Analytical Finite Element Analysis Research Articles

Finite Element Analysis and Computational Fluid Dynamics for the Flow Control of a Non-Return Multi-Door Reflux Valve

This paper presents a comprehensive analysis of a multi-door check valve using computational fluid dynamics (CFD) and finite element analysis (FEA) to evaluate flow performance under pressure test conditions, with an emphasis on its ability to prevent backflow. Check valves are essential components in various industries, ensuring fluid flow in one direction only while preventing reverse flow. The non-return multi-door reflux valve is increasingly preferred due to its superior backflow prevention, fluid control, and effective flow regulation. Rigorous testing under varying pressure conditions is essential to ensure that these valves perform optimally. This study uses CFD and FEA simulations to evaluate the structural integrity and flow characteristics of the valve, including pressure drop, flow velocity, backflow prevention effectiveness, and flow coefficient. A high-fidelity 3D model was created to simulate the valve’s behavior under various conditions, analyzing the effects of parameters such as the number of doors, their orientation, geometry, and operating conditions. The CFD results demonstrated a significant reduction in backflow and pressure drop across the valve. However, localized turbulence and flow separation near the valve doors, particularly under partially open conditions, have raised concerns about potential wear. The velocity profiles indicated a uniform distribution at full opening with laminar velocity profiles and minimal resistance to flow. The results of the FEA showed that the stresses induced by the fluid forces were below critical levels, with the highest stress concentrations observed around the hinge points of the valve doors. Although the valve structure remained intact under normal operating conditions, some areas may have required reinforcement to ensure long-term durability. Combined CFD and FEA analyses demonstrated that the valve effectively preserves system integrity, prevents backflow, and maintains consistent performance under various pressure and flow conditions. These findings provide valuable insights into design improvements, performance optimization, and enhancing the efficiency and reliability of reflux valve systems in industrial applications.

Long head of the biceps tendon plays a role in stress absorption and humeral head restriction during the late cocking and deceleration phases of overhead throwing: a finite element study

BackgroundEmerging evidence suggests that the long head of the biceps (LHBT) may play a role in stabilizing the glenohumeral joint, and this has led to controversy around the efficacy of biceps tenotomy for superior labral anterior and posterior (SLAP) lesions. Therefore, the aim of this finite element analysis (FEA) study was to determine the stress absorption and humeral head translation restriction effects of the LHBT within the glenohumeral joint during the late cocking and deceleration phases of overhead throwing with a view to resolving the controversy around tenotomy. MethodsEight FEA models were created using computed tomography and magnetic resonance imaging data from normal glenohumeral joints. The models represented four LHBT conditions: uninjured, subpectoral tenodesis, tenotomy, and type II SLAP lesions. The late cocking and deceleration phases of the overhead throwing were simulated for each model. The impacts of the four LHBT conditions on glenohumeral joint stress absorption and humeral head displacement restriction were studied based on 1) stress and related distributions on the cartilage, labrum, capsule, and LHBT and 2) humeral head translation variation. ResultsThe FEA analysis showed that the magnitude of the contact stress on the articular cartilage, labrum, and capsule was the lowest in the uninjured models, followed by the subpectoral tenodesis, tenotomy, and type II SLAP lesion models. Humeral head translation was the most restricted in the subpectoral tenodesis models, followed by the tenotomy and type II SLAP lesion models. ConclusionFinite element analysis demonstrated that the LHBT plays a significant role in stress absorption and displacement restriction in the late cocking and deceleration phases of overhead throwing. Subpectoral tenodesis of the LHBT exhibited lesser amount of stress and humeral head translation than those of tenotomy, thereby making it a better option for patients who engage in overhead throwing.

The Influence of Cement Thickness within the Cap on Stress Distribution for Dental Implants.

