Finite Element Analysis of High Pressure Composite

Vessels
A Dissertation Submitted
In Partial Fulfilment of the Requirements
For the Degree
of

MASTER OF TECHNOLOGY
In
CAD-CAM
By

DEEPAK KUMAR ARUN

(1515017502)

Under the Supervision of

Ankita Awasthi, Assistant Professor

College of Engineering and Technology, IILM Academy of Higher
Learning
Greater Noida (U.P.)
to
TheFaculty of Mechanical Engineering

DR. A.P.J. ABDUL KALAM TECHNICAL UNIVERSITY

(Formerly Uttar Pradesh Technical University)
LUCKNOW
JUNE, 2018
 CERTIFICATE

Certified that DEEPAK KUMAR ARUN (1515017502) has carried out the research work
presented in this thesis entitled “Design and Analysis of High Pressure Composite
Vessels” for the award of Master of Technology from Dr. A.P.J Abdul Kalam Technical
University, Lucknow under our supervision. The thesis embodies results of original work,
and studies are carried out by the student himself and the contents of the thesis do not form
the basis for the award of any other degree to the candidate or to anybody else from this or
any other University/Institution.

Signature
(Ankita Awasthi)
(Assistant Professor)
(CET-IILM-AHL, Gr. Noida)

Signature
(Mr. Shatrughan Singh)
( Head of Department)
(CET-IILM-AHL, Gr. Noida)

Date:

ii
 ABSTRACT

This article is proposed to 3D Modeling and design a cylindrical pressure vessel made up of
material composites. In Latest composite material considered is waspaloy for pressure vessel.
Present aviation brass is the major element used for construction of pressure vessels .

Pressure vessel is a shut compartment intended to hold gases or fluids at a weight

significantly extraordinary from the surrounding weight. This venture examines some plan
rules that are manages vessels are subjected to different connected powers acting in mix with
inner weight. Outline of various Pressure vessel worried about components such as shell,
Dish end, and spouts in view of norms and codes; and advancement of shell, dish end and
spouts broke down by methods for ANSYS .for three materials (composite material,
aluminum combinations and S-Glass) and afterward compere to pick the best outline.

At present pressure vessels are made of traditional metals like steels and aluminium alloys.
The performance or operating range depend upon weight of the pressure vessel. For getting
better performance weight can be reduced by reducing the weight of shell structure.so
composite materials are used to improve the strength of pressure vessel because these
material have special feature of low-weight and high strength.

In this research we have to design and analyse a high pressure cylindrical composite pressure
vessel of various fiber orientation angles whis are following
1-[+25/-25] FW
2-[+35/-35] FW
3-[+45/-45] FW
4-[+55/-55] FW
5-[+65/-65] FW
6-[+75/-75] FW.

3D Modeling and Analysis of Pressure vessel is done in APDL Ansys 15.0, a versatile FEA
software. The optimum fiber orientation are determined from the analysis.

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 ACKNOWLEDGEMENT

I would like to express my sincere gratitude to my guide Ms. Ankita Awasthi, Assistant
Professor, Mechanical Engineering at College of Engineering & Technology, IILM Academy
of Higher Learning, Greater Noida for the continuous support of my M.Tech research for her
motivation, valuable guidance, support and encouragement throughout my work help me to
complete this thesis successfully.

A special thanks to, Mr. Shatrughan Singh, HOD of Mechanical Engineering department &
Mr. Abhishek Kumar, M.Tech coordinator Mechanical Engineering department at CET-
IILM-AHL, Gr. Noida for their valuable guidance and encouragement during the completion
of Dissertation.

I thank to all the faculty members and lab staff of the Mechanical Engineering Department,
CET-IILM-AHL, Gr. Noida who have provided the most cooperative assistance for my
research work. My heartiest thanks also goes to all those persons who have shared their
valuable time and knowledge in completion of this thesis.

Lastly I have great pleasure in expressing my acknowledgement to my parents, my family

members, all my colleague and friends, who always helped me during the course.

DEEPAK KUMAR ARUN

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 TABLE OF CONTENTS
Page No.
Certificate ii
Abstract iii
Acknowledgement iv
Table of Contents v
List of Tables vii
List of Figures ix
Abbreviations and Nomenclature xi

CHAPTER 1: INTRODUCTION 1-7

1.1 Introduction 2-6
1.2 Problem 6
1.3 Pressure Vessel 6-7

CHAPTER 2: LITERATURE REVIEW 8-23

2.1 Introduction 9
2.2 Compressed Natural Gas and Hydrogen Storage 9
2.3 General Dynamics 9
2.4 Compressed Natural Gas (CNG) Storage Pressure 10

