualities beyond deformation, stress,
ability [36]. G Pandey et al. studied the natural fiber composites for and weight is required. Ink Kong et al. studied wood polymer composite
lightweight serial robot mechanics, using inspiration from the strength (WPC), an eco-friendly and sustainable building and construction ma
and durability of Signature spider silk and Bombyx mori silk. By intro terial used in various industries. Wood polymer composites (WPCs) have
ducing vinly ester, the Young’s modulus in both linear directions gained interest due to their unique properties, such as stiffness, lower
increased but the Poisson’s ratio fell. These composites highlight the water intake, high sustainability, and durability against environmental
multi-functionality of spider silk and Mulberry silk, acting as models for impacts. The study found that the stress concentration zone was caused
specialty fiber fabrication and potentially being used in bulletproof by the force applied, and the deformation rate varied with the speci
jackets due to their great toughness [37]. R. Drodge et al. devised a new men’s elongation. To create a precise analytical model, further research
transverse fiber impact technique to investigate the high strain-rate is needed to understand the fiber orientation and damage sites [46].
3
R. Saha et al. Results in Materials 22 (2024) 100588
Fibers like carbon, glass, Kevlar, and basalt are increasingly used in Glass fiber are imported from abroad. Properties of the Kevlar, Mulberry
Polymer matrix composites (PMCs) for reinforcement. Reza silk, and Glass fiber are given in Table 1.
Islami-Farsani et al. studied epoxy composites reinforced with
high-performance and oxidized polyacrylonitrile fibers (OPF). Hybridi 2.2. Wet-layup of composite
zation of OPF and high-performance fibers is a simple method for
adopting novel fibers with lower mechanical qualities [47]. Polymer Epoxy was wet laid up over the silk fabrics during the composite
matrix composites are increasingly used in industries like aerospace, fabrication (Fig. 1). The silk fabric is the continuous reinforcement
automotive, and wind turbines for weight reduction and safety. These phase, while the epoxy is the matrix that binds with the reinforcement to
composites are low-density, superior strength and stiffness, reducing create the composite. High structural toughness because of the matrix’s
vehicle weight. A study by Shohel et al. investigated the mechanical selection of epoxy. The two parts of the epoxy system are the resin and
strength of glass fiber laminated with resin epoxy composites under hardener. The resin and hardener will combine in a 10:6 proportion to
tensile loading conditions. Results showed that glass fiber laminated generate the mixture, which will then react with the epoxide groups to
with epoxy resin composite has a longer life cycle, higher stress-bearing create a highly cross-linked product polymer. The mixing is carefully
capacity, and a more convenient design [48]. Cao et al. optimized the done as the heat is generated by mixing the epoxy resin and the hard
constrained composite armor’s back plate sequence and thickness ratio ener. This epoxy method was chosen for its viscosity since it gives the
using finite element simulation on ANSYS/LS-DYNA. They found that operator enough time to wet layup many pieces of silk cloth.
boundary restrictions significantly affect ceramics resistance to pene
tration. The study identified four penetration phases: no-load, hard-
to-hard, abrasion, and backplane penetration. The ceramic cone’s 2.3. Fabrication of composite
growth and deterioration were analyzed, and the stress distribution of
the transition plate was transferred to the cone [49]. Combining Kevlar The fabric (Glass fiber, Mulberry silk, and Kevlar fiber) was initially
and carbon-based composites with less expensive textiles like glass can trimmed to meet the mold’s measurements (Fig. 2). The Dimension of
reduce material costs without compromising impact and mechanical the mold is 254 × 254 × 5.5 mm3. A suitable mold-release solution was
performance. These affordable high-velocity impact resistant (HVIR) initially applied to a square metal mold to aid its release. On the mold’s
composites are used in law enforcement and civilian protection, as well bottom surface, epoxy wet lay-up is utilized. K-M-G-K-M-G-G-M-K is the
as sacrificial cladding. Clifton Stephen et al. studied high-velocity sequence for pattern-1 composite (K- Kevlar Fabric, G- Glass Fiber, M −
impact resistance of fabric reinforced polymer (FRP) composites with Mulberry Silk Fabric). The same method is used to create pattern-2
Kevlar, carbon, and glass, resulting in impact performance comparable composites using the layer sequence K-M-G-K-M-G-K-M-G. Epoxy resin
to a neat Kevlar/epoxy composite while lowering material costs [50]. is utilized for covalent bonding in each stacking layer, and after the
Mulberry silk has flexibility and lightweight properties, while Kevlar stacking is complete, epoxy resin is employed once more on the upper
provides high tensile strength and impact resistance. Glass fiber adds surface of both composites. Both composites use 60 % of the total fibers
stiffness and durability. Combining these materials results in a com during stacking and 40 % of the epoxy resin mixture. A roller was used to
posite with greater overall qualities that can outperform those of the remove excess epoxy from the composite and release air bubbles trapped
individual materials alone. The specific combination of Mulberry silk between the fabric layers. After the requisite number of layers of silk
with Kevlar and Glass fiber may not have been explored before. Incor fabric had been put on the metal mold, a second square metal plate
porating Mulberry silk with different stacking sequences of Kevlar and coated with a mold-release chemical was placed on top of the composite.
