Simulation of the Lightweight Ceramic/Aluminum Alloy Composite Armor for Optimizing Component Thickness Ratios
The lightweight ceramic/aluminum alloy composite armor design is examined and optimized to get better protective performance. The armor penetrability is simulated via the smooth particle hydromechanics approach using the ANSYS/AUTODYN software. The accuracy of the program was verified by comparing w...
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Інститут проблем міцності ім. Г.С. Писаренко НАН України
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irk-123456789-1882982023-02-23T01:27:07Z Simulation of the Lightweight Ceramic/Aluminum Alloy Composite Armor for Optimizing Component Thickness Ratios Chang, Z.-L. Zhao, W.-L. Zou, G.-P. Sun, H.-Q. Научно-технический раздел The lightweight ceramic/aluminum alloy composite armor design is examined and optimized to get better protective performance. The armor penetrability is simulated via the smooth particle hydromechanics approach using the ANSYS/AUTODYN software. The accuracy of the program was verified by comparing with known data. Three composite armor types with the total thickness of 30, 40, and 50 mm, and five different ceramic/metal thickness ratios were analyzed in simulation of the residual bullet speed and the final distance. Simulation results are compared with the theoretical model. The best bullet protective performance of the three armor types was obtained with the ceramic/aluminum alloy thickness ratio of 4:1. Конструкция легковесной брони из композита керамика/алюминиевый сплав рассматривается и оптимизируется для улучшения защитных характеристик. Процесс проникновения в броню моделируется с использованием программы SPH программного обеспечения ANSYS/AUTODYN. Точность метода сглаженных частиц (метод SPH) была подтверждена путем сравнения полученных данных с известными. Рассматривались три типа композитной брони общей толщины 30, 40, 50 мм и с пятью различными отношениями толщина керамики/толщина металла при моделировании остаточной скорости пули и конечной длины. Результаты моделирования сравниваются с теоретической моделью. Лучшие пулезащитные характеристики трех типов брони из керамического композита были получены при отношении толщина керамики/толщина алюминия в композитной броне 4:1. Конструкція легковагій броні з композиту кераміка / алюмінієвий сплав розглядається і оптимізується для поліпшення захисних характеристик. Процес проникнення в броню моделюється з використанням програми SPH програмного забезпечення ANSYS / AUTODYN. Точність методу згладжених частинок (метод SPH) була підтверджена шляхом порівняння полу¬ченних даних з відомими. Розглядалися три типи композитної броні загальної товщини 30, 40, 50 мм і з п'ятьма різними відносинами товщина кераміки / товщина металу при моделюванні залишкової швидкості кулі і кінцевої довжини. Результати моделювання порівнюються з теоретичною моделлю. Кращі кулезахисні характеристики трьох типів броні з керамічного композиту були отримані при співвідношенні товщина кераміки / товщина алюмінію в композитної броні 4: 1. This work was supported by the National Natural Science Foundation of China (Nos. 11602068 and 11602066) and Fundamental Research Funds for the Central Universities (Nos. HEUCFM170203, HEUCFP201744, and HEUCFP201762). 2019 Article Simulation of the Lightweight Ceramic/Aluminum Alloy Composite Armor for Optimizing Component Thickness Ratios / Z.-L. Chang, W.-L. Zhao, G.-P. Zou, H.-Q. Sun // Проблеми міцності. — 2019. — № 1. — С. 16-23. — Бібліогр.: 10 назв. — англ. 0556-171X http://dspace.nbuv.gov.ua/handle/123456789/188298 539.4 en Проблемы прочности Інститут проблем міцності ім. Г.С. Писаренко НАН України |
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Научно-технический раздел Научно-технический раздел Chang, Z.-L. Zhao, W.-L. Zou, G.-P. Sun, H.-Q. Simulation of the Lightweight Ceramic/Aluminum Alloy Composite Armor for Optimizing Component Thickness Ratios Проблемы прочности |
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The lightweight ceramic/aluminum alloy composite armor design is examined and optimized to get better protective performance. The armor penetrability is simulated via the smooth particle hydromechanics approach using the ANSYS/AUTODYN software. The accuracy of the program was verified by comparing with known data. Three composite armor types with the total thickness of 30, 40, and 50 mm, and five different ceramic/metal thickness ratios were analyzed in simulation of the residual bullet speed and the final distance. Simulation results are compared with the theoretical model. The best bullet protective performance of the three armor types was obtained with the ceramic/aluminum alloy thickness ratio of 4:1. |
