Dome Thickness Prediction of Composite Pressure Vessels by a Cubic Spline Function and Finite Element Analysis

Dome Thickness Prediction of Composite Pressure Vessels by a Cubic

Spline Function and Finite Element Analysis
Rongguo Wanga,*, Weicheng Jiaoa, Wenbo Liub, and Fan Yanga
a
National Key Laboratory for Advanced Composites in Special Environment, Harbin Institute of Technology, Harbin
150080, P.R. China
b
School of Materials Science and Engineering, Harbin Institute of Technology, Harbin, 150001, P.R. China

Summary
Nowadays, finite element analysis (FEA) plays an important role in the design of composite pressure vessel. The
more accurate finite element models are created, the more precise results could be obtained. In order to create the
accurate finite element model for composite pressure vessels, a cubic spline function was developed to predict
the dome thickness basing on the principle of total volume preservation of all bands at dome section. In the
paper, the dome thickness of an arbitrary composite pressure vessel was forecasted by the cubic spline function
and compared with the existing methods and actual measured values. The results show that the cubic spline
function is more realistic than the other methods. Then the FEA considering the dome thickness pre-calculated
by various methods was performed and compared with experimental data. The results further indicate that the
cubic spline function could provide a more accurate model, which is approaching the real case.

1. Introduction
Composite pressure vessels due to
lightweight and high performance are
widely used in aerospace, automobile,
petrochemical field and so on 1~3.
However, composite pressure vessels
made by filament-winding have
complexity in analyzing the geometry
and properties along the longitudinal
axis, especially in their dome section4.
As the wound layers are added on a
mandrel, the curvilinear fiber path
leads to a continuous change in winding
angle and thickness5. Therefore FEA,
which can handle the winding angle
and thickness variation, are required to
predict the exact behavior of composite
pressure vessels1. But, in finite element
analysis of composite pressure vessels,
the exact shell thickness is critical.
Without knowing the accurate dome
thickness, it’s difficult to create an
accurate model and calculate the
stresses and displacements precisely.
*Corresponding email: wrg@hit.edu.cn
©
Smithers Rapra Technology, 2011
The dome thickness varies as a
function of dome radius and winding
pattern. Prediction of the dome
thickness is not easy. Early, a simple
thickness relation was used, which as
follows from the condition of filament
continuity6.
R cos α 0
t(r) = × tR
r cos α
Where R,a0 and tR are initial radius,
winding angle and thickness at
cylinder section or shell equator; r,a
and t(r) are arbitrary shell radius,
winding angle and thickness at the
vessel dome, respectively. Equation
(1) is proposed by using the fact that
the fiber band width is assumed to be
infinitely thin. But as follows from
Equation (1), thickness is infinite at
the polar radius. Subsequently, several
methods have been developed. Stang7
developed a graphical technique for
computing the number of plies at any
given location. It is more suitable for
the small size pressure vessels because
of the restrictions of cartography. Then
Knoell8 developed a set of analytical
equations to predict the dome thickness
using the Stang approach. Gramoll
and Namiki9 presented two refined
equations to represent composite shell
thickness, particularly in the regions
(1) near the dome openings where the
filament build-up becomes large. One
equation is valid within one-band
width of the opening and the other
one is valid for the remainder of the
dome. However, the dome thickness
equals zero at polar radius and there
is a sharply thickness peak near the
dome opening, which doesn’t actually
exist in composite shell. Krikanov10
supposed that a roving arc length
contacting the polar boss equals
roving width. A thickness relation
was derived at the polar radius and
then a cubic polynomial equation was
presented to refine dome thickness of
filament wound shells. The refined
thickness equation of composite shell
is satisfactory except in the polar boss
region.