Glass fiber can offer new material properties such as higher tensile, The square metal plate has a dimension of 228.6 mm × 228.6 mm2. The
flexural, and impact strength. Mulberry silk is also a natural fiber, which hot press machine is then used to apply pressure on both side of the
can create good compatibility and interfacial bonding between the composite.
synthetic fibers to develop a hybrid composite that is durable, cost-
friendly, and environmentally non-hazardous. The goal of this study is 2.4. Hot press setup
to increase the overall performance of the hybrid composite, which can
resist loads in different conditions. Pattern-1 and pattern-2 are specif The silk-epoxy composite panel is not subjected to external tension
ically selected for this study to check which combination can give while curing. The sole factor affecting the finished composite’s
maximum resistance against different loads without diminishing the compactness after curing is the pressure of the atmosphere acting on its
durability property of the composite. The limitations of this study can be surfaces. Additionally, rolling was employed to push off extra epoxy
procuring Mulberry silk in large quantities to develop the composite during the wet layup. Externally applied stress must be given to the
material commercially. Moreover, Kevlar is durable in different envi composite panel to enhance the volume % of silk fiber in the composite.
ronmental conditions, and can avoid corrosions but Mulberry silk may When the composite has finished curing, excess epoxy should be
not offer the same durability in those conditions. removed, but enough epoxy should be left over to connect the silk
reinforcement to the composite. A hot press enables external pressure
2. Methodology
2.1. Materials
This study used Kevlar fabric, Mulberry silk fabric, and Glass fiber.
Resin epoxy was used as matrix material. Kevlar, Mulberry silk, and
Table 1
Table for mechanical parameters of the materials used.
Material Young’s Modulus (GPa) Density (g/cm3) Poisson’s Ratio
4
R. Saha et al. Results in Materials 22 (2024) 100588
and heat to improve densification, compressing a laminate into a small was established in two directions. An oriented selection set property was
package and squeezing any extra material. The epoxy system cures faster then generated, encompassing all elements and the rosette configura
at higher temperatures since it usually takes at least 24 h to cure at room tion. Two distinct stacking sequence were employed: for pattern-1, the
temperature. The hot press’s top and bottom platens were set to 60 ◦ C. sequence was K-M-G-K-M-G-G-M-K, while for pattern-2, it was K-M-G-K-
The uncured silk-epoxy composite was put in the vacuum bag between M-G-K-M-G. Consequently, ply models were generated and integrated to
the two platens. When the two platens were shut, 1.38 MPa of pressure form a solid composite model.
was applied to the composite between the two platens. Following the
epoxy system’s suggested enhanced curing time, the setup was kept-in 3. Characterization of composites
this state for 3 h. The cured composite panel was gently forced aside
from the mold after 3 h. Before any tests were conducted on the com 3.1. Tensile strength test
posite panel, it was allowed to cool at room temperature for at least 24 h.