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Article |
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Chang, Z.-L. Zhao, W.-L. Zou, G.-P. Sun, H.-Q. |
author_facet |
Chang, Z.-L. Zhao, W.-L. Zou, G.-P. Sun, H.-Q. |
author_sort |
Chang, Z.-L. |
title |
Simulation of the Lightweight Ceramic/Aluminum Alloy Composite Armor for Optimizing Component Thickness Ratios |
title_short |
Simulation of the Lightweight Ceramic/Aluminum Alloy Composite Armor for Optimizing Component Thickness Ratios |
title_full |
Simulation of the Lightweight Ceramic/Aluminum Alloy Composite Armor for Optimizing Component Thickness Ratios |
title_fullStr |
Simulation of the Lightweight Ceramic/Aluminum Alloy Composite Armor for Optimizing Component Thickness Ratios |
title_full_unstemmed |
Simulation of the Lightweight Ceramic/Aluminum Alloy Composite Armor for Optimizing Component Thickness Ratios |
title_sort |
simulation of the lightweight ceramic/aluminum alloy composite armor for optimizing component thickness ratios |
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Інститут проблем міцності ім. Г.С. Писаренко НАН України |
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2019 |
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Научно-технический раздел |
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http://dspace.nbuv.gov.ua/handle/123456789/188298 |
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Simulation of the Lightweight Ceramic/Aluminum Alloy Composite Armor for Optimizing Component Thickness Ratios / Z.-L. Chang, W.-L. Zhao, G.-P. Zou, H.-Q. Sun // Проблеми міцності. — 2019. — № 1. — С. 16-23. — Бібліогр.: 10 назв. — англ. |
series |
Проблемы прочности |
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AT changzl simulationofthelightweightceramicaluminumalloycompositearmorforoptimizingcomponentthicknessratios AT zhaowl simulationofthelightweightceramicaluminumalloycompositearmorforoptimizingcomponentthicknessratios AT zougp simulationofthelightweightceramicaluminumalloycompositearmorforoptimizingcomponentthicknessratios AT sunhq simulationofthelightweightceramicaluminumalloycompositearmorforoptimizingcomponentthicknessratios |
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2025-07-16T10:17:56Z |
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fulltext |
UDC 539.4
Simulation of the Lightweight Ceramic/Aluminum Alloy Composite Armor
for Optimizing Component Thickness Ratios
Z.-L. Chang,
a
W.-L. Zhao,
b
G.-P. Zou,
a,1
and H.-Q. Sun
a
a College of Aerospace and Civil Engineering, Harbin Engineering University, Harbin, China
b College of Science, Heilongjiang University of Science and Technology, Harbin, China
1 zouguangping901@163.com
The lightweight ceramic/aluminum alloy composite armor design is examined and optimized to get
better protective performance. The armor penetrability is simulated via the smooth particle
hydromechanics approach using the ANSYS/AUTODYN software. The accuracy of the program was
verified by comparing with known data. Three composite armor types with the total thickness of
30, 40, and 50 mm, and five different ceramic/metal thickness ratios were analyzed in simulation of
the residual bullet speed and the final distance. Simulation results are compared with the theoretical
model. The best bullet protective performance of the three armor types was obtained with the
ceramic/aluminum alloy thickness ratio of 4:1.
Keywords: ceramic composite armor, smooth particle hydromechanics method, penetration.
Introduction. With the development of modern missiles and other weapons,
protective armors get thicker and heavier. Heavy armor substantially affects the mobility of
various military vehicles, ships, airplanes, etc. It is believed that ceramic with high
hardness can inactivate the projectile body and reduce its penetration ability. However, the
brittleness and low tensile strength of ceramic materials make them unable to absorb a large
amount of energy during fragmentation [1]. Therefore, in practice, ceramic is usually used
as a panel in combination with a metal back plate to form a ceramic/metal composite armor
for enhancing its dynamic penetration resistance. Among the various factors affecting the
penetration resistance of ceramic/metal composite armor, the ratio of ceramic to metal
thickness is an extremely important issue.
