Abstract
Compressed natural gas (CNG) composite vessels for vehicles consist of a dome part of the liner, a cylinder part of the liner, and a composite layer, and different kinds of manufacturing processes are required to form each of the aforementioned parts: a deep drawing and ironing (D.D.I.) process for the cylinder part, a hot spinning process for the dome part, and a winding process to reinforce the formed liner with composite materials. This study presents an integrated design for manufacturing processes to form each part of the CNG composite vessel by considering the mutual and systematic effects of each process, and involves a theoretical analysis of the D.D.I. continuous process, the optimal process design to extend the die life through a design of experiment (DOE) and finite element analysis (FEA). This paper also presents a FEA for the hot spinning process, assessment of the formability of the dome part, and introduces a theoretical analysis and FEA of a multi-layer coupled model consisting of the liner and the composite layer based on an isotropic material and an orthotropic material. The findings were validated through comparison with experimental results.
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