The wet layup process along with the compression process is shown at Mulberry silk-reinforced hybrid pattern-1 and pattern-2 composites
Fig. 3. underwent rigorous tensile testing, both experimentally and computa
tionally, to unravel their mechanical properties (see Fig. 4). Employing
2.5. Composite cutting for the specimens ASTM D638 Type-I specimen standards (Fig. 5), meticulously replicated
in SolidWorks and integrated into ANSYS Workbench, physical samples
Both pattern-1 and pattern-2 composites are fed into a laser cutting were meticulously prepared to align with these exacting standards.
machine once curing is complete to produce specimens from the com Material properties were rigorously entered into the engineering data,
posites. Both composites use the tensile test specimen dimension ac ensuring precision in the simulations. Degrees of freedom were sys
cording to ASTM D638 TYPE-I. The ASTM D4812 test standard is used tematically constrained across all dimensions, while a robust load 3000
for the impact test, while ASTM D790 is used for the flexural test. N was uniformly applied to one face.
The comparative analysis between experimental and simulated re
2.6. Pattern-1 and Pattern-2 composite design in ANSYS sults yielded strikingly congruent outcomes. Fig. 6 vividly illustrates the
tensile behavior of these specimens under both experimental and
In ANSYS, first, the specimen of testing for the composite was computational loads. Notably, the stress-strain curve elucidates the
designed for the tensile test as per ASTM D638 TYPE- 1, and for the profound impact of hybrid composite pattern-1’s layer arrangement,
flexural test, ASTM D790 was followed. After that, engineering materials which ideally reinforced the fiber matrix while enhancing the bond
following mechanical parameters were set [51–53] (Table 1). between the epoxy resin, Mulberry silk, and fibers. The result was a
Following that, the composite structure was developed using ANSYS dramatic surge in the load-bearing capacity coupled with enhanced
Composite Prep Post ACP (PRE). Initially, fabric geometries were con ductility. Impressively, pattern-1 composite showcased a staggering
structed for all constituent materials, followed by the creation and maximum tensile strength of 73 MPa, duly corroborated by computa
placement of individual elements. Subsequently, a rosette configuration tional analysis registering at 67.923 MPa. Conversely, the uniform
Fig. 3. Wet layup process for Pattern-1 composite fabrication (repeat process).
5
R. Saha et al. Results in Materials 22 (2024) 100588
Fig. 4. (a) Laser cutting of the composite (b) Specimens for mechanical testing.
Fig. 6. Tensile behavior of the hybrid composites (a) Experimental tensile graph (b) Simulated tensile graph.
Fig. 7. Tensile test of the (a) pattern-2 and (b) pattern-1 composite in ANSYS static structural.
6
R. Saha et al. Results in Materials 22 (2024) 100588
Fig. 9. Flexural behavior of the hybrid composites (a) Experimental flexural graph (b) Simulated flexural graph.
Fig. 10. Flexural test of the (a) pattern-2 & (b) pattern-1 composite in ANSYS static structural.
observed in pattern-2 emphasized its inferiority in comparison to pattern-2 (see Table 3) (see Fig. 12).
pattern-1 (see Fig. 10).
3.4. Bullet penetration test
3.3. Impact strength analysis ANSYS Workbench was used to model high-velocity bullet penetra
tion tests computationally. This solves the issue using the AUTO-DYN
Izod impact test using Impact Tester (JBW- 300B) was done to find module and applies to all projectile hits on plates and other objects.
the resistance of the composite against dynamic load. The dimension of This study uses explicit dynamics analysis to examine how Mulberry silk
the specimen was taken as per ASTM D4812 (Fig. 11) standard model for reinforced hybrid composites in different stacking sequences under the
the experimental test. impact of brass bullet projectiles. The process involves modelling the
In addition, ASTM D4812 standard model is also taken for simulation plate and bullet in ANSYS Design Modular and importing it into Work
which is modeled in SolidWorks and imported to ANSYS Workbench, bench. The plate’s dimensions were 254 × 254 mm2, the thickness was
and physical specimen was cut according to the same standard. Mate 3.2 mm, the original weight was 209 g, and the simulated weight was
rials properties were inputted in engineering data manually, and one 230.82 g; computational analysis is only used to determine how much
face of the specimen was fixed then, a velocity 9 m/s was applied to the deformation and equivalent stress the plate can endure. According to
swinging hammer. modern rifles, the bullet speed is 1200 m/s.