The purpose of this finite element analysis (FEA) was to evaluate the stress distribution within the prosthetic components and bone in relation to varying cement thicknesses (from 20 to 60 μm) utilized to attach a zirconia crown on a conometric cap. The study focused on two types of implants (Cyroth and TAC, AoN Implants, Grisignano di Zocco, Italy) featuring a Morse cone connection. Detailed three-dimensional (3D) models were developed to represent the bone structure (cortical and trabecular) and the prosthetic components, including the crown, cement, cap, abutment, and the implant. Both implants were placed 1.5 mm subcrestally and subjected to a 200 N load at a 45° inclination on the crown. The results indicated that an increase in cement thickness led to a reduction in von Mises stress on the cortical bone for both Cyroth and TAC implants, while the decrease in stress on the trabecular bone (apical zone) was relatively less pronounced. However, the TAC implant exhibited a higher stress field in the apical area compared to the Cyroth implant. In summary, this study investigated the influence of cement thickness on stress transmission across prosthetic components and peri-implant tissues through FEA analysis, emphasizing that the 60 μm cement layer demonstrated higher stress values approaching the material strength limit.

Designing Novel Endodontic Implants and Evaluation of the Stress Distribution in Maxillary Anteriors Using Finite Element Analysis.

Introduction Endodontic implants, or didontic implants, offer a promising solution for stabilizing compromised teeth with a guarded prognosis and prolonging their clinical survival rate. Despite their potential benefits, they retired out of practice due to failures that arose from the lack of a biocompatible seal and engaging in dentin. Novel designs, based on evidence-based research with the help of bioceramics, present an opportunity to overcome these challenges andhence, enhance the clinical efficacy of endodontic implants. Thus the aim of this study is to design novel endodontic implants and evaluate their stress distribution in maxillary incisors using finite element analysis (FEA). Materials and methodology FEAis a biomechanical study to assess the stress distribution and extent of displacementto assess the clinical efficacy of novel endodontic implants in maxillary anterior teeth. Three 3D models (Model 1, Model 2, and Model 3)are designed to be meshed, and material elastic properties of the tooth and periapical tissues are applied. Boundary conditions were established, and a constant axial load value of 600 N was applied at a 45° angle. The FEA analysis was done under the loading conditions to assess the stress patterns for the three 3D models in comparison to the intact tooth on the ANSYS software (ANSYS Inc, Pennsylvania). Results FEA simulations revealed the distribution of stress within the tooth structure under functional occlusal forces, as Von Misses stresses were analyzed to assess the likelihood of material yielding and failure, which was comparable to that of an intact tooth. The maximum stress of deformation was as follows: intact: 1.7589e-5 MAX; Model 1:3.3804e-6 MAX; Model 2:2.638e-5 MAX; and Model 3: 2.1986e-5 MAX. The area of stress concentrations did not occur at the interface of the coronal or apical seal, which prevented catastrophic failures. Conclusion By leveraging advanced design principles and materials, these implants offer a promising alternative to traditional approaches,particularlyin trauma cases with a poor prognosis for the survival of the teeth leading to loss of tooth. Further clinical studies are warranted to validate the efficacy and long-term success of these novel endodontic implants in diverse patient populations.

FEA-Based Camshaft Design and Analysis on a Range of Heat-Treated Materials

Camshafts play a critical role in internal combustion engines, dictating the timing and duration of valve opening and closing events. To ensure optimal engine performance and longevity, camshaft design must balance factors such as strength, durability, and weight. Finite Element Analysis (FEA) offers a powerful tool for evaluating camshaft designs under varying operating conditions. This paper presents a comprehensive study on the design and analysis of camshafts using FEA, focusing on the influence of different heat-treated materials. The study begins with an overview of material selection criteria for camshaft applications, considering factors such as strength, fatigue resistance, and wear characteristics. Various materials high-performance alloys are investigated for their suitability and performance enhancements through heat treatment processes such as carburizing, quenching, and tempering. A detailed 3D CAD model of the camshaft geometry is developed, capturing key features such as lobes, journals, and bearings. Finite element meshing techniques are employed to ensure accurate representation of the geometry and precise stress analysis. Boundary conditions are defined to simulate realistic operating conditions, including forces exerted by cam followers and valve springs. Material properties are assigned to finite elements based on the selected materials and heat treatment parameters. Static and dynamic FEA analyses are conducted to evaluate stress distribution, deformation, fatigue life, and natural frequencies of the camshaft under varying load scenarios. The results of the FEA analyses are used to optimize the camshaft design iteratively, considering factors such as weight reduction, performance enhancement, and durability improvement. Validation of FEA results is performed through physical testing and comparison with empirical data. Overall, this paper provides valuable insights into the design and analysis of camshafts using FEA, highlighting the importance of material selection and heat treatment processes in optimizing camshaft performance and reliability in automotive engine applications. Key Words: Design, Analysis, geartrain, idler gear, FEA, reciprocating motion, Solid works, CAD, ANSYS, efficiency, IC engines, camshaft.