Polymers & Polymer Composites, Vol. 19, Nos. 2 & 3, 2011 227
 Rongguo Wang, Weicheng Jiao, Wenbo Liu, and Fan Yang
All these methods could predict the
dome thickness of composite pressure
vessels. But in order to improve the
prediction accuracy of the dome
thickness, a cubic spline function is
presented in this paper. Using this cubic
spline function, the dome thickness of
an arbitrary composite pressure vessel
is forecasted. Then the finite element
models are created, that the thickness
at the dome region is pre-calculated
using the cubic spline function. And the
finite element analyses are performed.
2. Theoretical model
2.1 Geometrical Relationship
The filament-winding process for
a composite pressure vessel with
openings requires each fiber tow to
cross over each dome in a continuous
manner and to be tangent to the opening
at its polar radius. Fiber tows are laid
over the mandrel along pre-designed
pathway and butted side-by-side to
form a ply. The geometry and winding
patterns are the basic parameters.
Figure 1 is the top view of a dome.
In Figure 1, the geometrical location
about the fiber tows and mandrel is
represented approximately. The tows
are assumed to be straight, which are
actually slight curvy near the polar
Figure 1. Geometry relationship about fiber bands within
one-band width
228
radius. Its effect on the prediction of dome thickness could be ignored because
the thickness becomes very large near the polar hole. If the number of fiber tows
at arbitrary shell radius can be derived according to the geometrical relations
between the dome thickness and parameters of the composite vessel, the thickness
will be calculated11.
2.1.1 Dome Thickness Within One-Band Width
For filament-winding pattern, two points on the cylinder correspond to one
tangency point on the dome opening. Fiber tows are arranged side-to-side to
form a ply. Their quantity is mR and the number of the single plies (±a0) is nR
at cylinder section. So the whole quantities of fiber tows are mR·nR. Due to the
continuity of filament-winding process, the number of fiber tows at dome section
equal to that at cylinder section.
Within one-band width, as can be seen in Figure 1, all fiber tows between
point B and point C will cross over point A and stack on each other. The dome
thickness at point A equals to the sum of the thickness of these fiber tows. The
dome thickness within one-band width can be suggested as
p
t(r) = ⋅ m R ⋅ n R ⋅ t p , (r0 ≤ r ≤ r0 + b)
2π (2)
where p is ∠BOC; tp is thickness of a fiber tow which is constant; r0 is polar
radius; b is the width value of a fiber tow; r is an arbitrary shell radius within
one-band width.
In Figure 1
p = ∠BOC = ∠BOE + ∠COE = ∠COE + (∠AOD+ ∠AOE − ∠BOD) (3)
According to the filament-winding process, the fiber band is tangent to the polar
hole at its minimum radius. So Angle p could be expressed by
p = arccos(r0 / R) + arccos(r0 / r) + arccos(r0 / r) − arccos(r0 / R) = 2 arccos(r0 / r)
(4)
Figure 2. Geometry relationship about fiber bands
outside of one-band width 
Polymers & Polymer Composites, Vol. 19, Nos. 2 & 3, 2011
 Dome Thickness Prediction of Composite Pressure Vessels by a Cubic Spline Function and Finite Element Analysis

Substitute Equation (4) into Equation (2). The dome thickness within one-band Equation One: Dome thickness at
width could be calculated by polar radius

p m ⋅n As mentioned before, the quantities

t(r) = ⋅ m R ⋅ n R ⋅ t p = R R ⋅ arccos(r0 / r) ⋅ t p , (r0 ≤ r ≤ r0 + b)
2π π (5) of fiber tows at dome section equal
to that at cylinder section because of
2.1.2 Dome Thickness Outside of One-Band Width the continuity of filament-winding
In Figure 2, outside of one-band width, fiber tows between point B and point C, process.
point B’ and point C’, will cross over point A. So the dome thickness at point A
m 0 ⋅ n0 = m R ⋅ nR (10)
equals to the sum of the thickness of these fiber tows, too.
where m0 and n0 are the quantities of
2p p fiber tows and the number of single
t(r) = ⋅ m R ⋅ n R ⋅ t p = ⋅ m R ⋅ n R ⋅ t p , (r0 + b ≤ r ≤ R)
2π π (6) plies near the polar hole, respectively.
Simultaneously, the triangle DBOD equals to triangle DCOE in Figure 2 then At the cylinder section of a composite
angle p could be expressed as pressure vessel, shell thickness is tR =
2nR·tp and mR = 2pR/(b/cosa0), then
p = ∠BOC = ∠DOE = ∠AOD − ∠AOE = arccos(r0 / r) − arccos ((r0 + b) / r ) the Equation (10) can be express as
(7)
n0 = mR ⋅ nR / m 0 =
Substitute Equation (7) into Equation (6), the dome thickness outside of one-band
width could be calculated by    t R ⋅ πR ⋅ cos α 0 / (m 0 ⋅ b ⋅ t p )
(11)
mR ⋅ nR  Supposing the thickness at polar radius
t(r) = ⋅ arccos(r0 / r) − arccos ((r0 + b) / r ) ⋅ t p , (r0 + b ≤ r ≤ R)
π (8) is t(r0), the relation as follow can be
obtained.
2.2 A Cubic Spline Function Used to Predict Dome Thickness of
t(r0 ) = n 0 ⋅ t p = t R ⋅ πR ⋅ cos α 0 / (m 0 ⋅ b)
Composite Pressure Vessels
As follows from Equations (5) and (8), the dome thickness could be obtained. (12)
But it is noted that there is a sharply thickness peak near one-band width, which As follows from Equation (9), the
doesn’t exist in actual composite shell. Below another thickness relation is derived thickness at polar radius can be given as
for a composite vessel dome on the basis of Equations (5) and (8).
t(r0 ) = A × r00 + B × r01 + C × r02 + D × r03
As we know, the curing dome curve of the filament wound composite pressure
(13)
vessel is smooth and continuous. The sharply thickness peak is spread over the
region adjoining the peak because of fiber tows slipping, realignment, roving So
separation and so on. But the amounts of the fiber tows do not change. Dome
thickness should be refined, especially within two-band width around the polar t(r0 ) = t R ⋅ πR ⋅ cos α 0 / (m 0 ⋅ b) =
hole. A cubic spline function t(ri) is presented to refine dome thickness on the
  A × r00 + B× r01 + C × r02 + D × r03
basis of Equations (5) and (8). The cubic spline function t(ri) is not only suitable
for geodesic winding, but also suitable for non-geodesic winding, because it is (14)
developed based on the geometric relationships and continuity law of filament-
winding. t(ri) has the following characteristics: Equation Two: Thickness at two-band
width
t(ri) is a cubic polynomial equation in close interval [r0,R].
At two-band width, dome thickness can
be calculated by Equation (8)
0 1 2
t(ri ) = A × r + B × r + C × r + D × r
i i i i
3
(9)

