COMBAT_HELMET_USING_KEVLAR-129_&_UHMWPE_PPT_ NOOBTRON_PRIVATE_LIMITED-2.pptx

YULKGILK;,JK,m,
JKL"jk;L
KJ
JK.
/Jk

K
K.

1. GNANAMANI COLLEGE OF TECHNOLOGY DEPARTMENT OF INDUSTRIAL ENGINEERING PROJECT TITLE: AN EXPERIMENTAL INVESTIGATION ON ADVANCED COMBAT HELMET USING KEVLAR-129 & NATURAL FIBRE MATERIAL Dr.S.KRISHNAKUMAR,M.E,Ph.D , Assistant Professor , Department of Mechanical Engineering , PERPARED BY: MR.K.P.MANIKANDAM .BE, ME – INDUSTRIAL ENGINEERING PROJECT GUIDE :

2. ABSTRACT This study investigated an advanced lightweight ballistic helmet designed to protect military personnel from TBIs and other brain injuries caused by blunt and ballistic impacts. The helmet's hybrid design incorporates Kevlar-129, Kenaf, Sisal Fiber, and Pineapple Leaf Fiber (PALF), known for their high strength and light weight, resulting in a durable product. The helmet meets PN-V-87001:2011 and NIJ standards, providing excellent visibility, ease of movement, and no neck strain while protecting against projectiles traveling at approximately 676 m/s. Extensive testing, including electrical conductivity, thermal conductivity, fire resistance, and FRF tests, evaluated the helmet's material properties and performance.

3. Weighing only around 1.0 kg, the helmet combines high-strength fibres to offer robust protection while remaining easy to wear and move in. The research supports the helmet as an effective protective solution, enhancing the safety of military personnel and reducing the risk of head injuries in combat situations. Keywords: UHMWPE, Kevlar-129, Bullet Proof Helmet, Traumatic Brain Injury, Advanced Combat Helmet, NIJ standards.

4. INTRODUCTION For many years, protective equipment has been a crucial aspect of military and law enforcement personnel, especially in combat situations. Ballistic helmets are designed to protect against projectiles and explosions and are essential for maintaining the safety and well-being of individuals in high-risk environments. With the increase in weapon advancement and the threat of weapons of mass destruction, the demand for ballistic helmets has increased, and the need for more advanced helmets with better protection capabilities has become crucial.

5. To develop and investigate an advanced ballistic helmet using Kevlar 129 with Ultra-High Molecular Weight Polyethylene (UHMWPE) materials to increase protection for military personnel against Traumatic Brain Injuries (TBIs) and other types of head injuries. The study's objectives are to design and develop an advanced lightweight ballistic helmet using hybrid materials, to enhance durability and reduce the helmet's weight while meeting the requirements set out in the PN-V-87001:2011 and NIJ Standards. To ensure maximum protection for military personnel against TBIs and other head injuries and to meet the requirements set out in the PN-V-87001:2011 and NIJ Standards.

6. Hybrid materials, such as Kevlar and UHMWPE, are evaluated to provide more advanced ballistic helmet protection. The helmet's protective performance, weight and balance, and vibration characteristics are tested and evaluated to ensure that it meets the requirements set out in the PN-V-87001:2011 and NIJ Standards. The study is conducted to ensure maximum protection for military personnel against TBIs and other types of head injuries while providing an advanced lightweight ballistic helmet made from hybrid materials. This aims to enhance the capabilities of ballistic helmets and improve the safety of military personnel in high-risk environments, ultimately reducing the potential for injuries and enhancing operational efficiency.

7. In the current system, advanced combat helmets are made of kevlar and polycarbonate as the outer shell. While Kevlar provides good ballistic protection, the polycarbonate shell makes the helmet heavy, which can cause fatigue and discomfort. In addition, the polycarbonate shell is brittle and can shatter upon impact, providing little resistance to energy transfer to the wearer's head. Moreover, the current helmets usually do not address the issue of blast impact and overpressure injuries, which can cause severe brain damage and death even without a direct ballistic impact. EXISTING SYSTEM

8. To address these issues, the proposed system uses a hybrid design that combines the advantages of kevlar and ultra-high molecular weight polyethylene (UHMWPE). The resulting composite material provides a high strength-to-weight ratio, which can help reduce the weight of the helmet without lowering its protective capabilities. Additionally, the composite material absorbs impact energy more effectively, thereby reducing the risk of blast and ballistic injuries. The proposed helmet also has an ergonomic design that reduces fatigue and discomfort for the wearer.

9. PROPOSED SYSTEM The proposed advanced combat helmet uses composite material made of kevlar and UHMWPE-reinforced epoxy composites as the outer shell and resin as the filling substance. The composite material is designed to provide a high strength-to-weight ratio and good impact-absorbed energy. The outer shell of the helmet is optimized for blast and bullet impact protection, while the filling resin is specifically designed to prevent penetration of the projectile. The helmet is also designed to be comfortable and ergonomic, making it easy to wear for long periods. The helmet is also designed to meet or exceed the requirements of the PN-V-87001:2011 and NIJ Standards.

10. The proposed system aims to provide enhanced protection for military personnel against traumatic brain injuries (TBIs) and other types of head injuries, while at the same time reducing weight and improving comfort. The composite material provides better impact-absorbed energy, which can help reduce the risk of head injuries, and the ergonomic design of the helmet makes it more comfortable and easier to wear. The helmet also meets or exceeds the requirements of the PN-V-87001:2011 and NIJ Standards, ensuring that it meets or exceeds the specifications for advanced ballistic helmets.

11. MATERIALS & METHODOLOGY This involved fabricating bullet-proof helmets using Pineapple fiber , Kenaf fiber , and Sisal fiber through a Sandwich method layering process, treated with sodium hydroxide and epoxy resin, and molded at 150°C, to assess their effectiveness against various bullet types and velocities.