STRESS, EQUIVALENT STRAIN AND DEFORMATION FOR MACHINING OPERATION UTILIZING EXPLICIT DYNAMIC ANALYSIS FOR VARIOUS MATERIALS

Subtractive and additive manufacturing methods constitute the two main categories of modern manufacturing technology used in the manufacturing sector. The subtractive method is used for material removal and is performed in (Brass, Aluminum and Teflon), the machining process is achieved using CNC (Computer Numerical Method) turn machine. The main objective of the paper is to perform FEA (Finite Element Analysis) over the three material (Brass, Aluminum and Teflon). The CNC machine is used to perform a machining over the three-material stated above, but within the CNC machine there is no provision for achieving the various values of (stress, strain and deformation) during the machining operation. During the machining process, it’s very difficult to get and accurate value of stress for the tool and raw (test) material, so Ansys FEA analysis method is adopted to predict the parameter like stress, strain and total deformation. The analysis part is achieved by the developing the CAD model using Solid work and FEA analysis using Ansys and thereby the output will be helpful to understand the various stress parameters. The results highlight that Teflon has a higher value for total deformation followed by aluminum and brass. The equivalent strain for the Teflon is higher and followed by brass and aluminum. The stress is acting in axial and compressive direction, so brass have a higher value followed by aluminum and Teflon. This method and analysis procedure can be adopted for understanding the deformation, stress and stain acting on any material, which will be highly useful for material of higher with a higher hardness value.

FEA and CFD analysis and optimization of tube in tube heat exchanger for various cases

This research describes the use of advanced simulation techniques to investigate use of different materials for a tube-in-tube heat exchanger. Finite Element Analysis (FEA) and Computational Fluid Dynamics (CFD) simulations are employed to simulate thermal aspects and optimize the heat exchanger design. The objective is to identify the best-Suitable material combination considering both design and thermal considerations. The findings of this research contribute to the development of more efficient heat exchanger designs.

Hip Implant Design using Stainless Steel 316L for Enhanced Stability and Patient Comfort

In a hip replacement procedure, the damaged bone and cartilage are removed and replaced with an artificial component known as prosthesis. Despite advancements in implant sterilization, design, fixation techniques, and the introduction of robotic surgery, a persistent challenge is to identify an optimal, patient-specific hip implant that meets individual criteria. The primary objective of the proposed study was to create a highly accurate patient-specific hip implant by standardizing the existing design. The secondary objective aimed to demonstrate the superiority of a customized design over a conventional one. Geometric measurements of the hip were extracted from CT scans using MIMICS 20.0 software, and the implant design was developed using SolidWorks. Finite Element Analysis (FEA) was employed for meshing and analyzing the planned implant. Comparative research through FEA analysis indicated that a customized implant made from SSL 13 material outperformed the standard implant, showcasing its suitability for the patients studied.