CHAPTER 3: ENGINEERING MATERIAL 24-39

3.1 Conventional Engineering Materials 25-26
3.2 Types of Engineering Material 26
3.2.1 Metallic Materials 27
3.2.1.1 Ferrous Metals 27
3.2.1.2 Non-Ferrous Metals 28
3.2.2 Polymeric Materials 28
3.2.2.1 Thermoplastics 29
3.2.2.2 Thermosets 29
3.2.2.3 Elastomers 29
3.2.3 Ceramics 29
3.2.4 Composites 30
3.2.5 Others 31
3.3 Material Selection 31
3.3.1 Functional Properties 31
3.3.2 Manufacturing Properties 31
3.3.3 Economics 31
3.4. Selected Materials for Research 32
3.4.1 AL-ALLOY 6061-T6 32
3.4.1.1 Application 32
3.4.1.2 Chemical Composition 33
3.4.1.3 Temper Types 33
3.4.1.4 Supplied Forms 33
3.4.1.5 Generic Physical Properties 33
3.4.1.6 Mechanical Properties 34
3.4.1.7 Weldability 34

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 3.4.1.8 Fabrication 34
3.4.2 S-Glass 34
3.4.2.1 Material Properties 35
3.4.2.2 Applications 35
3.5 Composite Materials 36-37
3.6 Types of Composites 38
3.6.1 Composites reinforced by Particles 38
3.6.2 Composites reinforced by Chopped Strands 38
3.6.3 Unidirectional Composites 38
3.6.4 Laminates 39
3.6.5 Fabric reinforced plastics 39
3.6.6 Honeycomb Composite Structure 39

CHAPTER 4: METHODOLOGY 40-44

4.1 Composites 41
4.2 Fiber 41
4.3 Laminates 42
4.4 Stresses in a Thin-Walled Cylinder 42
4.5 Failure Criteria 43
4.5.1 Fiber Buckling 43
4.5.2 Fiber Breakage 43
4.5.3 Matrix Cracking 44
4.5.4 Delamination 44

CHAPTER 5: FINITE ELEMENT ANALYSIS 45-56

6.1 Introduction 46-52
6.2 Application of Finite Elements 52-55
6.3 Finite Element Modelling of Composite Vessel 55

CHAPTER 6: FEA RESULT AND DISCUSSION 56-128

6.1 Analysis Result 57-114
6.2 Discussion on Result 114-126
6.3 Minimum Stress Plot 127-128

CHAPTER 7: ESTIMATION 129-131

7.1 Material Estimation of Composites 130-131

CHAPTER 8: CONCLUSION 132-133

8.1 Conclusion 133

REFERENCES 134-138

CURRICULUM VITAE 139-142

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 LIST OF TABLES
Table No. Title Page No.
6.1 Weight Calculation of Composite I 57
6.2 Weight Calculation of Composite II 61
6.3 Weight Calculation of Composite III 64
6.4 Weight Calculation of Composite IV 67
6.5 Weight Calculation of Composite V 71
6.6 Weight Calculation of Composite VI 74
6.7 Weight Calculation of Composite VII 77
6.8 Weight Calculation of Composite VIII 80
6.9 Weight Calculation of Composite IX 83
6.10 Weight Calculation of Composite X 87
6.11 Weight Calculation of Composite XI 90
6.12 Weight Calculation of Composite XII 93
6.13 Weight Calculation of Composite XIII 96
6.14 Weight Calculation of Composite XIV 99
6.15 Weight Calculation of Composite XV 102
6.16 Weight Calculation of Composite XVI 105
6.17 Weight Calculation of Composite XVII 109
6.18 Weight Calculation of Composite XVIII 112
6.19 Stresses for Composite I, Composite II and Composite III 115
6.20 Deformation for Composite I, Composite II and 115
Composite III
6.21 Stresses for Composite IV, Composite V and Composite 117
VI
6.22 Deformation for Composite IV, Composite V and 117
Composite VI
6.23 Stresses for Composite VII, Composite VIII and 119
Composite IX
6.24 Deformation for Composite VII, Composite VIII and 119
Composite IX
6.25 Stresses for Composite X, Composite XI and Composite 121
XII
6.26 Deformation for Composite X, Composite XI and 121
Composite XII
6.27 Stresses for Composite XIII, Composite XIV and 123
Composite XV
6.28 Deformation for Composite XIII, Composite XIV and 123
Composite XV
6.29 Stresses for Composite XVI, Composite XVII and 125
Composite XVIII
6.30 Deformation for Composite XVI, Composite XVII and 125
Composite
XVIII
6.31 Stresses for Minimum Stress Plot 127
6.32 Deformation for Minimum Stress Plot 127
7.1 Material estimation for Composite I, Composite II, 130
Composite III, Composite IV and Composite V
7.2 Material estimation for composite Composite VI, 130
Composite VII, Composite VIII, Composite IX and
Composite X

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7.3 Material Estimation Composite XI, Composite XII, 131
Composite XIII, Composite XIV and Composite XV
7.4 Material Estimation Composite XVI, Composite XVII and 131
Composite XVIII