For these reasons, we numerically simulated the breakout process to find the optimal
ratio of ceramic/metal composite armor of different thicknesses by the smooth particle
hydromechanics (SPH) method in ANSYS/AUTODYN. Compared with the traditional
finite element method, the SPH method [2, 3] is a mesh-free particle method based on
Lagrange’s description. It does not pull in background mesh and complex erosion
algorithm, and can simulate high-speed intrusion and other large deformation problems. In
this paper, SPH particle method is used to study the optimal ratio of ceramic/aluminum
alloy composite armor with three different total thicknesses. The residual speed and the
final length of a bullet were studied at five different thickness ratios and compared with
known experimental results. The accuracy of SPH method was verified. It provides a
theoretical basis for numerical calculation and design of the ceramic composite armor. The
optimal ratio value is consistent with the theoretical solution. The study supplies an
important knowledge for practical applications.
1. Experimental Materials and Principles.
1.1. Experimental Materials and Methods. According to the experimental plan
described in [4], the thickness (in mm) of the ceramic/aluminum composite armor was
configured as follows: F20/B10, F20/B15, F25/B10, and F25/B15, where F represents the
ceramic front panel and B represents the aluminum alloy backboard. The diameter of the
ceramic composite armor specimen was 150 mm. The short bullet has a diameter of 12 mm,
© Z.-L. CHANG, W.-L. ZHAO, G.-P. ZOU, H.-Q. SUN, 2019
16 ISSN 0556-171X. Ïðîáëåìè ì³öíîñò³, 2019, ¹ 1
a length of 35.2 mm, a speed of 1240 m/s and tungsten metal material. The SPH method in
ANSYS/AUTODYN was used for simulation.
1.2. Experiment Principle.
1.2.1. Optimization Model of the Ceramic Composite Armor with the Given Thickness.
The classic model of a projectile penetrating into the ceramic composite armor is the
Florence–Ahrens model [5], as is shown in Fig. 1. In the Florence–Ahrens model, the bullet
is simplified to a short, flat round rod that hits the ceramic panel. Then the bullet moves
forward together with the ceramic cone formed by the impact and continues to penetrate the
rest of the composite armor. The metal plate absorbs the residual energy of the bullet
through deformation. To derive the expression of the ballistic limit speed, the following
aspects need to be simplified:
(1) The diameter of the front surface of the ceramic cone equals to the diameter of the
bullet head, and the angle of the ceramic cone formed is 63�.
(2) The deformation history of the metal backplane can be modeled as an indentation
of the ceramic cone in a backplane. The initial state of the formed ceramic cone is
controlled by the initial state of the bullet and the conservation of the momentum of the
bullet and the bulge.
(3) The metal back plate reaches its limit tensile strain and destroy.
The ballistic limit speed of the Florence–Ahrens model [5] is
V h m f ap p� � �2 2 2 091[ . ( )], (1)
a a hp� �2 1 , f a m m h d h d ap p( ) {[ ( )] },� � �1 1 2 2
2�
where �2 is the fracture strain of the back plate, � 2 is the tensile strength of the back
plate, a p is the radius of the bullet, mp is the mass of the bullet, h1 and h2 are the
thicknesses of the ceramic panel and the back plate, respectively, and d1 and d2 are the
densities of the ceramic panel and the back plate, respectively.
It can be seen from the above formula that the anti-ballistic performance of the entire
ceramic composite armor is related to the mass of the bullet, the density and the thickness
of the ceramic panel and back plate. When the material density is higher, and the plate
thickness is thicker, the armor ballistic performance is better. Also, the armor ballistic
performance is better if the fracture strain of the back plate is higher and the tensile strength
is larger.
Wang and Lu [6] developed the optimal design method of the ceramic composite
armor under given thickness constraints within the framework of the Florence–Ahrens
Simulation of the Lightweight Ceramic/Aluminum Alloy Composite Armor ...
ISSN 0556-171X. Ïðîáëåìè ì³öíîñò³, 2019, ¹ 1 17
Fig. 1. The Florence–Ahrens intrusion model.
theory model for the ceramic composite armor penetration. Based on the Florence–Ahrens
model, Wang and Lu considered the total thickness of the composite armor T as follows
[6]:
h T h a a p2 1 2� � � � . (2)
Substituting Eq. (2) into (1), there is
091 1
2
2
2 2
.
( )
.