Analysis of Off-Road Tire Cornering Characteristics by Using Advanced Analytical Techniques

ABSTRACT This paper focuses on analysis of the cornering characteristics of an off-road truck tire running under several operating conditions over different soils. The finite element analysis (FEA) method is used to model the Goodyear RHD 315/80R22.5 truck tire, and the smoothed-particle hydrodynamics (SPH) method is used to model the soil. The goal of this research is to provide a virtual testing environment in Pam-Crash software as an alternative to actual tests for FEA and SPH analyses of rolling tire interactions on deformable terrains. The study on the effects of different operating parameters on the cornering performance combined with the sensitivity study can be of interest to tire engineers or vehicle engineers because they provide insight into the design and real-time behavior of a vehicle. Tire and soil models are validated using experimental data and published measurements, showing good agreement. The tire–soil interaction is investigated under different tire conditions, such as longitudinal speed, inflation pressure, vertical load, and slip angle, and under various soil characteristics, such as cohesion, internal friction angle, and rut depth. Cornering force, self-aligning moment, and overturning moment are studied as the fundamental cornering characteristics that affect truck lateral stability and control. Owing to the excessive computational demands posed by the FEA-SPH tire–soil models, we propose unique mathematical relationships for estimating the cornering characteristics of free-rolling as well as driven truck tires in an efficient manner. The genetic algorithm (GA) technique is used to develop relationships between the cornering parameters and operating conditions. We conclude that the identified mathematical relationships could provide very good estimations of the cornering characteristics under a broad range of operating conditions and soils. The GA equations will ultimately be implemented into a full vehicle model to evaluate the full vehicle performance.

Designing a Morphing Wing for Fixed-Wing UAVs By IJISRT

This project report details the original conceptualization, design, and analysis of a morphing wing structure for fixed-wing Unmanned Aerial Vehicles (UAVs). Our approach incorporates an octahedron cell structure coupled with the application of shape memory alloys(SMAs) to facilitate controlled wing morphing. The primary goal is to augment the UAVs aerodynamic efficiency and adaptability to various flight conditions. The octahedron cell structure is employed as the foundational framework, providing a balance between structural integrity andflexibility for shape adjustments. The integration of shape memory alloys, known for their reversible phase transformations, enables precise and efficient control over the morphing process. Through this combination, we aim to optimize the UAVs flight characteristics, including improved efficiency, stability, and maneuver ability. To validate the feasibility and performance of the morphing wing design, Finite Element Analysis (FEA) has been conducted. This computational approach allows for a comprehensive evaluation of the structural integrity and aerodynamic behavior of the morphing wing under diverse loading conditions. The FEAresults offer crucial insights into the structural response, stress distribution, and deformation patterns, guiding the iterative refinement of the design for optimal functionality. This project represents a unique contribution to UAV technology, presenting an original perspective on morphing wing design that harnesses the benefits of octahedron cell structureand shape memory alloys. The insights gained from the FEA analysis provide valuable guidance for the ongoing development and implementation of morphing wing structures in fixed- wing UAVs. This work sets the stage for improved adaptability and performance in a range of operational scenarios, without reliance on external sources or existing research

Design and FEA analysis of hub based dual rotor machine for optimal energy generation in four wheeled electric vehicle application

This research article focuses on the design and Finite Element Analysis (FEA) analysis of a hub-based Dual Rotor Machine (DRM). Conventional, electric machines can perform either motoring or generating operations at an instant of time for electric vehicle (EV) applications. However, the proposed DRM can perform both motoring and generating modes of operation simultaneously. For this dual operation, a power rating of 15 kW Brushless DC Machine is selected with outer rotor configuration to achieve high starting torque in motoring operation and a power rating of 6 kW Permanent Magnet Synchronous Machine is considered for generating operation with an inner rotor. Based on theoretical results, the design of DRM is developed and analysed using FEA software programs such as MagNet, Jmag and ThermNet. By using a two-dimensional (2-D) transient solver, the proposed DRM performance is simulated and validated with cogging torque, electromagnetic, thermal and stress analysis. The performance of the proposed DRM model is also tested with drive cycle data of WLTP-II (Worldwide Harmonised Light Vehicle Test Procedure) in ANSYS Motor-CAD software. The simulation results confirm the proposed DRM can consume only 252 Wh over 405 Wh energy consumed by a single rotor machine and ensuring its applicability for EV applications.

