Proceedings of the ASME 2017 International Mechanical Engineering Congress and Exposition

IMECE2017
November 3-9, 2017, Tampa, Florida, USA

IMECE2017-71843

DESIGN OPTIMISATION OF COMPOSITE OVERWRAPPED PRESSURE VESSEL

THROUGH FINITE ELEMENT ANALYSIS

Shah Alam Abhijeet Divekar

Assistant Professor Grad. Research Assistant
Texas A&M University-Kingsville Texas A&M University-Kingsville
Kingsville, Texas, USA Kingsville, Texas, USA

1. ABSTRACT
COPVs are currently used at NASA to contain high-
pressure fluids in propulsion, science experiments and life
support applications. These COPVs have a significant weight
advantage over all-metal vessels; but, as compared to all-metal
vessels, COPVs require unique design, manufacturing, and test
requirements. The most significant difference from metal
pressure vessel designs is that COPVs involve a much more
complex mechanical understanding due to the interplay
between the composite overwrap and the inner liner.
Often only limited analysis is performed to obtain an initial
design, and then the design is refined through number of “build
and burst” iterations. However, the cost in material and
resources to fabricate multiple test specimens is extremely
prohibitive. To avoid these high cost and time for build and
burst iterations, FEA is often employed in an attempt to reduce
the number of iterations required. FEA process becomes more
of a design confirmation effort rather than a design iteration
effort. In this research, we aimed to establish a detailed design
optimization of a complete COPV through Finite Element
simulation.
2. INTRODUCTION
COPVs are currently used at NASA to contain high-
pressure fluids in propulsion, science experiments and life
support applications. These COPVs have a significant weight
advantage over all-metal vessels; but, as compared to all-metal
vessels, COPVs require unique design, manufacturing, and test
requirements. The most significant difference from metal
pressure vessel designs is that COPVs involve a much more
complex mechanical understanding due to the interplay
between the composite overwrap and the inner liner. A metallic
liner is typically used in a COPV as a fluid permeation barrier.
The metallic liner design requirements are as per traditional
metal pressure vessels standards. However, the application of
metallic vessel design standards to the composite pressure
vessel is not straightforward. Different failure modes exist for
the COPVs, and the understanding of these failure modes is
difficult and at a much more rudimentary level than for metal
vessels [1].
The composite word used means that a matrix of continuous
fibres contained within a resin and wrapped over a pressure
barrier just like a string mounted over a ball to forma vessel for
gas or a liquid containment. Composite in COPV is
combination of structural fibres and a resin that forms the
overwrapped structure. The role of continuous fibre is to
provide a tensile strength while the resin carries the shear load

