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Abstract
A numerical analysis of lament-reinforced internally pressurized cylindrical vessels with over-wrapped metallic liner is presented. The method uses the load-bearing liner approach and leak-before-rupture as design criteria. The structure is modeled as an
elastic, ideally plastic liner-reinforced with a quasi-isotropic elastic composite. Based on a balanced stress condition in the pressure
vessel, the head shape is obtained by a numerical solution of an elliptic integral. The winding process creates a variable thickness in
dome area and results in considerable changes in the on-axis stress distribution incorporated in this study. A 3-D, 2-node interface
element is also used to model contact at discrete points between the metallic liner and its surrounded composite shell. Numerical
results are reported for the eects of dierent head shapes and the superiority of optimum geodesic head shapes in reducing the
maximum stresses is also investigated.
Incorporating the metallic liner in the analysis produces marked changes in on-axis stresses and resultant displacements. 2000
Elsevier Science Ltd. All rights reserved.
Keywords: Finite element analysis; Composite pressure vessels; Load sharing metallic liner
1. Introduction
Modern composites, using continuous bres in a resin
matrix, are important candidate materials in the engineering of energy-ecient structures. In many applications, bre/matrix materials are lighter, stronger and
more cost eective when compared with traditional
materials like metals. Many high-strength composite
products are fabricated using the lament winding
process. In this process, bands of resin-impregnated bre are wound over a cylindrical mandrel using a computer controlled bre placement machine. Fibre
application to the metallic mandrel is usually accomplished by a transverse feed head over a rotating surface,
capable of achieving any desired winding orientation.
Filament-wound tubular structures, more specically
pressure vessels, oer signicant weight saving over
conventional all metallic ones for containment of high
pressure gases and liquids.
A rational engineering procedure has evolved for
minimum weight design of lament-reinforced metallined vessels which couples strength and strain compatibility analyses with experimental data. In aerospace
applications, composite tanks with load-sharing liners
provide signicant weight saving on the order of 40% or
more over the highest performance of homogeneous
0263-8223/00/$ - see front matter 2000 Elsevier Science Ltd. All rights reserved.
PII: S 0 2 6 3 - 8 2 2 3 ( 9 9 ) 0 0 0 4 4 - 6
248
2. Analytical approach
2.1. Geodesic path
The term ``geodesic isotensoid pressure vessel'' is
applied to pressure vessel consisting entirely of laments
that are loaded to identical stress levels. The theory of
such a pressure vessel under internal pressure has been
discussed by Kitzmiller et al. [2] and was applied by
them appropriately to head shapes without openings. A
generalization of their results requires the laments lie
along geodesic lines. In the region of the cap, the lament path is normally adapted to helical winding. Using
shell theory [7] for balanced stresses in the dome, the
bre path needs to satisfy the following condition, Fig. 1
N/ Nh
P:
R 1 R2
The meridian and circumferential radii, R1 and R2 , respectively, are dened [6] as follows:
2
1 y 0
;
R1
y 00
2 1
1 y 0 2
R2 x
;
y0
Nh ru t sin2 a;
where a is the winding angle, (Fig. 1), and ru the ultimate tensile strength of the composite in the bre
direction. The relation between meridian and circumferential radii are simplied as
R2
2 tan2 a:
R1
1=2
2 tan2 a:
X0
:
x
249
11
y 0 1
The solution of the above equation becomes the following elliptic integral of the third kind which can be
solved by a computer [8]
y
x3 dx
1 x2 x2 a1 x2 a2
1=2
C;
where
#
1=2
1 4X02
1 ;
1 X02
"
#
1=2
1
1 4X02
1 :
a2
2
1 X02
1
a1
2
"
10
250
1
Eaxial
1
E11
1 E11
2
4
4
cos a
sin a
2m12 sin 2a ;
E11
4 G12
E22
1
Ehoop
1
E11
1 E11
sin4 a
cos4 a
2m12 sin2 2a :
E22
E11
4 G12
12
(b) Metal shell compressive strength is adequate so
that adhesive bonding is not required to prevent metal shell buckling. The minimum liner thickness
against buckling may be calculated from the following equation
1=2
tl
3rl 1 m2
El
R:
13
n b
1:
N
14
In this equation, n is the loading cycles, N is the number of fatigue cycles at the maximum operating strain
range that would produce fatigue failure, the maximum strain capability of the virgin material and b
the strain at required burst pressure.