V m
f a
T
a ap p p
� �
� �
�
�
�
�
�
� (3)
Derivation of Eq. (3) with the variable a yields:
f a
f a
T a a p
( )
� ( )
.�� � �2 (4)
The following dependence can be obtained from Eq. (3):
� ( )
( )[ ( ) ]
f a
f a m Td a
d d
a a a
m a Td
p p
p
��
� �
�
�
�
2 4
2
5 42
2 1 2 2
2
� �
�a
d d
a a ap
3 1 2 3
2
�
�
��( )
. (5)
From Eqs. (4) and (5) we obtain
3 5 21 2
4
1 2 2 1
3( ) [( ) ( ) ]d d a d d a d d T ap� � � � � �� �
� � � � � � � �2 4 4 3 2 22
2 1 2 1 2
2 2�[ ( ) ] ( ) ] (T d d d T a d d a a m a m T ap p p p p ) .� 0 (6)
For given composite armor parameters, the value of a can be determined. Thus, the
thickness ratio of the front and back plate is
h
h
a a
T
a a
a a
T a a
p
p
p
p
1
2
2
2
2
�
�
�
�
�
�
� �( )
. (7)
When the value of a is determined, the thickness ratio can be calculated.
For small-caliber bullets, Eq. (7) can be simplified, removing mp and a. They are
small and make a little effect on the overall value. Therefore, Eq. (7) becomes
3 5 8 01 2
2
2 1
2
2( ) ( ) .d d a d d Ta T d� � � � � (8)
The solution is
a
T
d d d d d d d
d d
�
� � � � � �
�
5 2 25 2 96
6
2 1 2 1
2
2 1 2
1 2
( ) ( ) ( )
( )
. (9)
Z.-L. Chang, W.-L. Zhao, G.-P. Zou, and H.-Q. Sun
18 ISSN 0556-171X. Ïðîáëåìè ì³öíîñò³, 2019, ¹ 1
The thickness ratio is
h
h
a T
a T
d d d d d d d
d
1
2
2 1 2 1
2
2 1 2
1
2
5 2 25 2 96
7
�
�
�
� � � � � �
�
( ) ( ) ( )
2 25 2 962 2 1
2
2 1 2d d d d d d� � � �( ) ( )
. (10)
It can be seen that the optimal solution of the problem under this constraint is only
related to the density of the material, the total thickness, and the bullet speed not affect it.
From Eq. (10) it can be found the best thickness ratio of alumina ceramic/aluminum alloy
of 4.2.
1.2.2. Numerical Simulation of Breakout Process in Ceramic/Aluminum Composite
Armor. A bullet is made of tungsten metal, its equation of state is described by the shock
equation [7]. The bullet strength is modeled by the Steinberg et al. [8] material strength
model. Alumina ceramic material model uses Johnson–Holmquist strength and damage
model to describe the damage of ceramic material process [9]. A description of the dynamic
mechanical behavior of metal materials mostly uses Johnson–Cook strength model [10].
The ceramic/aluminum alloy thicknesses (in mm) were: F20/B10, F20/B15, F25/B10,
and F25/B15, where F is the ceramic panel and B is the aluminum alloy backplane. The
penetration process is shown in Fig. 2. The residual bullet speed and its final length are
compared with the experimental results in [4]. The results are presented in Table 1.
ISSN 0556-171X. Ïðîáëåìè ì³öíîñò³, 2019, ¹ 1 19
Simulation of the Lightweight Ceramic/Aluminum Alloy Composite Armor ...
Fig. 2. The penetration process in the alumina oxide ceramic/aluminum alloy composite armor.
1 �s 10 �s
20 �s 60 �s
Different time stages of the composite armor penetrated by the bullet are shown in
Fig. 2. At the initial stage of the collision, the bullet interacts with the ceramic. Due to a
high ceramic hardness, the head of the bullet erodes and shatters, the energy of the bullet
dissipates. Under the bullet impact a cone of about 63� forms in a ceramic layer. Since the
stress wave is faster than the bullet, the wave reflected from the back plate causes radial
damages of the far end of the bullet, accompanied by spallation. Bullet and the formed
ceramic cone moves forward, and the blunted bullet intrudes into ceramics. Finally, under
the effect of tensile and shear stresses, the ceramic breaks down. During this process, due to
the formation of the ceramic cone, the interaction with the aluminum alloy back plate
increases, so the energy absorbed by the back plate through the deformation increases as
well. The aluminum alloy back plate supports ceramic and mitigates its destruction, and
also absorbs impact energy due to toughness.