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 and its helps to keep the fibres bonded to each other. In the
general case fibre/resin composite is not considered as pressure
tight. So, to make it pressure tight and structurally solid a
metallic liner is added to the structure. The main role of a
metallic liner is that it will allow some more structural stability
to the pressure vessel moreover the metallic liner will act as a
leak barrier for the gas or liquid in the pressure vessel. The liner
used has a very small thickness. The liner will also act as a
support to the fibre wrapping. The load sharing liner is the
common liner term used in the composite overwrapped
pressure vessel field which shares the internal pressure load
along with the composite structure.
FIGURE 1, GENERAL LAYOUT OF COPV
The above figure shows the general arrangement of
composite overwrapped pressure vessel with aluminium liner
and number of composite overwraps. Aluminium liner acts as a
barrier to the content of the cylinder that is it won’t allow the
insides of the cylinder to leak also it will share the load that is
internal pressure along with the composite overwraps so it can
be called as load sharing metallic liner [2].
When the internal pressure is applied to the vessel, stress is
induced on metallic liner as well as composite overwrap. To
study the COPVs, understanding of the failure criteria is
important. There are four basic failure criteria for the COPVs.
• Burst due to over-pressure – When the internal pressure in
the vessel somehow increased and the amount of pressure
exceeds the burst pressure of a vessel then this type of
failure occurs [1]. The way of prevention for this type of
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failure is knowing the burst pressure value for the material
used for the manufacturing of pressure vessel. In the phase
of testing, design and proof pressurisation can be done. In
design and proof pressurisation as per the design and
material selection, internal pressure is applied and the
magnitude of the pressure is increased gradually. Based on
the properties of material burst pressure is already known
so the vessel is tested for that amount of pressure, if the
test succeeds the vessel can be said to be safe for this
failure criteria.
• Fatigue failure of a metallic liner – Metallic liner is the
first member which encounters an internal pressure. Hence
failure of the liner due to fatigue is occurred [1]. To cure
this failure, non-destructive testing of a metallic liner can
be done to screen the flaws in it. The COPV can be
subjected to the pressurised cycles to assure the adequate
design life.
• Burst of metallic liner or composite material – When the
internal pressure exceeds the design limit that is more than
the burst pressure this type of failure is occurred [1]. The
failure of composite may be mitigated by appropriate
control from damage and damage tolerance testing. To
identify the surface damage visual inspection can be
deployed. Though identification of damage is not fully
possible up to certain extent it can be done.
• Stress rupture of composite overwrap – Stress rupture
which also called as static fatigue is situation in which the
composite experiences degradation and this degradation is
time dependent. The degradation results into sudden
structural failure of composite overwrap resulting into the
leakage of the material in COPV.
As noticed in the information on pressure vessel,
failure criteria and design parameters, burst pressure is the
critical parameter. The magnitude of burst pressure also
depends on the thickness of the metallic liner, material of the
metallic liner and orientation of the composite overwrap.
3. LITERATURE REVIEW
Various researchers have performed and tried to dig
deep in the field of composite overwrapped pressure vessels.
They tried to find the effect of different boundary conditions on
the pressure vessels with composite over-wrapped and filament
wounding. The composite used in all the research papers
reviewed had variation in the orientation angles and material.
The review of the research paper was done in the two steps;
first, the papers on finite element analysis of COPVs was done
 and after that research papers mainly on the burst pressure
analysis of COPVs were found and reviewed.
In the “Analysis of multi-layered thick-walled
filament-wound hydrogen storage vessel”, three-dimensional
elastic analysis was performed on hydrogen storage vessel.
Hydrogen storage vessel is a type of COPV, that is why this
paper was chosen for the review. The exact solution to the
stresses on the liner were calculated based on the Lekhnitskii’s
theory and plain strain assumptions. The governing equations
were derived to calculate the radial displacement of the
pressure vessel. Aluminium liner was used to carry out the
analysis and for the various thickness of the aluminium liner
shear stress and twisting rate in a normal plane were calculated.
Results calculated were compared with the other results
obtained from the previous researchers which showed that if
the liner is added the magnitude of the stress developed was
reduced. Also with increase in the thickness liner decrease in
the stress liner were noticed. Same case happened on the effect
of twisting effect [2].
“Stress and damage analysis of composite
overwrapped pressure vessel” carried out the numerical
analysis on COPV with aluminium liner subjected to the
internal pressure. Four failure methods for the composite
material were considered which are fibre tension, fibre
compression, matrix tension and matrix compression. The
effect of damage evolution to determine the burst pressure and
auto-frettage pressure are analysed in this paper. This paper
also discussed the effect of auto-frettage pressure on mean
stress and stress amplitude of the aluminium liner under zero
and service pressure. In the conclusion paper showed that
matrix crack damage appears on the head of the vessel while
fibre tensile damage appeared on the middle part of the cylinder
when subjected to the service pressure. Auto-frettage has the
small effect on stress amplitude while significant effect on the
mean stress [3].
The research was done to find what if the composite
material is used for the cylinder which stores and transports the
liquefied petroleum gas (LPG) instead of the steel. The paper
“Composite LPG cylinder as alternative to steel cylinder”
performed this analysis on the composite cylinder made up
with cross plies. This paper compared the results by applying
loads on both steel and composite cylinder model in finite
element software package. Internal pressure, axial load, radial
load and impact load were applied to both the models.
Performing finite element analysis on both the models it was
found that composite pressure vessel has more stress carrying
capacity [4].
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Burst pressure of mild steel pressure vessel was
conducted in “Finite element analysis to estimate burst pressure
of mild steel pressure vessel using Ramberg-Osgood model.
Prediction of the burst pressure of any pressure vessel is
necessary as burst pressure is a design safety limit which
should not be exceeded. If burst pressure value increases
pressure vessel may get permanently. This paper performed a
non-linier finite element analysis by applying non-linier stress.
As material curve is needed to calculate the burst pressure
numerically this paper used material curve derived from
Ramberg-Osgood equation. The results obtained by this paper
was then compared to the results obtained by another author.
Six CAD drawings were done on commercial software CATIA
with constant length and variable inner and outer diameter.
Meshing was done on the HYPERMESH and for post-
processing NASTRAN was used. Initially one bar pressure was
applied to the inside of the pressure vessel and further it was
increased with steps until stress induced in vessel exceeds
ultimate strength of the material. The pressure at which induced
stress exceeds ultimate strength of the material it is considered
as a burst pressure of a cylinder [5].
Non-linier finite element model is done in “Analysis
of composite hydrogen storage cylinder subjected to localised
flame impingements”. The storage pressure vessel is subjected
to high pressure and local flame impingements. Axi-symmetric
model is done to carry out the analysis. The system includes
various sub-models to predict the temperature evolution of
composite cylinder wall. Commercial software ANSYS is used
for pre-as well aas post-processing. Hydrogen storage vessel is
typically made up of high molecular weight polymer or
aluminium liner which prevents hydrogen leakage from the
pressure vessel. A filament wound composite laminate over-
wrapped outside of the aluminium liner provides the desired
load bearing capacity. Polymer rein-forced composite is
flammable so there is possibility of failure due to fire. Fire
source is modelled as a constant heat flux in the simulation.
Carrying out the analysis stresses, failure type and temperature
profile were reported [6].
In the paper “Analytical and finite element modelling
of pressure vessel for seawater reverse osmosis desalination
plants”, an analytical solution and finite element model is used
to optimise the pressure vessel design parameters. Stainless
steel and fibre reinforced composite material are the two types
of materials used for the comparison with each other. In
addition to it hybrid composite materials are introduced for the
layers through the vessel thickness. Different pressure vessel
sizes were used by considering the standard sizes available in