Fig. 13 and Table 2 demonstrates the impact strength of Mulberry Fig. 14(a) shows the pattern-2 composite plate for the bullet pene
silk hybrid composites. In the computational test result, the higher tration test after the bullet projectile impacts the plate. The red line
impact strength of 5.4898 J is found in the pattern-1 sequence com indicates the maximum stress 4345.5 MPa stress the plate felt. In
posite. However, the impact strength of pattern-2 in the computational contrast, Fig. 14(b) shows the pattern-1 composite plate for the bullet
test has been founded to be 5.4891 J. Even though in the experimental penetration test after the bullet projectile impacts the plate. The red line
test both composites had a similar impact strength of 6 J. Pattern-1 indicates the maximum stress 24124 MPa stress the plate felt. The result
sequence increases the interfacial bonding between the fibers and showed that the pattern-1 composite is more bullet resistant than the
resin epoxy. Moreover, in the sequence, Kevlar at both ends of the pattern-2 composite.
composite increased uptake of energy, and Mulberry silk helped to
uniformly distribute the impact energy. As a result, in computational 3.5. Scanning electron microscope (SEM) analysis
tests, pattern-1 showed better capacity to withstand impact energy than
SEM images of the surface area, as illustrated in Fig. 15 (a) and (b) of
the pattern-2 sequence composite reveal poor bonding of Kevlar fiber
and glass fiber. Furthermore, clustering and aggregation of Kevlar/glass
fiber result in weak strength between fibers and hybrid resin matrix.
Fig. 15 (c) and (d) showed that in pattern-1 changing the last sequence
from K-M-G to G-M-K amplified the interfacial adhesion between the
fibers and hybrid resin epoxy. As a result, pattern-1 has no voids, and
consistent distribution of resin epoxy.
7
R. Saha et al. Results in Materials 22 (2024) 100588
Fig. 12. Impact test of the (a) pattern-2 and (b) pattern-1 composite in ANSYS explicit dynamics.
4. Conclusion
1200 40 4345.5 60.575 24124 113.67 Rajesh Saha: Writing – original draft, Visualization, Resources,
Investigation, Formal analysis, Data curation. Syed Abrer Nafis Uddin
Ahmed: Writing – original draft, Visualization, Software, Methodology,
Investigation, Formal analysis, Data curation. Saquib Jamil: Writing –
original draft, Visualization, Validation, Software, Resources, Project
Fig. 14. Bullet penetration test result generated in ANSYS software explicit dynamics (a) pattern-2 composite after penetration (b) pattern-1 composite after
penetration.
8
R. Saha et al. Results in Materials 22 (2024) 100588
Fig. 15. SEM micrographs for mulberry silk reinforced composites (a) & (b) pattern-2 composite, (c) & (d) pattern-1 composite.
administration, Methodology, Investigation. Md. Rezaul Karim: [5] P.N.B. Reis, J.A.M. Ferreira, F.V. Antunes, J.D.M. Costa, Flexural behaviour of
hybrid laminated composites, Compos. Part A Appl. Sci. Manuf. 38 (6) (2007)
Writing – review & editing, Validation, Supervision, Resources, Project
1612–1620, https://doi.org/10.1016/j.compositesa.2006.11.010.
administration, Methodology, Conceptualization. Adib Bin Rashid: [6] S. Naik, R.D. Dandagwhal, P. Kumar Loharkar, A Review on Various Aspects of
Writing – review & editing, Visualization, Supervision, Methodology, Kevlar Composites Used in Ballistic Applications, 2020.
Formal analysis. [7] J. Zhou, et al., Advanced functional Kevlar composite with excellent mechanical
properties for thermal management and intelligent safeguarding, Chem. Eng. J.
428 (July 2021) (2022) 131878, https://doi.org/10.1016/j.cej.2021.131878.