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 LIST OF FIGURES
Figure Tittle Page No.
No.
1.1 Pressure Vessel 3
3.1 Engineering Materials With Mechanical Properties 26
3.2 Chemical Composition of AL-ALLOY 6061-T6 33
3.3 General Physical Properties of AL-ALLOY 6061-T6 33
3.4 Mechanical Properties of AL-ALLOY 6061-T6 34
3.5 Material Properties of S-Glass 35
3.6 Classification of composites processing techniques 36
3.7 Composite Laminates Manufacturing Process 37
3.8 Different Types of Composites (a) Composites reinforced 38
by Particles (b) composites reinforced by Chopped
Strands (c) Unidirectional Composites (d) Laminates (e)
Fabric reinforced plastics (f) Honeycomb Composite
Structure
4.1 Fiber 41
4.2 Typical Laminate 42
4.3 Hoop and axial stresses working on thin-walled tubes 43
4.4 Hoop and axial stresses working on thin-walled tubes 44
5.1 Plate with a Hole 47
5.2 Finite Element Model 47
5.3 Stress Distribution In Plate 47
5.4 Modeling and Testing of Human Prototype Skull 52
5.5 Human Body Model for Biomedical Telemetry. 52
5.6 Virtual crash simulations of passenger car against 54
different LTV
5.7 Aerodynamics of Aero plane 54
5.8 Flow Around The Car 54
6.1 Layer Stacking for Variant I 58
6.2 Von Mises Stress for Variant I 58-60
6.3 Layer Stacking for Variant II 61
6.4 Von Mises Stress for Variant II 61-63
6.5 Layer Stacking for Variant III 64
6.6 Von Mises Stress for Variant III 65-67
6.7 Layer Stacking for Variant IV 68
6.8 Von Mises Stress for Variant IV 68-70
6.9 Layer Stacking for Variant V 71
6.10 Von Mises Stress for Variant V 71-73
6.11 Layer Stacking for Variant VI 74
6.12 Von Mises Stress for Variant VI 75-77
6.13 Layer Stacking for Variant VII 78
6.14 Von Mises Stress for Variant VII 78-79
6.15 Layer Stacking for Variant VIII 80
6.16 Von Mises Stress for Variant VIII 81-83
6.17 Layer Stacking for Variant IX 84
6.18 Von Mises Stress for Variant IX 84-86
6.19 Layer Stacking for Variant X 87
6.20 Von Mises Stress for Variant X 87-89
6.21 Layer Stacking for Variant XI 90

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6.22 Von Mises Stress for Variant XI 90-92
6.23 Layer Stacking for Variant XII 93
6.24 Von Mises Stress for Variant XII 93-95
6.25 Layer Stacking for Variant XIII 96
6.26 Von Mises Stress for Variant XIII 96-98
6.27 Layer Stacking for Variant XIV 99
6.28 Von Mises Stress for Variant XIV 99-101
6.29 Layer Stacking for Variant XV 102
6.30 Von Mises Stress for Variant XV 103-105
6.31 Layer Stacking for Variant XVI 106
6.32 Von Mises Stress for Variant XVI 106-108
6.33 Layer Stacking for Variant XVII 109
6.34 Von Mises Stress for Variant XVII 109-111
6.35 Layer Stacking for Variant XVIII 112
6.36 Von Mises Stress for Variant XVIII 112-114
6.37 Stresses for Variant I, Variant II and Variant III 116
6.38 Deformation for Variant I, Variant II and Variant III 116
6.39 Stresses for Variant IV, Variant V and Variant VI 118
6.40 Deformation for Variant IV, Variant V and Variant VI 118
6.41 Stresses for Variant VII, Variant VIII and Variant IX 120
6.42 Deformation for Variant VII, Variant VIII and Variant IX 120
6.43 Stresses for Variant X, Variant XI and Variant XII 122
6.44 Deformation for Variant X, Variant XI and Variant XII 122
6.45 Stresses for Variant XIII, Variant XIV and Variant XV 124
6.46 Deformation for Variant XIII, Variant XIV and Variant 124
XV
6.47 Stresses for Variant XVI, Variant XVII and Variant XVIII 126
6.48 Deformation for Variant XVI, Variant XVII and Variant 126
XVIII
6.49 Stresses for Minimum Stress Plot 128
6.50 Deformation for Minimum Stress Plot 128

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ABBREVIATIONS AND NOMENCLATURE

M- Mass
W- Weight
g- Acceleration due to gravity
E- Young’s Modulus
G- Rigidity Modulus
v- Poisson’s Ratio
ρ- Density
Δ- Delta
mm- Milli Meter
Kg- Kilogram
GPa- Giga Pascal
MPa- Mega Pascal
Π- Pie
σ- Sigma
Di- Inner Diameter of Vessel
Do- Outer Diameter of Vessel
T- Thickness of Vessel
ANSYS APDL- Ansys Parametric Design Language

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