Study on Winding Forming Process of Glass Fiber Composite Pressure Vessel.

Area of Science:

• Materials Science
• Mechanical Engineering
• Composite Materials

Background:

• Composite pressure vessels offer superior strength-to-weight ratios and corrosion resistance compared to traditional metal designs.
• Design flexibility in composites allows for tailored performance characteristics.

Purpose of the Study:

• To investigate the structural design, winding process, finite element analysis (FEA), and experimental validation of a glass fiber-reinforced composite low-pressure vessel.
• To assess the accuracy of simulation tools like CADWIND and Abaqus in predicting vessel performance.

Main Methods:

• A high-density polyethylene (HDPE) liner was blow-molded, followed by a three-layer filament winding process simulated using CADWIND.
• Finite element analysis in Abaqus was used to identify stress concentrations and predict failure points.
• Experimental hydrostatic burst tests were conducted for validation, alongside SEM analysis for material integrity.

Main Results:

• The filament winding simulation determined an optimal three-layer scheme with a calculated thickness of 0.375 mm and 107% coverage.
• FEA predicted failure at 5.00 MPa due to fiber breakage at the polar transition; experimental tests confirmed failure at 5.06 MPa (1.2% error).
• Head sealing was critical, with unsealed vessels failing at 2.46 MPa, while SEM confirmed strong fiber-matrix adhesion and ductile fracture.

Conclusions:

• The close agreement between FEA predictions and experimental results validates the proposed design methodology.
• CADWIND and Abaqus are reliable tools for predicting the structural performance of composite pressure vessels.
• The study highlights the importance of proper sealing in ensuring the integrity of composite pressure vessels.