12. Ballistic protection is a primary consideration in the fielding of a new helmet. The ballistic performance of a composite helmet depends on the material used, helmet thickness, and fabrication method. A compromise often has to be made between the weight allowed and the ballistic protection requirements. Fig 9: Ballistic effect of a helmet

13. Hot Mould Pressing The raw material have been purchased from the local market and pre-processed with the basic processing of cleaning, measurement, dimension calculation of helmet size and according to the size the raw material has been marked and cutted to the desired stacking sequence. Furthermore, these materials have been processed for basic inspection such as properties of material thickness, layer, weight of raw material, dimension and so on.

14. FRF (Frequency Response Function) Testing Free vibration tests were performed for Combat Helmet and fixed-end boundary condition of beam using impulse frequency response test. A disturbing force was given to constrained helmet shell by means of an impulse hammer accompanied with a force transducer facility ( Dytron model 5800B3), and the vibration response was measured using piezoelectric accelerometer ( Dytron model 3055B2).

15. EXPERIMENTAL PROCEDURE & TESTING METHODS Schematic Diagram Experimental Testing Setup of a Helmet

16. Indentation/Rebound Drop Test An Indentation/Rebound Drop Test was developed to physically show force being transferred through a plumb bob of weight 2.0 KGS from a height of 1.0 Meter. A modeling compound was placed onto the table and was smoothed out to ensure an even surface for accurate measurements.

17. FRF Calculation of PALF Helmet Experimental Graph 1 FRF Calculation of PALF + KENAF + SISAL Helmet Experimental Graph 2

18. FRF Calculation of Kevlar-129 Helmet Experimental Graph 3

19. A keen exploration of the proposed ACH is as follow: The utilization of natural fibers in the laminated hybrid composites to completely replacing the synthetic fibers is already a promising line of investigation The Proposed Natural fibers are ease the way of Mass Production in industry, Eco- friendly in nature Natural Fiber Material based Combat/ Defence Helmet is purely an Indian Made whereas, Kevlar is a foreign, that makes a demand to depend on foreign countries Weight of the Helmet have reduced, the change from synthetic fibers to natural fiber provides more profitability to producers and the growth of agro-industry DISCUSSION

20. Recyclability of the helmet made easier, pollution free that causes eco-friendly in surrounding. During the impact test 4.5Kg of load dropped from the height of 3 m height on the helmet place on the dummy head. Cost of the helmet becomes 3 times lesser than the existing material cost, that helps the defence , industry and the agro-industry to grow economically as well the time consumption of helmet manufacturing have been reduced about 2 mins during production The Damping factor of Pineapple Leaf Fiber Material performs higher efficient comparatively twice the performance of Kevlar material, Thus in all factors including Life Cycle and Economical efficiency the proposed Helmet draws excellent outcomes

21. In this project, a Natural-Fiber Oriented Advanced Ballistic Military Helmet was developed using natural fibers such as Pineapple Leaf Fiber (PALF), Kenaf Fiber, and Sisal Fibers as replacements for Kevlar. Various models with different material stacking configurations were tested. Despite minor pressure differences between helmet configurations, different injury mechanisms were identified: non-contact impacts caused inertia-induced strain in the brain, while contact impacts resulted in localized helmet indentations on the skull. Tensile tests using an Instron 1125 in tension mode with a Cload cell revealed that PALF and PALF + Sisal Fiber + Kenaf Fiber combinations performed better than other materials. Flammability tests confirmed that these materials passed with some variations due to differing flame resistance intensities. CONCLUSION

22. Both static and dynamic tests, following Defence standards, showed that Pure PALF material exhibited a high damping coefficient of 15.54% up to an upper frequency of 92.887 Hz, providing excellent damping compared to the 8.16% damping coefficient of the PALF + Kenaf + Sisal Fiber composite material at 136.374 Hz. Overall, the proposed natural fiber materials demonstrated twice the performance of existing Kevlar-129 combat helmet materials. These materials are deemed safe against projectiles, bomb blasts, and can be easily manufactured, offering a significant advancement in military helmet technology.

23. REFERENCES [1] Sarvghad -Moghaddam, H., Rezaei, A., Eslaminejad , A., Ziejewski , M. and Karami, G., 2016. Mechanical Response of the Brain Under Blast: The Effect of Blast Direction and the Head Protection. In ASME 2016 International Mechanical Engineering Congress and Exposition. American Society of Mechanical Engineers Digital Collection. [2] Zhu, Y., Ma, J., Fan, Z., Wen, Y., Xu, C. and Xia, M., 2024. Ballistic impact performance and blunt injury assessment of ceramic/UHMWPE laminate composite body armor . Journal of Materials Research and Technology, 29, pp.1703-1728. [3] Viliš , J., Neumann, V., Vítek , R., Zouhar , J., Pokorný , Z. and Marek, M., 2023. Analysis of Ballistic Impact of 7.62 mm FMJ M80 Rifle Projectile into Twaron /UHMWPE Composite Armor. Journal of Composites Science, 7(9), p.390. [4] Wang, H., Weerasinghe, D., Hazell, P.J., Mohotti , D., Morozov, E.V. and Escobedo-Diaz, J.P., 2023. Ballistic impact response of flexible and rigid UHMWPE textile composites: Experiments and simulations. Defence Technology, 22, pp.37-53. [5] Wantang , T., Pipathattakul , M. and Wiwatwongwana , F., 2023. Experimental investigation of ballistic capabilities in Carbon-Kevlar composites: Effects of weight and layer variations against 9 mm projectiles. Results in Materials, 20, p.100464.

24. THANKYOU