Comparing the residual bullet speed and its final length calculated by ANSYS/
AUTODYN with the experimental and numerical results in [4], the numerical simulation
results are in good agreement with the experimental ones, indicating the applicability and
high precision of the SPH particle method.
2. Results and Analysis. Consider the total armor thickness of 30 mm as an example.
The diameter of the ceramic composite armor is 150 mm. A short tungsten bullet has a
diameter of 12 mm, a length of 35.2 mm and its speed is 1240 m/s. A monitoring point to
obtain the residual speed is set at the tail of the bullet. The state of the ceramic composite
armor with different thickness ratios after the breakout is shown in Fig. 3.
It can be seen from Fig. 3, at different thickness ratios, the bullet forward distance and
loss are not the same. The damage degree of the ceramic panel under the bullet impact is
also different. The metal back plate is also damaged in different ways; the deformation area
of the thick plate is obviously smaller than the deformation area of the thin plate. And in
the process of disruption, the thinner plate not only forms a protrusion which moves
forward with the bullet but also has tensile failure fracture nearby. The final bullet length
and the residual speed in composite armors with different ceramic/aluminum thickness ratio
are listed in Table 2.
It can be seen from Table 2 that the ceramic composite armor with 1:1 thickness ratio
is more efficient than 2:1 and 3:1 ratio composite armors, while less efficient than 4:1 ratio
armor. From 2:1 to 4:1, with the increase of the proportion of ceramic thickness, the
residual speed of the bullets also reduces, and the armor anti-ballistic efficiency improves.
With the increase in the thickness of the ceramic panel, the loss of bullets also increases,
but the loss of a bullet in the armor with 5:1 ratio is smaller than in the armor with 4:1 ratio.
This is because the thickness of the aluminum alloy backplane is too small, the support to
20 ISSN 0556-171X. Ïðîáëåìè ì³öíîñò³, 2019, ¹ 1
Z.-L. Chang, W.-L. Zhao, G.-P. Zou, and H.-Q. Sun
T a b l e 1
Comparison between the Numerical Simulation and Experimental Result
Thickness
(ceramic/
aluminum
alloy, mm)
Experimental
residual bullet
speed in [4]
(m/s)
Numerical
calculation
of the
residual
bullet speed
(m/s) in [4]
Residual
bullet speed
(m/s)
calculated
numerically
in this paper
Experimental
final bullet
length (mm)
Final bullet
length (mm)
calculated
numerically
in [4]
Final bullet
length (mm)
calculated
numerically
in this paper
F20/B10 930 1035 970 22 23 25
F20/B15 930–960 970 930 24–27 20 25
F25/B10 960 960 910 25 22 24
F25/B15 939 880 870 24 18 23
the ceramic panel is less efficient, thus the erosion of the bullet is reduced. And the ceramic
without aluminum alloy backing has the lowest ballistic performance.
Figure 4 shows the residual bullet speed as a function of the thickness ratio at three
different total thicknesses of the composite armor. It can be seen from the curves that under
the protection of ceramic composite armor with different total thickness, the minimum
bullet residual speed is near the thickness ratio of 4:1. For the armor with the total thickness
of 30 mm, 40 mm, and 50 mm, the minimum residual velocities after bullet breakout are
950, 807, and 653 m/s, respectively. The obtained by numerical simulation optimal
anti-ballistic performance of the ceramic/aluminum composite armor is in good agreement
with the calculated optimal thickness ratio of 4.2:1 in the theoretical model by Wang and
Lu. It can be seen from Fig. 4, that with the decrease in the aluminum alloy back plate
thickness after the optimal configuration ratio of 4:1, the overall ballistic performance of
the composite armor obviously decreases regardless the total thickness.
ISSN 0556-171X. Ïðîáëåìè ì³öíîñò³, 2019, ¹ 1 21
Simulation of the Lightweight Ceramic/Aluminum Alloy Composite Armor ...
