Wound Composite Cylinders Research Articles

Non-invasive inspection methods for the defect analysis of filament wound composite cylinders and the process optimization

Non-invasive inspection methods for the defect analysis of filament wound composite cylinders and the process optimization

In-plane shear damages consideration of hoop wound composite cylinders using acoustic emission method

The objective of this study was to examine the in-plane shear properties of filament-wound composite cylinders and assess the associated damage mechanisms using acoustic emission techniques. Two distinct composite materials, namely carbon/epoxy and glass epoxy, were manufactured for this purpose. The cylinders were subjected to torsion load conditions in accordance with ASTM D5448. Throughout the testing process, various parameters such as torque, angle of torsion, and strain were meticulously recorded. Additionally, the acoustic emission sensors were utilized to capture signals indicating the occurrence of damages. The findings of the study indicate that the in-plane shear strength and shear modulus of the carbon/epoxy specimens surpass those of the glass/epoxy counterparts. The results from acoustic emission testing indicated that in the CFRP specimens, there were no instances of fiber/matrix debonding. Instead, the main mode of damage observed was fiber breakage, accounting for approximately 71% of the total damage detected. On the other hand, in the GFRP specimens, the primary damage mechanism was found to be fiber/matrix debonding, making up approximately 50% of the overall damage recorded.

Strength and Failure Analysis of Fiber-Wound Composite Gas Cylinder via Numerical Simulation.

Based on the classical grid theory and related regulations, a structure model of a fiber-wound composite gas cylinder was designed in this paper. Based on the design results, a finite element model of a fully wound composite cylinder of an aluminum alloy inner liner with a working pressure of 35 MPa was established based on the ABAQUS software, and its stress distribution under working pressure and minimum burst pressure was analyzed. According to engineering experience, the pressure tolerance of composite cylinders can be improved by proper autofrettage pressure before working pressure, so the influence of autofrettage pressure was analyzed in this paper. The optimum autofrettage pressure was selected by setting the autofrettage gradient, and damage analysis was carried out on the cylinder with nominal working pressure of 35 MPa based on the Hashin failure criterion. The results show the initial damage sequence: matrix stretching occurs before the fiber stretching, and the damage generally starts from the spiral-wound layer. The tensile damage first appears in the transition section between the head and the barrel body, and the damage of the spiral-wound layer develops from the inner layer of the wound layer to the outer layer, while the damage of the circumferentially wound layer develops from the outer layer to the inner layer.

Morphological analysis of as-manufactured filament wound composite cylinders using contact and non-contact inspection methods

Filament winding is a versatile technique for producing pressure vessels throughout the deposition of continuous fiber filaments on a rotating mandrel under determined conditions. Considering the relative safety requirements, these structures are expected to demonstrate high load carrying capacity to ensure the proper storage and transportation of pressurized fuels. Therefore, the quality of the manufactured product and the identification of defects, both structural and morphological, is essential. In the present work, measurements have been carried out in as-manufactured helicoidally filament wound cylinders, made of carbon fiber reinforced polymer, for identifying their morphological characteristics and the presence of variations of the winding angle and gaps or voids. A contact-based ultrasound system is employed to measure the wall thickness and to evaluate the existence of gaps between the layers through the thickness. Furthermore, a non-contact vision-based system is employed to scan and measure the variability of the winding angle. These techniques were applied to 2 identically fabricated filament wound products to identify the repeatability of the manufacturing process as well. The results revealed a deviation between the designed and manufactured product in terms of wall thickness and the actual filament winding angle and a strong variation of both through the various zones of interest through the length and the circumference.

Buckling of helically wound composite cylinders under uniform external pressure

ABSTRACT This study investigated the buckling behaviours of helically wound composite cylinders subjected to uniform external pressure. Three composite cylinders with lengths 180, 280, and 380 mm were manufactured through ±55° winding. Cylinders with a wall thickness of 3.12 mm and inner radius of 103 mm were constructed from carbon fibre reinforced resin matrix composites. Externally hydrostatic tests were conducted to determine the collapse strength and postcollapse modes of the three cylinders. Furthermore, the analytical, linear eigenvalue, and Riks methods were used to study their buckling behaviours. The experimental, analytical, and numerical data agreed well with each other. The Riks method considers Hashin damage initiation and linear damage evolution and can therefore be used to reasonably estimate the postcollapse modes of cylinders.

