This research project aimed to analyze and design the pattern of a bulletproof metal armor plate as well as build a bulletproof metal armor plate for a small armored regular truck. The methodology consisted of the NIJ standard test and the finite element analysis. The bulletproof plates created were tested for a real firing. Their firing results were compared with those of NIJ-standard using a finite element program in this case applying with the program Ansys/Explicit Dynamic. SolidWorks program is employed as a tool to design and create 3D models of armor plates and bullets. The materials taken in the finite element simulation were SKD11 and SUS304 and the parameters utilized in the research were material types hardness values spacing between the plates and thickness. In the case of two armor plates stacked SKD11 material was designed for the first armor plate to be hit by the bullet. It served to destroy bullets. In addition the second armor plate made of SUS304 material served to absorb energy and obstruct the movement of bullets. For testing a 30-06 caliber M2 AP 166 Gr bullet was selected at a 0-degree angle and the velocities measured and set by the Ansys/Explicit Dynamic program were 901.7 m/s and 880 m/s respectively. The front plate made of SKD11 material with a thickness of 10 mm and the back plate made of SUS304 material with a thickness of 10 mm were fired 1 shot. The results showed that the bullet could penetrate the front armor plate but not penetrate the back-armor plate. In the NIJ 3 standard tests the shooting with a 7.62x51 mm NATO FMJ 148 Gr shell at a 0-degree angle for 5 times with velocities equal to 846.4 841.3 839.1 838.2 and 845.3 m/s was performed on the stacking front and back armor plates both made of SUS304 material with a thickness of 8 mm. The bullet velocity simulated by the Ansys program was 847 m/s resulting in the front plate having a bullet penetration and a slight bulge on the back plate. From the finite element simulation results and the actual test results it was found that the damage to the armor plates detected by both methods was consistent. Therefore the finite element program was selected to simulate the damage of armor plates resistant to penetration according to the NIJ standard Level 4. The results of the research could be concluded that the use of armor plates stacked with suitable different materials in multiple layers would affect the penetration resistance. Increased thickness and optimal spacing between the armor plates were important parameters in penetration resistance. Moreover it revealed that the higher the material hardness the better its ability to resist penetration. In particular this suggestion should be applied to the first armor plate or front armor plate.

This research has been studied and created the ceramic armor plates with composite materials that been proceeded from drying compression process with mold. Al2O3 that use for compression forming has been analyzed by SEM and XRD. It showed that compound and powder particle led to 5 microns-sized. It had flat circle shape of colundum Al2O3 and hexagonal crystal system. Upper punch of molding has designed and analyzed by FEA to 2 forms first form was the end-point had flat face and second form was the end-point had a convex. Upper punch had been made from AISI 52100 with 64 HRC ceramic armor plate had been produced by compression at 1000 kN which had hexagon side shape of width 25.98 mm for each side or height between parallel side of 45 mm. Al2O3 had been compressed to investigate the distribution of relative density for the height after compression of 15 and 30 mm by analyzing 4 cases that consist of 1.) a case of smooth face of upper punch which has green compact of 15 mm height 2.) a case of convex face of upper punch which has green compact of 15 mm height 3.) a case of smooth end face of upper punch which has green compact of 30 mm height 4.) a case of convex face of upper punch which has green compact of 30 mm height. The result of this study is to propose the distribution of relative density on horizontal axis as it is a relative radius and vertical axis is a relative distance from the upper punch that is an axis of moving down action. This study found that the distribution of relative density form had analogous form for these 4 cases the density had few differences and had high value at the town edge of green compact due friction between die wall and upper punch. The ceramic armor plate has been set up on UHMWPE fiber plate and used special silicone to connect them together then will get the NIJ 3 standard of ceramic armor plate with Composite materials

This thesis was an analysis of the significance of angle of inclination and the thickness of the armor plate on the penetration resistance of bullets on aluminum and stainless steel armor plates determined by the finite element method. In this study the information results obtained from actual firing of bulletproof armor and the finite element simulation according to NIJ 3 standards were compared to create a pattern of bulletproof and bulletproof armor using the SolidWorks program. The simulation model of the armor shooting was created by the Ansys/Explicit Dynamics program. The bullet material was 7.62 mm tungsten carbide (WC). There were three plate types used in the simulation were made of different bulletproof armor materials: 1) stainless steel SUS304 using for the plate thickness of 5 6 8 10 14 20 30 40 45 and 55 mm. 2) aluminum AL7075 using for the plate thicknesses of 6 8 10 and 20 mm. Additionally 3) tungsten carbide using for the plate thicknesses of 6 8 and 10 mm. Each of these plates had a width x length of 300 x 300 mm. The simulation models were divided into two types: Type 1 a simulation firing at one plate at a time. Type II a simulation firing at two layered plates stacked together without any gaps between plates. The front and the back plates made of stainless steel and aluminum respectively or tungsten carbide and stainless steel respectively were determined. The angles of firing at bulletproof armor were set at 0 30 and 45 degrees. The output results were that in Type I the stainless-steel plate with a thickness of 30 mm or more could resist the penetration of bullets. However in Type II 2 stacked layers of the armor plates using the front stainless plate with a thickness of only 20 mm and the back aluminum plate with a thickness of only 8 mm could provide the same constructive results as those of tungsten carbide and stainless steel plates for the front and back plates with both thickness setting at 16 mm. All of them showed the resistance of the penetration to the bullets. More observation was that the increases in angles as a result enhanced more resistance of the bulletproof plates to bullet penetration.