T a b l e 2
The Bullet Final Length and Residual Speed in 30 mm Composite Armor
with Different Thickness Ratio
Ceramic/aluminum
thickness ratio
Final bullet length
(mm)
Residual bullet speed
(m/s)
1:1 26.6 960
2:1 26.1 970
3:1 25.9 963
4:1 25.2 950
5:1 25.3 975
No aluminum back plate 25.3 990
Fig. 3. The breakout of 30 mm composite armor with different ratio of ceramic/aluminum
thicknesses.
Conclusions. In this paper, we used the SPH particle method and ANSYS/AUTODYN
software to study the failure process of ceramic/aluminum alloy composite armors with
different thickness configurations at high-speed projectile impact. The results obtained
made it possible to draw the following conclusions.
1. The numerical simulation results of the residual bullet speed and its final length
calculated by AUTODYN are in good agreement with the experimental and numerical
results obtained earlier in [4]. This indicates the applicability and high precision of the SPH
particle method for design of ceramic/aluminum alloy composite armors.
2. Using the SPH program of ANSYS/AUTODYN finite element simulation software,
the numerical simulation of ceramic composite armors with different total thickness and
five different ceramic/aluminum alloy thickness ratios was performed. The simulation and
experimental results were compared and analyzed. Ceramic/aluminum composite armors of
3 different thicknesses possess the best anti-ballistic efficiency at the thickness ratio of 4:1.
This is consistent with the theoretical model introduced by Wang and Lu 4.2:1, which
provides an important reference for the engineering design.
Acknowledgments. This work was supported by the National Natural Science
Foundation of China (Nos. 11602068 and 11602066) and Fundamental Research Funds for
the Central Universities (Nos. HEUCFM170203, HEUCFP201744, and HEUCFP201762).
1. H.-L. Hou, X. Zhu, Z.-J. Liu, et al., “Experimental study on performance of ceramic
composite warship armor under impact of high speed fragment,” Ordnance Mater.
Sci. Eng., No. 3, 5–10 (2007).
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3. R. A. Gingold and J. J. Monaghan, “Smoothed particle hydrodynamics – Theory and
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22 ISSN 0556-171X. Ïðîáëåìè ì³öíîñò³, 2019, ¹ 1
Z.-L. Chang, W.-L. Zhao, G.-P. Zou, and H.-Q. Sun
Fig. 4. The bullet residual speed with different total thickness and different thickness ratio.
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Received 15. 03. 2018
Simulation of the Lightweight Ceramic/Aluminum Alloy Composite Armor ...
ISSN 0556-171X. Ïðîáëåìè ì³öíîñò³, 2019, ¹ 1 23
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/ENU (Use these settings to create Adobe PDF documents best suited for high-quality prepress printing. Created PDF documents can be opened with Acrobat and Adobe Reader 5.0 and later.)
>>
/Namespace [
(Adobe)
(Common)
(1.0)
]
/OtherNamespaces [
<<
/AsReaderSpreads false
/CropImagesToFrames true
/ErrorControl /WarnAndContinue
/FlattenerIgnoreSpreadOverrides false
/IncludeGuidesGrids false
/IncludeNonPrinting false
/IncludeSlug false
/Namespace [
(Adobe)
(InDesign)
(4.0)
]
/OmitPlacedBitmaps false
/OmitPlacedEPS false
/OmitPlacedPDF false
/SimulateOverprint /Legacy
>>
<<
/AddBleedMarks false
/AddColorBars false
/AddCropMarks false
/AddPageInfo false
/AddRegMarks false
/ConvertColors /ConvertToCMYK
/DestinationProfileName ()
/DestinationProfileSelector /DocumentCMYK
/Downsample16BitImages true
/FlattenerPreset <<
/PresetSelector /MediumResolution
>>
/FormElements false
/GenerateStructure false
/IncludeBookmarks false
/IncludeHyperlinks false
/IncludeInteractive false
/IncludeLayers false
/IncludeProfiles false
/MultimediaHandling /UseObjectSettings
/Namespace [
(Adobe)
(CreativeSuite)
(2.0)
]
/PDFXOutputIntentProfileSelector /DocumentCMYK
/PreserveEditing true
/UntaggedCMYKHandling /LeaveUntagged
/UntaggedRGBHandling /UseDocumentProfile
/UseDocumentBleed false
>>
]
>> setdistillerparams
<<
/HWResolution [2400 2400]
/PageSize [612.000 792.000]
>> setpagedevice
|