The role of winding pattern on filament wound composite cylinders under radial compression

AbstractFilament wound (FW) structures present a geometric characteristic in their helical layers: the winding pattern. The pattern, however, is usually disregarded in conventional experimental or numerical approaches even though it can affect the behavior of FW structures, and most studies that account for the pattern are only theoretical. This study aims at deepening the understanding of pattern effects via a comprehensive experimental campaign focusing on composites cylinders under radial compression. Ten winding patterns were considered, from 1 to 10 units along the circumferential direction. Strength, stiffness, absorbed energy and failure mechanisms were evaluated. The results show that the pattern may have a strong influence on both maximum bearing load and absorbed energy, whereas stiffness is less affected.

Influence of mosaic pattern on hygrothermally-aged filament wound composite cylinders under axial compression

The mechanical response of composite structures may be affected by harsh environments, particularly when the matrix has a major contribution, e.g. with off-axis plies. This study aims at investigating the influence of the winding pattern on the axial compressive behavior of filament wound composite cylinder under hygrothermal conditioning. Carbon fiber-reinforced epoxy cylinders were manufactured via filament winding with 1/1, 3/1, and 5/1 mosaic winding patterns and submitted to distilled and artificial seawater environmental conditioning. Water uptake for each hygrothermal conditioning was periodically monitored. The winding pattern influenced both compressive strength and stiffness, and the environmental conditioning decreased strength up to ≈10%. The winding pattern with three diamonds around the circumference of the cylinders provides the properties in term of compressive strength and stiffness.

Computational Investigation of the Effect of Reinforcement Schemes and Angles on the Stress-Strain State and Strength of Composite Cylinders Under Axisymmetric Internal Explosion. Part 3. Results of Calculations for Two-Layer Cylinders with Orthogonal and Combined Reinforcement of the Layers

The effect of reinforcement patterns and angles on the stress-strain state and strength of two-layer wound composite cylinders of finite length with orthogonal reinforcement and two types of combined reinforcement of the layers under axisymmetric internal explosion has been numerically investigated. Using the data presented in Part 2, a comparative analysis of the effect of winding angles on strength for five different reinforcement patterns has been performed according to three failure criteria for an anisotropic material. The obtained results allow one to choose reinforcement patterns and angles, which ensure the highest and lowest initial strengths of the cylinder, according to the maximum stress and strain criteria and the generalized von Mises criterion, as well as circumferential stiffness.

Computational Investigation of the Effect of Reinforcement Schemes and Angles on the Stress-Strain State and Strength of Composite Cylinders Under Axisymmetric Internal Explosion. Part 2. Calculation Results for Single- and Two-Layer Cylinders with Symmetrical Reinforcement of the Layers

The effect of reinforcement schemes and angles on the stress-strain state and strength of single- and two-layer wound composite cylinders of finite length with symmetrical reinforcement of the layers under the internal explosion of a spherical explosive charge in the center of symmetry of cylinders in an air environment has been numerically investigated. The obtained results allow one to choose reinforcement schemes and angles which ensure the highest and lowest initial strength of cylinder according to the maximum stress and strain criteria and the generalized von Mises criterion, as well as circumferential rigidity.

Design of portable 3-axis filament winding machine with inexpensive control system

Filament winding technology is one of the fundamental methods in composite material fields, which needs a high degree of automation. It is the process in which continuous strands or filament of fibres are wound on the mandrel, which is more suitable for making high-pressure vessels, pipes, shaft and ducts. The filament winding machines have existed in enterprises or factories, which are high costs, heavy, complex control system, simple products so far. This paper describes the development of a new 3-axis filament winding machine for the production of wound composite cylinders, which is designed to be more portable, lightweight, low costs, high efficiency and easy control system compared to previous machines. It relates to design hardware control system and the software control system. Based on three axes movement principles, a 3-axis prototype filament winding machine has been developed. The x-axis is the movement left and right of the carriage, the y-axis is the rotation of mandrel and the z-axis is the movement of the feeder. Arduino Uno and CNC (Computer Numeral Control) shield module are used as hardware of control system. Universal G-Code Sender (UGS) and Grbl (G-codes) are adopted as software control system. In conclusion, a protable 3-axis filament winding machine has been successfully designed and performed, which offers potential filament wound composite cylinders with simple control system.

