Numerical analysis of ply arrangements in laminated composites under impact loading

Purpose The purpose of this study is to investigate the influence of ply stacking sequences – particularly unconventional helical orientations – on the impact behavior of laminated composite materials. By using numerical simulation, the research aims to identify lay-up configurations that can enhance energy absorption and reduce internal damage under impact loading. The ultimate goal is to propose an innovative ply design approach that improves the structural performance and durability of composite components used in advanced engineering applications. Design/methodology/approach This study investigates the impact behavior of laminated composite materials through a numerical approach using the Abaqus finite element software. The focus is on analyzing the effect of ply orientation – both conventional and unconventional – on the energy absorption and damage resistance of composite plates subjected to impact. Two geometric models, a square and a rectangular plate, were modeled under different boundary conditions. The simulation considered conventional stacking sequences such as unidirectional plies ([0°]37) and quasi-isotropic configurations ([0°/45°/90°/ … /180°]37), as well as novel helical ply orientations ([0°/5°/10°/ … /180°]37 and [0°/10°/20°/ … /360°]37). The results demonstrate that ply lay-up has a substantial effect on both the energy absorbed during impact and the extent of internal damage. Notably, helical stacking with small angular increments (5 and 10°) significantly enhances impact resistance, indicating the potential of this new design approach to improve the structural integrity of laminated composites. Findings The numerical results demonstrate that the ply lay-up configuration significantly affects the impact performance of laminated composite plates. Conventional stacking sequences show limited energy absorption and larger damage zones under impact. In contrast, helical stacking sequences—particularly those with small incremental angles of 5° and 10° – exhibit improved impact resistance, with greater energy absorption and reduced damage propagation. The study confirms that helical orientations provide a more uniform stress distribution and delay damage initiation, making them a promising alternative to traditional lay-up strategies in applications requiring enhanced structural integrity under impact loading. Originality/value This study introduces a novel concept of helical ply orientations in laminated composites, diverging from traditional stacking sequences. By numerically analyzing the impact response of both conventional and helical lay-ups, the work highlights the superior performance of small-angle helical configurations (5 and 10°) in enhancing energy absorption and minimizing damage. This approach offers a new design pathway for improving the impact resistance of composite structures, with potential applications in aerospace, automotive and defense sectors. The findings provide valuable insights for researchers and engineers seeking to optimize composite performance through advanced lay-up strategies.