Experimental and FEA Analysis of Bonded Connection in Glass Fiber-reinforced Polymer Short Column

Glass Fibre Reinforced Polymer (GFRP) is a synthetically manufactured material that is derived by compressing multiple layers of glass fiber in a resin matrix. GFRPs can be used as compressive members and hold good compressive strength. These materials display a brittle mode of failure at maximum loading and this aspect is the major disadvantage of these materials. This study intends to tackle this disadvantage by designing and analyzing a connection method called non-bearing spliced connection by Eurocode 3 based on BS EN 1990 and BS EN 1991 guidelines. The connections are established using only bonding as the type of connection. There are two types of bonds established in this study based on the thickness of the epoxy used to establish the bonded connection. A 2 mm thick bond and a 5 mm thick bond are used to create 5 samples of each bond thickness samples. A detailed study of their behavior is established in this study by testing them manually and by using Finite Element Analysis (FEA). The required properties such as failure load, maximum displacement, stiffness, compressive strength, failure modes, and load versus displacement graph behavior are compared and explained in detail in this study.

Numerical Investigations of Combustion Dynamics and Thermo-Mechanical Stress in the Ignition Assistance System for Small Aircraft Engines

ABSTRACT The utilization of ignition assistance devices offers an effective solution to overcome the challenges associated with ignition control in the development of propulsion systems for unmanned aerial vehicles (UAVs) that rely on sustainable aviation fuels. These devices actively control the combustion process to ensure successful ignition at different altitudes. The objective is achieved by introducing a controlled thermal energy deposit into the combustion chamber, mitigating potential ignition failures. This research presents a comprehensive analysis of the ignition characteristics and subsequent flame structure based on varying electric-circuit energy inputs, employing three-dimensional simulations. The ignition delay patterns are further examined from a fuel chemistry perspective, specifically focusing on the negative temperature coefficient (NTC). Additionally, this study introduces a strategic analysis of the thermo-mechanical stress experienced by the ignition assistance device when subjected to the impact of the spray-jet flame. To accomplish this, a coupled simulation approach combining computational fluid dynamics (CFD) and finite element analysis (FEA) is employed to analyze the transient wall stress. The parametric inputs obtained from the CFD simulations facilitate the FEA analysis, revealing critical mechanical-thermal stress accumulation on the heating element of the ignition assistance device.

Design and fabrication of a wrist splint for burn patient rehabilitation using 3D printing technologies.

Severe and common injuries involving burns to the hands and wrists can often lead to permanent loss of motion. The issue is exacerbated by the delicate nature of tendons and muscles in the hands, along with the formation of scar tissue. While rehabilitation exercises can help improve the range of motion, early-stage recovery requires additional tension on the affected areas. To address this concern, a novel project was initiated, aiming to develop a specialized splint for later-stage rehabilitation. This innovative splint allows users to carry out their daily tasks while wearing it, constantly applying a beneficial load on the wrist, hand, and digits to enhance range of motion. The development of the splint involved leveraging Fused Deposition Modelling (FDM) 3D printing and medically safe materials for the initial prototype. Finite Element Analysis (FEA) was employed to analyze the design. The process underwent iterative design improvements and parameter adjustments, ultimately resulting in the final prototype. The FEA analysis confirmed the strength and durability of the PLA components, while the TPU digit resistance bands were evaluated using a hyper-elastic model. As a result, the final design effectively applies tension to the digits without compromising day-to-day tasks’ usability and wearer’s comfort. Future iterations of the splint could focus on enhancing fastening methods, reducing brace movement during usage, creating various sizes to accommodate different arm/hand dimensions, and optimizing mass-manufacturing processes.