Comparative Vibration Analysis of Multilayered Filament Wound Composite Cylinders with Various End Conditions

This work includes design, fabrication and comparative vibration analysis of multi-layered filament wound composite cylinders of S-Glass epoxy and Basalt epoxy of 500mm length, 100mm diameter and 3mm thickness. The Vibration analyses were done separately on both the cylinders for various end conditions viz., free-free, fixed-free, and fixed-fixed. The natural frequencies of two materials are compared experimentally. Natural frequencies varies with end conditions, material properties, proportions of constituent materials present in the composites, geometrical parameters etc.The natural frequencies of all such parameters were determined using experimental setup which consists of a exciter, accelerometer and DAQ (DEWESOFT 7.0.5 software).

Buckling Behaviour of Circular Ring Stiffened Filament Wound Composite Pressure Hull through Finite Element Analysis

The aim of present study was investigate the buckling pressure of moderately thick-walled filament-wound carbon–epoxy stiffened composite pressure vessel subjected to external hydrostatic pressure through finite element analysis and compare the result with un-stiffened filament wound carbon/epoxy composite pressure vessel used in under water vehicle applications. The winding angles were [±30/90] FW, [±45/90] FW and [±60/90] FW. ANSYS 14.0 APDL, a commercial finite element software package successfully predicted the buckling pressure of filament-wound composite pressure vessel with a deviation much higher than the results of un-stiffened filament wound composite cylinder .All the finite element analysis shows that the composite pressure vessel with winding pattern [±60/90] FW has the higher value of critical buckling pressure. Major failure modes in both the analysis were dominated by the helical winding angles.

Influence of Winding Pattern on Compressive Behavior of Filament Wound Composite Cylinders

Influence of Winding Pattern on Compressive Behavior of Filament Wound Composite Cylinders

Effect of Winding Tension on Elastic Modulus of Filament Wound Composite Cylinder under Axial Loading

Effect of winding tension on elastic modulus of filament wound composite pipes were investigated with experiments in this paper. Three winding tension configuration were utilized and axial tension experiments were carried out. quantity of fiber tension descent from inner to outside in each configuration, which is always used in practices. The result of experiment shows that elastic modulus increase with fiber tension's raising and effect of fiber tension is not too remarkable.

Strain Characteristic of Filament Wound Composite Cylinder under Axial Loading

Experimental investigations were performed on strain characteristic of filament wound composite cylinder. Cylinders are wound with S-1 glass fiber and epoxy resin, and then subjected to an axial tension. During loading, strains at three fiber crossing position and one laminate region on cylinder’s surface are measured by gauges for better understanding strain field. For all specimens, strains at fiber crossing positions are larger than that of laminate region. This indicates that fiber undulation caused by winding process affects mechanical response of filament wound composites.

AE 기법을 이용한 외부수압을 받는 복합재 원통의 균열 검출

복합재료의 비파괴 검사 방법에 관한 연구는 복합재료의 신뢰성 및 안전성을 개선시키는데 매우 중요하다. AE기법은 소성변형, 섬유파손, 모재균열 또는 박리에 의해 생성되는 탄성파에서 감지되는 변형 에너지를 감지하여 결함을 평가하는 기법이다. 본 논문에서는 외부 수압을 받는 필라멘트 와인딩 복합재 원통과 샌드위치 원통의 수압시험이 수행되었고, PVDF센서로부터 측정된 AE 신호특성을 분석하였다. 또한, L-C 동조회로와 Band-pass filter 회로를 가진 AE 신호분석기를 설계, 제작 하였으며, 필라멘트 와인딩 원통과 샌드위치 원통에 대한 수압실험에서 제작된 AE 신호분석기의 균열 검출 능력을 평가하였다. The studies on the non-destructive testing methods of the composite materials are very important for improving their reliability and safety. AE(Acoustic Emission) can evaluate the defects by detecting the emitting strain energy when elastic waves are generated by the generation and growth of a crack, plastic deformation, fiber breakage, matrix cleavage or delamination. In this paper, the AE signals of the filament wound composite cylinder and sandwich cylinder during the pressure test were measured and analyzed. The signal characteristics of PVDF sensors were measured, and an AE signal analyzer which had the band-pass filter and L-C resonance filter were designed and fabricated. Also, the crack detection capability of the fabricated AE signal analyzer wes evaluated during the pressure tests of the filament wound composite cylinder and the sandwich cylinder.