 the market for the same purpose. For stainless steel pressure
vessel, the same wall thickness was obtained from both that is
analytical and finite element solution. In case of composite
pressure vessel analytical analysis showed that pressure vessel
thickness depends on fibre orientation and material type for
certain lay-up. For the composite materials like carbon-epoxy
vessel has allowable thickness lower than E-glass/epoxy vessel.
In case of hybrid pressure vessel material, the allowable value
of thickness is between E-glass/epoxy and carbon-epoxy
material depending upon amount of each material and the
arrangement of the layers through material thickness. In the
analysis done in this paper composite pressure vessel shows the
better weight saving compared to stainless steel pressure vessel.
Also, finite element solution showed good agreement with the
analytical solution [7].
The effect of impact on a cylindrical part of a pressure
vessel is studied in the paper “Burst pressure reduction of
various thermoset composite pressure vessel after impact on
cylindrical part”. The paper carried out the study on residual
burst pressure of composite cylinder after mechanical impact.
More than 200 impact test results were gathered to perform this
analysis. The analysis covered the cylindrical characteristics
such as volume, pressure, liner material, geometry,
manufacturer and testing conditions like inner pressure impact
energy etc. Despite these conditions common behaviour of four
models of cylinder were tested [8].
3D parametric finite element model is proposed in
“Finite element analysis of burst pressure of composite
hydrogen storage vessel”, to predict the damage evolution and
failure strength of composite hydrogen storage vessel which is
subjected to the internal increasing pressure. Only cylindrical
part of the pressure vessel is considered for the finite element
analysis. The liner used in this paper is 6061-T6 aluminium
liner with 10 carbon fibre/epoxy composite material for the
cylinder. To make the calculations easy and to reduce the
solution calculation time axi-symmetric model is used. Four
failure criteria were used and distribution of the Mises stress
under increasing internal pressure is plotted for four failure
criteria. Internal pressure was first set so as no element fails at
the initial pressure and after that pressure is increased
gradually. The principle stresses for composite element and
maximum shear stress for liner was monitored. Analysis stated
that, comparing to all the failure criteria Tsai-Wu failure
criteria is the most accurate [9].
Behaviour of the liner under burst pressure is
investigated in “Experimental and numerical analysis of A
LLDPE/HDPE liner for a composite pressure vessel”. Liner
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used in this research was a polymer blend of 95 wt.% low linier
density polyethylene (LLDPE) and 5 wt.% of high density
polyethylene (HDPE). The pressure vessel is manufactured by
filament winding process with variable composite thickness
carbon/epoxy CNG shell. Simulation was done on the
commercial software package as well as testing in the
laboratory was also carried out. LLDPE/HDPE liner samples
were subjected to burst pressure and results were compared
with ASME boiler and pressure vessel code. It also includes the
testing of liners with different thickness [10].
In the paper “Burst analysis of cylinder shells”, the
attempt was made to show that the burst pressure of cylindrical
shells which is subjected to internal pressure can be calculated
by finite element method. To solve the non-linier equations
involved in the analysis author used the Newton-Raphson and
Arc length method. Though composite material was not used in
this paper, the geometry considerations were useful. The model
of the pressure vessel was considered symmetric and to save
the calculation time only half of the model was modelled on the
software. The research also includes the effect on the cylinder
shell with slight thickness variation and the cylindrical shell
with hole [11].
In “Dynamics burst pressure simulation of cylindrical
shells”, short term burst pressure of metal cylinders under short
term dynamic loading conditions was tested. The influence of
geometric parameters like diameter, thickness and loading
parameters like dynamic pressure vs. time is examined in this
paper. Author had developed empirical formulae based on
experimental data. The results obtained in this analysis were
then compared to the finite element solution. Though
composite material is not used in this paper for the future scope
same analysis can be performed with the composite material
and results can be compared with the same analysis carried on
conventional material [12].
The paper on “Design and burst pressure analysis of
CFPR composite pressure vessel for various fibre orientation
angles”, study of cylindrical section of carbon fibre reinforced
polymer composite pressure vessels having four layers was
done. Paper considered both hoop and helical winding of the
fibre and modelling was done for the both methods. To predict
the burst pressure analysis on various fibre orientation was
conducted. In the conclusion, the author stated that, ±45º
orientation angle is found to be optimum among all the fibre
orientation angles analysed [13].
“Development of new generation of filament wound
composite pressure cylinder”, considered the pressure vessels
with thermoplastic liner and glass filament winding. The
 commercial software ABAQUS was used to examine the
mechanical behaviour of pressure vessel under internal burst
pressure. The results obtained from the finite element analysis
were then compared with the experimental results [14].
4. METHOD
The steps involving creating geometry of the finite
element model using software package with appropriate
thickness of load sharing metallic liner and composite material
overwrap with its different orientation angles. The main
problem of conducting a research on composite overwrap
pressure vessel is, creating a composite layer on a pressure
vessel geometry. When the layer is created then the whole
assembly of pressure vessel, load sharing metallic liner and
composite overwrap can be taken into the module of finite
element software where boundary conditions on the model can
be applied.
In this paper ANSYS 16.0 software is used for
creating pressure vessel geometry along with load sharing
metallic liner and composite overwrap.
4.1 FAILURE CRITERIA
Failure analysis is a tool for predicting the strength of a
laminated composite. Failure theories are based on stresses in a
material axes or local axes because a lamina is orthotropic.
Failure theories are not based on principal normal stresses and
maximum shear stresses. Failure theories are based on first
finding the stresses in the local axes and using five strength
parameters of a unidirectional lamina to find whether a lamina
has failed.
Failure analysis is a tool for predicting the strength of a
laminated composite. Failure theories are based on stresses in a
material axes or local axes because lamina is orthotropic.
Failure theories are not based on principle normal stresses and
maximum shear stresses. Failure theories are based on first
finding the stresses in the local axes and using strength
parameters of a unidirectional lamina to find whether the
lamina has failed.
The failure criteria used for the analysis are maximum stress
and strain, Tsai Hill and Tsai Wu. The internal pressure is
applied gradually with small load increment and failure index is
observed. When failure index is more than one, then the applied
load is considered as burst pressure.
Maximum Stress criterion identifies composite material failure
caused by three possible modes of loading. The three failures
are longitudinal failure, transverse failure and shear failure.
S+11 = Value of σ11 at longitudinal tensile failure
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S-11 = Value of σ11 at longitudinal compressive failure
S+22 = value of σ22 at transverse tensile failure
S-22 = value of σ22 at transverse compressive failure
S12 = Absolute value of σ12 at longitudinal shear failure
Longitudinal failure occurs whenever σ11 ≥ S+11 or σ11 ≤ S-11
Transverse failure occurs whenever σ22 ≥ S+22 or σ22 ≤ S-22
Longitudinal shear failure occurs whenever | σ12 | ≥ σ12max
Failure index = Max. absolute value of (σ11/ S+11, σ11/ S-22, σ22/
S+22, σ22/ S-22, σ12/ S-22) ≥ 1
A maximum stress criterion is no interaction between modes of
failure that is the critical stress for one mode is unaffected by
the stresses tending to cause the other modes. Failure then
occurs when one of these critical values σ1u, σ2u and τ12u is
reached [15]. These values refer to the laminar principle axes
and can be resolved from the applied stress system by using the
transformation equation.
4.2 Finite element model
First, geometry was created in ANSYS geometry
module which was then coupled with composite pre-post
module of ANSYS to setup a metallic liner and composite
overwrap. First, a model is created on ANSYS with random
dimensions of pressure vessel, thickness and material of load
sharing metallic liner and thickness of composite materials and
material for practice. Once the model is done as per the
requirements any changes in material properties, thickness and
other parameters can be done parametrically. The basic
geometry is drawn with head radius to be 1m and the length of
pressure vessel to be 3m excluding head part on both sides.
FIGURE 2, BASIC GEOMETRY
The surface model of the pressure vessel along with
its sectional view for the better understanding of the geometry
is showed in the following figures.