[8] J.K.D. dos Santos, R. Dantas da Cunha, W.F. de Amorim Junior, R.C.T.S. Felipe, J.
Declaration of competing interest L. Braga Neto, R.C.S. Freire Júnior, The variation in low speed impact strength on
glass fiber/Kevlar composite hybrids, J. Compos. Mater. 54 (21) (Sep. 2020)
3009–3019, https://doi.org/10.1177/0021998320906205.
The authors declare that they have no known competing financial
[9] A.N. Nair, S. Sundharesan, I.S.M. Al Tubi, Kevlar-based composite material and its
interests or personal relationships that could have appeared to influence applications in body armour: a short literature review, in: IOP Conference Series:
the work reported in this paper. Materials Science and Engineering, IOP Publishing Ltd, Nov. 2020, https://doi.org/
10.1088/1757-899X/987/1/012003.
[10] Y. Hu, et al., Influence of high temperature on the tribological properties of hybrid
Data availability PTFE/Kevlar fabric composite, Tribol. Int. 174 (July) (2022), https://doi.org/
10.1016/j.triboint.2022.107781.
Data will be made available on request. [11] Xinyu wu, Y. Lu, C. Zhao, W. Zhang, Research on the Thermal Damage of Kevlar
Composites in Laser Processing, SPIE-Intl Soc Optical Eng, Nov. 2021, p. 68,
https://doi.org/10.1117/12.2606782.
References [12] S.S. Asemani, G. Liaghat, H. Ahmadi, Y. Anani, A. Khodadadi, S.C. Charandabi, The
experimental and numerical analysis of the ballistic performance of elastomer
matrix Kevlar composites, Polym. Test. 102 (Oct) (2021), https://doi.org/
[1] Tazbiul Mahmud Aranno et al 2019 IOP Conf. Ser.: Mater. Sci. Eng. 628
10.1016/j.polymertesting.2021.107311.
012011DOI 10.1088/1757-899X/628/1/012011.
[13] R. Velumayil, A. Palanivel, Hybridization effect on mechanical properties of
[2] Mahima Haque, S M Mohaimenul Islam, Pavel Chowdhury, K.M. Rafi Uddin Labib,
basalt/kevlar/epoxy composite laminates, Polymers 14 (7) (Apr. 2022), https://
Adib Bin Rashid, A comparative study on the influence of MWCNT, GO, and Al(OH)
doi.org/10.3390/polym14071382.
3 gel matrix modification on hierarchical structured composite reinforced with
[14] K. Karthik, J.U. Prakash, J.S. Binoj, B.B. Mansingh, Effect of stacking sequence and
needle-punched jute fiber and glass fiber, Results in Engineering, Volume 21, 2024,
silicon carbide nanoparticles on properties of carbon/glass/Kevlar fiber reinforced
101671, ISSN 2590-1230, https://doi.org/10.1016/j.rineng.2023.101671.
hybrid polymer composites, Polym. Compos. 43 (9) (2022) 6096–6105, https://
[3] Adib Bin Rashid, Asif Mahmud Rayhan, Samira Islam Shaily, S M Mohaimenul
doi.org/10.1002/pc.26912.
Islam, An experimental study of physical, mechanical, and thermal properties of
[15] H. Fayaz, et al., An investigation on the activation energy and thermal degradation
Rattan fiber reinforced hybrid epoxy resin laminated composite, Results in
of biocomposites of jute/bagasse/coir/nano TiO2/epoxy-reinforced polyaramid
Engineering, Volume 22, 2024, 102053, ISSN 2590-1230, https://doi.org/10.10
fibers, J. Nanomater. 2022 (2022), https://doi.org/10.1155/2022/3758212.
16/j.rineng.2024.102053.
[16] V. Ramesh, P. Anand, Thermal analysis of Kevlar/basalt reinforced hybrid polymer
[4] M. Wang, Z. Pan, Z. Ying, Z. Wu, Symmetric and asymmetric intercalation effect on
composite, Mater. Res. Express 8 (11) (2021) 115302, https://doi.org/10.1088/
the low-velocity impact behavior of carbon/Kevlar hybrid woven laminates,
2053-1591/ac3aa6.