Evaluation of Cell Deformation in Functionally Graded Natural Rubber Foam via Finite Element Analysis

Functionally graded structures from natural rubber foams were constructed and evaluated in this study. The structures were assembled based on density gradient achieved by stacking layers of natural rubber foams with different densities. Both physical and computational structures were constructed and assembled through experimental work and computer-aided design (CAD) modelling, respectively. Finite Element Analysis (FEA) simulation were conducted on two different assembled structures under compressive deformation mode using Ogden foam hyper-elastic model available in the simulation software package. Experimental result found that the middle section foam with 4/16/4 stacking sequence was deformed significantly compared to that of foam with 16/4/16 stacking sequence. The FEA simulation results indicated that Ogden foam hyper-elastic model is useful in representing deformation at low strain region as the results were in good agreement with those of obtained from the experimental foam compression tests especially for foam with 16/4/16 stacking. The study was able to show that FEA analysis is a good approach to supplement limitation that are encountered by experimental approach in understanding deformation behaviour of functionally graded natural rubber foams.

Development, Physiochemical characterization, Mechanical and Finite element analysis of 3D printed Polylactide-β-TCP/α-Al2O3 composite

Herein, material extrusion (MEX) technique is utilized to develop 3D printed models based on reinforcing β-Ca3(PO4)2/α-Al2O3 composite in polylactide (PLA) matrix. β-Ca3(PO4)2/α-Al2O3 composite has been synthesized through co-precipitation method and the phase content of β-Ca3(PO4)2 and α-Al2O3 components are respectively determined as 64 and 36 wt%. The resultant β-Ca3(PO4)2/α-Al2O3 composite mixed with PLA at various weight ratios were extruded as filaments and subsequently 3D printed into definite shapes for the physiochemical, morphological and mechanical evaluation. 3D printed bodies that comprise 5 wt % β-Ca3(PO4)2/α-Al2O3 composite yielded an increasing tensile, compressive and flexural strength in the corresponding order of ∼15, ∼15 and 22% than 3D printed pure PLA. Further, the Representative volume element (RVE) unit cells developed based on the various investigated compositions of PLA-β-Ca3(PO4)2/α-Al2O3 were subjected to mechanical evaluation through Finite element analysis (FEA) under both static and dynamic loading conditions on ASTM standard specimens. The results from experimental and FEA analysis demonstrated good uniformity that confirmed the reinforcement of 5 wt % β-Ca3(PO4)2/α-Al2O3 in PLA matrix as an optimum combination to yield better mechanical strength.

Comparison of conventional preparation with modified access preparation on fracture resistance of primary molars - A finite element analysis

ObjectiveTo investigate the influence of Conventional Straight (CS) line and Modified Straight (MS) line access preparations with various restorative materials on the fracture resistance of primary molars using Finite Element Analysis (FEA). MethodologyThree FEA models for each of the primary molars were divided into Group I- Intact tooth model; Group II- Model with CS outline and Group III- Model with MS outline. Based on the restorative material used, Group II and III were further subdivided into subgroup 1- GIC restoration, subgroup 2 – composite resin with GIC base and subgroup 3- Stainless Steel Crown (SSC). Each model was subjected to 5 different force loads directed at the occlusal surface. Maximal von Mises (VM) stresses calculated from stress distribution patterns. ResultThe maximum displacement, in all the models of primary molars were seen in GIC restored models in molars with both CS and MS access whereas the minimal displacement was seen in the SSC restored molars of MS group. ConclusionIn primary maxillary second molar and mandibular first and second molar with intact marginal ridges, the fracture resistance of tooth with MS outline restored with GIC base followed by Composite resin was comparable with the tooth restored with SSC and CS outline. Clinical outcomeBased on the results of this FEA analysis, composite restorations with MS outline would be appropriate for endodontically treated primary molars that have intact margins.

Design Guidelines for Thin Diaphragm-Based Microsystems through Comprehensive Numerical and Analytical Studies.