FIGURE 3, REVOLVED SURF ACE BODY OF PRESSURE
VESSEL
FIGURE 4, CUT SECTION
Meshing is done on ANSYS with the face meshing
command. Once the mesh is created the geometry of pressure
vessel is ready to be coupled to the ANSYS Composite pre-post
module to setup the layer of load sharing metallic liner and
composite overwrap.
FIGURE 5, MESHING
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In this study, the thickness of metallic liner is taken as
half (0.5) inch and total thickness of composite layer
considering six numbers of plies is taken as quarter (0.25) inch.
The steps involving the setup in ANSYS composite
pre-post module are listed below.
• Create fabrics
• Create a rosette
• Create orientation selection sets
• Create modelling groups
• Create a section cut
• Create a solid model
Six (6) layers of composite overwrap of material
epoxy carbon unidirectional is used and for load sharing
metallic liner aluminium is used. In case of the composite layer
the orientation, angles are taken as 00, 900, 00, 900, 450 and -450
respectively. The following snapshot shows the setup and the
direction of the one of the plies with 45 0 as the angle of
orientation of the ply.
FIGURE 6, PLY WITH 450 ORIENTATION ANGLE
When the section cut of the model is created it will
literally show the layer of load sharing metallic liner and
composite overwrap around the created pressure vessel
geometry. The following section cut figure clearly shows the
layers around the pressure vessel.