Compos. Struct. 297 (November 2021) (2022) 115919, https://doi.org/10.1016/j.
compstruct.2022.115919.
9
R. Saha et al. Results in Materials 22 (2024) 100588
[17] B. Murali, et al., Mechanical and dynamic mechanical properties of hybrid kevlar/ [36] S.S. Shera, N. Kulhar, R.M. Banik, Silk and silk fibroin-based biopolymeric
natural fiber composites, Mater. Res. Express 10 (1) (2023), https://doi.org/ composites and their biomedical applications, in: Materials for Biomedical
10.1088/2053-1591/ad02e1. Engineering: Biopolymer Fibers, Elsevier, 2019, pp. 339–374, https://doi.org/
[18] V. Ramesh, K. Karthik, K. Arunkumar, N.K. Unnam, R. Ganesh, C. Rajkumar, Effect 10.1016/B978-0-12-816872-1.00012-1.
of sawdust filler with Kevlar/basalt fiber on the mechanical properties [37] G. Pandey, M. Sreekumar, Development of high strength bio-composite material
epoxy–based polymer composite materials, Mater. Today Proc. (October) (2022), for light weight serial robot mechanisms, Procedia Comput. Sci. 76 (2015)
https://doi.org/10.1016/j.matpr.2022.09.208. 512–521, https://doi.org/10.1016/j.procs.2015.12.328. Iris.
[19] V. Ramesh, K. Karthik, R. Cep, M. Elangovan, Influence of stacking sequence on [38] D.R. Drodge, B. Mortimer, C. Holland, C.R. Siviour, Ballistic impact to access the
mechanical properties of basalt/ramie biodegradable hybrid polymer composites, high-rate behaviour of individual silk fibres, J. Mech. Phys. Solid. 60 (10) (2012)
Polymers 15 (4) (2023), https://doi.org/10.3390/polym15040985. 1710–1721, https://doi.org/10.1016/j.jmps.2012.06.007.
[20] D. Rajamani, E. Balasubramanian, A. Ziout, M. Alkahtani, Synergistic effect of r-GO [39] H.A. Tuan, S. Hirai, Y. Tamada, S. Akioka, Preparation of silk resins by hot pressing
on the mechanical, microstructural and high velocity impact behaviour of synthetic Bombyx mori and Eri silk powders, Mater. Sci. Eng. C 97 (December 2018) (2019)
fibre reinforced NiTi intermetallic laminates, J. Mater. Res. Technol. 25 (2023) 431–437, https://doi.org/10.1016/j.msec.2018.12.060.
3967–3984, https://doi.org/10.1016/j.jmrt.2023.06.185. [40] Adib Bin Rashid, Md Enamul Hoque, 14 - Polymer nanocomposites for defense
[21] S.L. Valenҫa, S. Griza, V.G. De Oliveira, E.M. Sussuchi, F.G.C. De Cunha, Evaluation applications, in: Md Enamul Hoque, Kumar Ramar, Ahmed Sharif (Eds.),
of the mechanical behavior of epoxy composite reinforced with Kevlar plain fabric Woodhead Publishing in Materials, Advanced Polymer Nanocomposites,
and glass/Kevlar hybrid fabric, Composites, Part B 70 (2015) 1–8, https://doi.org/ Woodhead Publishing, 2022, pp. 373–414. https://doi.org/10.1016/B978-0-12-
10.1016/j.compositesb.2014.09.040. 824492-0.00015-5. ISBN 9780128244920.
[22] AB Rashid, ME Hoque, N Kabir, FF Rifat, H Ishrak, A Alqahtani, MEH Chowdhury, [41] B.R. Adib, H. Mahima, I. S M Mohaimenul, U.L. K M Rafi, Nanotechnology-
Synthesis, Properties, Applications, and Future Prospective of Cellulose enhanced fiber-reinforced polymer composites: Recent advancements on
Nanocrystals, Polymers 15 (20) (2023) 4070. https://doi.org/10.3390/polym1520 processing techniques and applications, Heliyon 10 (2) (2024) e24692. https://doi.