Autofrettage Pressure Analysis of Carbon-fiber Wound Composite Gas Cylinders

Despite the widening use of the carbon fiber wound composite gas cylinder, the research on its structure is mainly focused on the experiment method. In this paper, the APDL language in ANSYS was used to create a model of carbon fiber wound aluminum alloy liner composite gas cylinders with the thickness and the wound angle of both heads varied. The autofrettage process of the cylinder was analyzed and the range of autofrettage pressure value was determined by the DOT CFFC standard. It is expected that the finite element analysis results would be conducive to the engineering practice.

마이크로 유전자 알고리즘을 이용한 외부 수압을 받는 필라멘트 와인딩 복합재 원통의 최적 설계

본 연구에서는 마이크로 유전자 알고리즘을 이용하여 외부 수압을 받는 필라멘트 와인딩 복합재 원통의 최적설계를 수행하였다. 목적함수는 파손하중과 좌굴하중을 동시에 고려하여 설계하중을 최대화하는 것이다. 좌굴 및 파손해석은 MSC.NASTRAN을 이용하였고, Carroll의 공개된 마이크로 유전자 알고리즘에 기초한 최적화작업을 수행하였다. 설계변수로는 헬리컬(helical) 와인딩 각도와 후프(hoop) 와인딩 층의 두께비가 고려되었다. 본 연구를 통해 마이크로 유전자 알고리즘을 이용하여 다양한 형상을 갖는 필라멘트 와인딩 복합재 원통의 좌굴 및 파손하중 최적화가 가능함을 확인하였고, 제안된 알고리즘이 일반 유전자 알고리즘과 비교해서도 높은 효율을 보였다. In this study, a micro-genetic algorithm was utilized for the optimal design of filament wound composite cylinders subjected to hydrostatic pressure for underwater vehicle application. The objective of the optimization was to maximize the design allowable load considering the buckling and static failure loads. A commercial finite element program, MSC.NASTRAN, was used for buckling and failure analysis. An open-source micro genetic algorithm by Carroll was modified for the optimization. The design variables are the helical winding angle and hoop layer thickness. The results of examples show that the micro genetic algorithm can be successfully applied to the optimization of filament wound cylinders with various geometries and gives better efficiency than general genetic algorithms.

Entire Life Time Monitoring of Filament Wound Composite Cylinders Using Bragg Grating Sensors: I. Adapted Tooling and Instrumented Specimen

This paper is the first of three describing the monitoring of filament wound cylinders using Bragg grating sensors. Part I describes the technological issues and the development of specimens instrumented with embedded gratings and thermocouples. The aim is to monitor the temperature and strain changes during cylinder manufacture (see Part II) and in-service behaviour (see Part III). Specimens are filament wound glass reinforced epoxy composites, so two technological problems have to be solved: one is to collect data during fabrication and the second is to remove the specimen from the mandrel without damaging the sensors. These were accomplished by design of a specially adapted split mandrel and a rotating interface between the filament winding machine and the composite cylinder in fabrication. Immediately after sensor insertion it was possible to monitor the fabrication process, by collecting Bragg grating wavelength and temperature response, using this specially adapted tooling.

Entire Life Time Monitoring of Filament Wound Composite Cylinders Using Bragg Grating Sensors: III. In-Service External Pressure Loading

This article is the third of three papers describing a study of the monitoring of filament wound composite cylinders for underwater applications. Part I described the technological issues and the development of specimens instrumented with embedded gratings and thermocouples, with the aim of monitoring the temperature and strain changes during the cylinder manufacturing presented in Part II. Residual strains are not negligible, over 1,000 axial micro-strain at the end of the curing cycle. Part III describes the response of these cylinders to hydrostatic pressure loading. The same embedded fiber optical Bragg gratings (FBGs) used for parts I and II of the study are here used as strain gauges. Their response is compared to that of classical resistive strain gages bonded to the inner surface of the tube. Results from these initial tests demonstrate the embedded FBG sensor’s capability to monitor structural health of an underwater structure from fabrication throughout its service life. Embedded instrumentation records strains during pressure cycles up to final failure, without affecting the cylinder response.