Design and Analysis of Flexible UHMWPE–Rubber Composite Panels under Ballistic Impact

Abstract This study presents the development and evaluation of a flexible ballistic armour system composed of lightweight, cost-effective, commercially available materials, specifically unidirectional ultra-high molecular weight polyethylene (UHMWPE UD; Dyneema® HB26) and styrene–butadiene rubber (SBR-65, Shore A hardness 65). Three panel configurations with identical thickness and areal density were designed to isolate the effect of rubber layer placement, positioning the rubber as an intermediate layer, on the striking face, and on the rear face, respectively. Ballistic performance was evaluated through experimental testing and validated finite element simulations against a 9-mm full metal jacket (FMJ) projectile at an impact velocity of 356 m/s. It was observed that all configurations successfully arrested the projectile, while the placement of the rubber layer significantly influenced the impact response: The rear-face configuration showed greater performance, being characterized by faster projectile deceleration, improved energy absorption, and reduced back-face deformation (BFD). The back-face deformation remained within acceptable limits for all configurations. The findings from both experiments and simulations demonstrate that varying rubber position alone significantly influences energy absorption characteristics, projectile deceleration behaviour, and back-face deformation.