4070. org/10.1016/j.heliyon.2024.e24692. ISSN 2405-8440.
[23] Noshin Tasnim Tuli, Sinthea Khatun, Adib Bin Rashid, Unlocking the future of [42] A. Avci, H. Arikan, A. Akdemir, Fracture behavior of glass fiber reinforced polymer
precision manufacturing: A comprehensive exploration of 3D printing with fiber- composite, Cement Concr. Res. 34 (3) (2004) 429–434, https://doi.org/10.1016/j.
reinforced composites in aerospace, automotive, medical, and consumer industries, cemconres.2003.08.027.
Heliyon, Volume 10, Issue 5, 2024, e27328, ISSN 2405-8440, https://doi.org/10. [43] M.J. Aubad, B.A. Abass, S.N. Shareef, Investigation of the effect of multi wall
1016/j.heliyon.2024.e27328. carbon nano tubes on the dynamic characteristics of woven kevlar/carbon fibers-
[24] L. Lv, et al., Biomimetic hybridization of kevlar into silk fibroin: nanofibrous polyester composites, Mater. Res. Express 7 (1) (Jan. 2020), https://doi.org/
strategy for improved mechanic properties of flexible composites and filtration 10.1088/2053-1591/ab5d67.
membranes, ACS Nano 11 (8) (2017) 8178–8184, https://doi.org/10.1021/ [44] R. Muthalagu, J. Murugesan, S. Sathees Kumar, B. Sridhar Babu, Tensile attributes
acsnano.7b03119. and material analysis of kevlar and date palm fibers reinforced epoxy composites
[25] J. Zhang, J. Kaur, R. Rajkhowa, J.L. Li, X.Y. Liu, X.G. Wang, Mechanical properties for automotive bumper applications, in: Materials Today: Proceedings, Elsevier
and structure of silkworm cocoons: a comparative study of Bombyx mori, Ltd, 2021, pp. 433–438, https://doi.org/10.1016/j.matpr.2020.09.777.
Antheraea assamensis, Antheraea pernyi and Antheraea mylitta silkworm cocoons, [45] C. Lopes Martins Marques, S.R. Kumar, C. Goswami, R. Verma, Numerical
Mater. Sci. Eng. C 33 (6) (2013) 3206–3213, https://doi.org/10.1016/j. simulation of armor materials and optimization using gray relational analysis,
msec.2013.03.051. Mater. Today Proc. 44 (2020) 4717–4730, https://doi.org/10.1016/j.
[26] S. Ataollahi, S.T. Taher, R.A. Eshkoor, A.K. Ariffin, C.H. Azhari, Energy absorption matpr.2020.10.942.
and failure response of silk/epoxy composite square tubes: experimental, [46] S.G. Nukala, I. Kong, A.B. Kakarla, V.I. Patel, H. Abuel-Naga, Simulation of wood
Composites, Part B 43 (2) (2012) 542–548, https://doi.org/10.1016/j. polymer composites with finite element analysis, Polymers 15 (9) (May 2023),
compositesb.2011.08.019. https://doi.org/10.3390/polym15091977.
[27] S.A. Oshkovr, S.T. Taher, A.A. Oshkour, A.K. Ariffin, C.H. Azhari, Finite element [47] H. Ebrahimnezhad-Khaljiri, R. Eslami-Farsani, E. Akbarzadeh, Effect of interlayer
modelling of axially crushed silk/epoxy composite square tubes, Compos. Struct. hybridization of carbon, Kevlar, and glass fibers with oxidized polyacrylonitrile
95 (2013) 411–418, https://doi.org/10.1016/j.compstruct.2012.07.032. fibers on the mechanical behaviors of hybrid composites, Proc. Inst. Mech. Eng.
