Composite Structure as a Stress Wave Barrier Zone Under Impulse Loading: Microscale Numerical Analysis of Attenuation

This study investigates the design factors of stress wave barrier zones intended for manufacturing machines under impulse loading, using polymer discontinuously reinforced composites with specified internal microstructures, which effectively suppress stress at the wave front, promote uniform stress distribution, improve impact resistance, and reduce vibrations and noise. Two-dimensional representative unit cells and explicit finite element simulations were used to analyze stress wave propagation under impulse loading. The effects of inclusion shape, orientation, distribution, interlayer, and size of the interface on stress wave scattering and attenuation were examined. In our models, hollow inclusions demonstrated 20.6% higher attenuation compared to solid inclusions, with the hollow fiber inclusion showing the most significant improvement. Inclusion orientation relative to the stress wave direction affected attenuation by 18.5%, while redistribution of inclusions and addition of a compliant interlayer contributed additional increments of 3–11%. These results highlight the critical role of microscale topology in stress barrier zone designing, such that the combined adjustment of inclusion shape, orientation, interlayer presence, and spatial distribution provides an effective strategy to maximize stress wave attenuation.