A Hybrid Mesh Filament‐Level Model for Quasi‐Static Puncture of Woven Fabrics: Boundary Effects and Damage Mechanisms

ABSTRACT This study investigates the quasi‐static puncture response of aramid plain‐weave fabric through an integrated experimental and numerical approach. A novel full‐scale filament‐level model based on a hybrid mesh technique within the Digital Element Approach framework is developed, enabling efficient simulation with fiber‐level resolution. Four experimental configurations combining two boundary conditions (four‐edge clamped vs. two‐edge constrained) and two indenter geometries (hemispherical vs. cylindrical) were tested and simulated. The results show that hemispherical indenters induce tensile‐dominant filament failure with peak forces approximately double those of cylindrical indenters under four‐edge constraints, whereas cylindrical indenters promote shear‐dominated failure along their sharp edges. Boundary conditions critically modulate the response: two‐edge constraints significantly reduce yarn engagement and overall resistance. The model is validated with less than 20% deviation in peak force and accurately captures deformation patterns and stress propagation. Parametric studies further reveal that the puncture force is insensitive to velocity in the 5–20 m/s range, exhibits moderate size dependence, but increases linearly with areal density (35% rise from 150 to 250 g/m 2 ). This work provides a validated filament‐level modeling platform for designing puncture‐resistant fabrics by elucidating the interplay among indenter shape, boundary constraint, and fabric architecture.