[28] S. Chen, M. Liu, H. Huang, L. Cheng, H.P. Zhao, Mechanical properties of Bombyx Part C J. Mech. Eng. Sci. 234 (9) (May 2020) 1823–1835, https://doi.org/10.1177/
mori silkworm silk fibre and its corresponding silk fibroin filament: a comparative 0954406219897935.
study, Mater. Des. 181 (Nov) (2019), https://doi.org/10.1016/j. [48] S.M. Shohel, S.H. Riyad, A.A. Noman, Materials Today : proceedings Study to
matdes.2019.108077. analyze the mechanical strength of composite glass fiber laminated with resin
[29] L. Ranakoti, M.K. Gupta, P.K. Rakesh, Silk and silk-based composites: opportunities epoxy , resin polyester , and PVC foam under tensile loading conditions by
and challenges, in: Materials Horizons: from Nature to Nanomaterials, Springer numerically using finite element analysis via Ansys, Mater. Today Proc. (2023),
Nature, 2019, pp. 91–106, https://doi.org/10.1007/978-981-13-6019-0_7. https://doi.org/10.1016/j.matpr.2023.05.062 xxxx.
[30] H. Qu, L. Chen, F. Yang, J. Zhu, C. Qi, G. Peng, Synthesis of an environmentally [49] J. Cao, J. Lai, J. Zhou, N. Kang, L. Du, Y. Miao, Experiments and simulations of the
friendly modified mulberry branch-derived biochar composite: high degradation ballistic response of ceramic composite armors, J. Mech. Sci. Technol. 34 (7)
efficiency of BPA and mitigation of toxicity in silkworm larvae, Int. J. Mol. Sci. 24 (2020) 2783–2793, https://doi.org/10.1007/s12206-020-0611-8.
(4) (2023), https://doi.org/10.3390/ijms24043609. [50] C. Stephen, B. Shivamurthy, A.H.I. Mourad, R. Selvam, M. Mohan, Experimental
[31] S. Chand, S. Chand, B. Raula, Usage of silkworm materials in various ground of and finite element study on high-velocity impact resistance and energy absorption
science and research, J. Nat. Fibers 20 (1) (2023), https://doi.org/10.1080/ of hybrid and non-hybrid fabric reinforced polymer composites, J. Mater. Res.
15440478.2022.2139328. Technol. 18 (May 2022) 5406–5418, https://doi.org/10.1016/j.jmrt.2022.05.007.
[32] B.O. Ode Boni, et al., Immune response to silk sericin–fibroin composites: potential [51] A. Borisova, T. Glaskova-Kuzmina, A. Aniskevich, Šiluminės ir mechaninės
immunogenic elements and alternatives for immunomodulation, Macromol. Biosci. bisfenolio A epoksidin ės dervos, užpildytos daugiasieniais anglies nano
22 (1) (Jan. 2022), https://doi.org/10.1002/mabi.202100292. John Wiley and vamzdeliais, savybės, Lith. J. Phys. 55 (3) (2015) 191–199, https://doi.org/
Sons Inc. 10.3952/physics.v55i3.3148.
[33] C. Ranjan, G. Sarkhel, K. Kumar, Investigation of mechanical, tribological, and [52] M. Humenik, T. Scheibel, A. Smith, Spider Silk: Understanding the Structure-
electrical properties of silk reinforced polymeric composite, Adv. Mater. Sci. Eng. Function Relationship of a Natural Fiber, first ed., vol. 103, Elsevier Inc., 2011,
2023 (2023), https://doi.org/10.1155/2023/1507891. https://doi.org/10.1016/B978-0-12-415906-8.00007-8.
[34] H. Xu, et al., Obtaining high mechanical performance silk fibers by feeding purified [53] O. Hakimi, D.P. Knight, F. Vollrath, P. Vadgama, Spider and mulberry silkworm
carbon nanotube/lignosulfonate composite to silkworms, RSC Adv. 9 (7) (2019) silks as compatible biomaterials, Composites, Part B 38 (3) (2007) 324–337,
3558–3569, https://doi.org/10.1039/c8ra09934k. https://doi.org/10.1016/j.compositesb.2006.06.012.
[35] Y. Yang, et al., Non-mulberry silk fiber-based scaffolds reinforced by PLLA porous
microspheres for auricular cartilage: an in vitro study, Int. J. Biol. Macromol. 182
(Jul. 2021) 1704–1712, https://doi.org/10.1016/j.ijbiomac.2021.05.145.
10