2.3. Finite element modelling
The nite element software, Numerical Integrated
System Analysis (NISA-II), is employed in this study.
The 3D laminated composite general shell element,
NKTP 32, is chosen for this purpose. NISA-II translates the loads (internal pressure), boundary conditions
and material specication from the nite element preand post-processor code for an accurate stress analysis of
the cylinder. The 3D shell element includes the deformations due to membrane, bending and membranebending coupling and transverse shear eects and is
Fig. 3. Finite element modeling assembly of metal/gap/composite pressure vessel. (a) 3D gap/friction element (NKTP 50) (b) Finite element mesh
for metal-composite pressure vessels.
251
R cos a0
t0 ;
16
x cos an
where t0 is the total thickness of the helical layers and
can be determined from basic thin-walled pressure vessels relations in terms of internal pressure, P, ultimate
tn
PR
:
2ru cos2 a0
17
3. Numerical evaluation
The hybrid pressure vessel comprised of a stainless
steel liner reinforced by a Kevlar 49/Epoxy composite
has a 150 mm inside diameter with a 50 mm diameter at
the polar boss, the total length is 742 mm and the cylindrical portion is 642 mm. The maximum operating
pressure is 22 Mpa and the proof pressure factor is 1.5.
This study ignores the cycles for fatigue life. The elastic
constants of the composite material are: E11 90 GPa,
E22 4.115 GPa, m12 0.29, G12 1.8 GPa, and
Table 1
Coordinates of geodesic head contour
y (mm)
x (mm)
Thickness (tn )
(mm)
Winding angle an
0
6
11.87
17.47
22.71
27.5
31.78
35.53
38.74
41.44
43.67
45.41
54
75
74.54
73.19
71
68.03
64.38
60.15
55.44
50.34
44.96
39.37
32
25
2.373
2.427
2.595
2.91
3.443
4.381
6.345
14.955
11.415
10.958
10.467
9.937
9.359
19.5
19.62
20
20.6
21.6
22.9
24.6
26.8
29.8
33.8
39.5
51.5
90
252
Nh
Nc
PR
2 tan2 a;
2tru
19
Fig. 6. Resultant displacement of internally pressurized composite vessel, P 220 bars (a) Dome with variable thickness (b) Dome with constant
thickness.
253
254
4. Conclusion
For lament wound structures, determination of the
elastic constants plays a very important role in the
structural analysis since many variables and assumptions
are involoved. The present work takes the form of a
feasibility study investigating the practicality and superiority of end-closure shapes in over-wrapped metallic
cylindrical high pressure vessels. Based on a balanced
stress conditions, the optimized shapes for the metallic
mandrel are examined in this work. To establish the optimum contour path an analytical formulation is postulated leading to the solution of an elliptic integral which
yields the coordinates of the closure head. The loadbearing liner approach is introduced as a design criterion
for metallic over-wrapped hybrid pressure vessels and is
255
Acknowledgements
The author would like to acknowledge nancial
support from Prof. M. Pandey and assistance from Prof.
A.N. Sherbourne for the writing of this manuscript
during a short visit to the University of Waterloo.
References
[1] Johna RH, Kaufman A. Filament overwrapped metallic cylindrical
pressure vessels. In: AIAA/ASME seventhth Structures and Materials Conference, Cocoa Beach, FL, 1966:5263.
[2] Kitzmiller AH, Dehaven CC, Yuong RE. Design considerations
for spirally glass-reinforced lament-wound structures as rocket
inert parts. ARS preprint 983-59, 1959.
[3] Morris EE, Alfring RJ. Cryogenic boron-lament-wound containment vessels. NASA CR-72330, 1967.
[4] Rosato DV, Grove CS. Filament winding, its development,
manufacture, applications and design. Ch.7. New York: Interscience, 1964.
[5] Sabbaghian M, Nandan D. New concepts on the design of
multilayer cylindrical vessels technology. Part I. Design and
analysis, 1969:649657.
[6] Shibley AM, Filament winding. In Lubin G, editor. Handbook of
bre-glass and advanced plastic materials. New York: Van
Nostrand Reinhold, 1969:438484.
[7] Ugural AC. Stresses in plates and shells, New York: McGraw Hill,
1981.
[8] Zickel J. Isotensoid pressure vessels. ARS Journal 1962:950951.