This paper presents comprehensive guidelines for the design and analysis of a thin diaphragm that is used in a variety of microsystems, including microphones and pressure sensors. It highlights the empirical relations that can be utilized for the design of thin diaphragm-based microsystems (TDMS). Design guidelines developed through a Finite Element Analysis (FEA) limit the iterative efforts to fabricate TDMS. These design guidelines are validated analytically, with the assumption that the material properties are isotropic, and the deviation from anisotropic material is calculated. In the FEA simulations, a large deflection theory is taken into account to incorporate nonlinearity, such that a critical dimensional ratio of a/h or 2r/h can be decided to have the linear response of a thin diaphragm. The observed differences of 12% in the deflection and 13% in the induced stresses from the analytical calculations are attributed to the anisotropic material consideration in the FEA model. It suggests that, up to a critical ratio (a/h or 2r/h), the thin diaphragm shows a linear relationship with a high sensitivity. The study also presents a few empirical relations to finalize the geometrical parameters of the thin diaphragm in terms of its edge length or radius and thickness. Utilizing the critical ratio calculated in the static FEA analysis, the basic conventional geometries are considered for harmonic analyses to understand the frequency response of the thin diaphragms, which is a primary sensing element for microphone applications and many more. This work provides a solution to microelectromechanical system (MEMS) developers for reducing cost and time while conceptualizing TDMS designs.

Finite element analysis of bending and torsional loading of two different endodontic rotary files with different off-center geometric sections

Abstract The aim of this study was to evaluate the performance of two endodontic rotary files with different off-center geometries in bending and torsional tests using finite element analysis (FEA). Trunatomy Prime (TRN-P) and WaveOne Gold Primary (WOG-P) files were used in the study. Geometric models for finite element analysis were obtained by micro-computed tomography scanning. FEA analyses were performed according to ISO 3630-1 specifications to evaluate the bending and torsional tests of the files. Trunatomy Prime showed higher flexibility than WOG-P when subjected to bending. In terms of torsional strength, WOG-P showed higher torsional strength than TRN-P. The geometry of a rotary instrument file influences the mechanical behavior (bending and torsion) of rotary files. The clinician should be aware of the behavioral differences in rotary files and use the appropriate file according to the clinical situation in addition to the manufacturer’s instructions.

FEA and experimental ultimate burst pressure analysis of type IV composite pressure vessels manufactured by robot-assisted radial braiding technique

Composite pressure vessels (CPVs) are lightweight and high-strength containers that can be used for the storage of compressed gases, including hydrogen. While hydrogen is a promising alternative energy source, storage of hydrogen comes with its significant challenges which requires a need for the efficient production of CPVs. Most commonly, CPVs are manufactured using filament winding technology. Due to the rise in the need for pressure vessels, there is a need for alternative high-throughput manufacturing techniques. Braided, in comparison to filament winding, has a high throughput and is less research manufacturing technology for CPVs. In this study, the applicability of braiding for the manufacturing of CPV is researched. Two types of 2D braids, namely the conventional and unidirectional, braiding were studied for their application in such structures, 24K and UD tanks, respectively. Dry carbon fiber (T700S – 24K) and HDPE liner were used to manufacture two different types of composite pressure vessels (CPVs), by robot-assisted radial braiding technique. After the preform of the braiding process was finished, CPVs were cured with a vacuum infusion process (VIP) by using a mold system. Produced braided CPVs were subjected to a hydrostatic burst test in order to determine their ultimate burst pressure point. Finite element analysis (FEA) was used to optimize and correlate experimental burst pressure test results. Ansys ACP was utilized to design composite structures by dividing both tanks’ domes into sub-sections. Results suggest that the experimental burst pressure test of 24K and UD tanks were identified as 200 bar and 150 bar, respectively. UD vessel ruptured close to the dome, whereas the 24K fracture point was located in the center of the dome. UD braided CPV was shown to have a smaller apparent burst deformation (rupture) scale than 24K CPV. In comparison to 24K, the UD braided CPV is 5.7% lighter and requires 20.9% less carbon fiber in production. FEA results were consistent with experimental results in terms of the burst pressure point. For both 24K and UD, the fiber failure starts at the point where the cylinder section and boss system are connected under pressure, and fiber failures continue to progress steadily as the pressure increases.