FIGURE 7, SECTION CUT
Once this setup is done then the assembly of pressure
vessel, load sharing metallic liner and composite overwrap is
ready to be coupled to the static structure module of the
ANSYS 16.0. The model is fixed at both ends.
The pressure vessel is subjected to high internal
pressure values and the burst pressure of the pressure vessel is
predicted by incrementally increasing the values of internal
pressure from working pressure of 5000 psi. At each increment
in the value of internal pressure, the maximum stress is
calculated and compared with the ultimate stress for the
pressure vessel by the following relation. σ max ≤σu Where σmax
and σu are the maximum stress and ultimate stress for the
pressure vessel.
5. RESULTS AND DISCUSSION
The results for total deformation, directional
deformation specifying deformation at y-axis and equivalent
stresses are plotted in Figures 8 and 10.
FIGURE 8, TOTAL DEFORMATION
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FIGURE 9, DIRECTIONAL DEFORMATION
FIGURE 10, EQUIVALENT STRESS
From the simulation, the burst strength calculated was
about eight thousand (8000) psi for the subject pressure vessel
of length three meter and head diameter meter long, along with
aluminium liner thickness of half inch and composite overwrap
thickness quarter inch with six layers of orientation angles, 0 0,
900, 00, 900, 450 and -450 .
6. Future Scope
In this research paper the dimensions and material of
pressure vessel, thickness and material of load sharing metallic
liner, thickness, material and orientation angles of composite
overwrap and applied internal pressure was taken at random.
But for further research a pressure vessel for particular
application like pressure vessel used in aerospace application
can be analysed with particular dimensions and for this
dimension and the real applied internal pressure optimum
configuration of load sharing metallic liner and composite
overwrap with its material can be found out.
The following flow chart will explain how the setup
method explain in this research paper can be used to carry out
the iterations to get optimum combination of load sharing
metallic liner and composite overwrap.
 Create geometry overwrap. Thus, if bs1is less than the bs_ref that clearly means
the set one is not suitable for the desired burst strength hence
try another set of different materials for composite overwrap
Create a mesh and load sharing metallic liner. Iterate the simulation up to the
point where burst strength of a certain set is equal to the bs_ref.
If the iterations are carried out following this flow chart
Export to ACP optimum combination of load sharing metallic liner and
composite overwrap for an application can be obtained.
Create a 7. CONCLUSION
metallic liner
Simulation was carried out on a finite element
set 1
software package to setup the composite overwrapped pressure
vessel with load sharing metallic liner. Step by step procedure
was explained to setup the layer of composite overwrap in the
Create
finite element simulation software ANSYS. An example of a
composite
pressure vessel with random thickness and boundary conditions
overwrap set 1
was analysed. Future scope was suggested to find out the
optimum combination of composite overwrap and load sharing
metallic liner.
Export to
static 8. REFERENCES
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