where A, B, C and D are unknown coefficients. m R ⋅ nR

t(r2b ) =
π
t(ri) is continuous and differentiable in close interval [r0,R], t(ri)∈C2[r0,R].   r0   r + b 
  ⋅ arccos   − arccos  0  ⋅ t p
  r2b   r2b 
If A, B, C and D are determined, the thickness could be calculated. In order to
calculate the four unknown coefficients, four equations are introduced. (15)

Polymers & Polymer Composites, Vol. 19, Nos. 2 & 3, 2011 229
 Rongguo Wang, Weicheng Jiao, Wenbo Liu, and Fan Yang

where t(r2b) and r2b are the thickness and shell radius at two-band width, respectively.

As follows from Equation (9), the thickness at two-band width can be expressed as
0 1 2 3
t(r2b ) = A × r2b + B× r2b + C × r2b + D × r2b (16)

Substitute Equation (16) into Equation (15)

m R ⋅ nR  r   r + b  0 1 2 3
t(r2b ) = ⋅ arccos  0  − arccos  0  ⋅ t p = A × r2b + B × r2b + C × r2b + D × r2b
π  r
 2b  r
 2b  (17)

Equation Three: Derivatives of the Equation (8) and Equation (9) to provide curve smoothness

The curing dome shape is smoothness. It requires thickness curve of composite shell should be continuous and derivative.

So as follows from Equation (8),

 
dt(r2b ) m R ⋅ n R r0 rb
= ⋅ −  ⋅ tp
dr π  r × r2 − r2 r × r2 − r2 
 2b 2b 0 2b 2b b  (18)

Derivative of the Equation (9) is

dt(r2b ) 2
= B+ 2 × Cr2b + 3D × r2b
dr (19)

Substitute Equation (18) into Equation (19)

 
dt(r2b ) m R ⋅ n R r0 rb 2
= ⋅ −  ⋅ t p = B + 2 × Cr2b + 3D × r2b
dr π  r × r2 − r2 r × r2 − r2 
 2b 2b 0 2b 2b b  (20)

Equation Four: The amounts of all fiber tows do not change within two-band width

Although fiber tows slipping, realignment and roving separation and so on, the amounts of all fiber tows are constant
within two-band width.
r2 b rb
m R ⋅ nR
r2 b
m R ⋅ nR  r   r + b 
∫ 2πr × t(ri )dr = ∫ 2πr ⋅ π
⋅ arccos(r0 / r) ⋅ t p dr + ∫ 2πr ⋅ π
⋅ arccos  0  − arccos  0
 r2b   r2b 
 ⋅ t p dr ⋅
r0 r0 rb  (21)

The unknown coefficients A, B, C and D could be solved from Equations (14), (17), (20) and (21) by numerical methods.
Last, the spline function t(ri) can be expressed by:

t(ri ) = A × ri0 + B × ri1 + C × ri2 + D × ri3 with

 t R ⋅ πR ⋅ cos α 0 / (m 0 ⋅ b) 
 2 3   
1 r0 r r  m R ⋅ nR   r0   r0 + b  

0 0
  A  ⋅ arccos   − arccos   ⋅ t p 
 1 r2b r 2
r 3

 B   π r
 2b  r
 2b 
2b 2b 
 0 1 2r2b 3r 2   =  
2b  C     
  m ⋅n r0 rb
π r 2 − r 2 2π 3 π 4 2π 5 5 
   R R ⋅ −  ⋅ tp 
 ( 2b 0 ) 3
(r2b − r03 ) 2
(r2b − r04 ) 5
(r2b − r0 )D  π  r2b × r2b2 − r02 r2b × r2b2 − rb2  
 
 Vconst 

rb
m R ⋅ nR
r2 b
m R ⋅ nR  r   r + b 
Vconst = ∫ 2πr ⋅ π
⋅ arccos(r0 / r) ⋅ t p dr + ∫ 2πr ⋅ π
⋅ arccos  0  − arccos  0
 r2b   r2b 
 ⋅ t p dr ⋅
r0 rb  (22)

230 Polymers & Polymer Composites, Vol. 19, Nos. 2 & 3, 2011
 Dome Thickness Prediction of Composite Pressure Vessels by a Cubic Spline Function and Finite Element Analysis

3. Results and
discussion
3.1 Using the Cubic Spline
Function to Predict the Dome
Thickness of an Arbitrary
Composite Pressure Vessel
Using the cubic spline function,
the dome thickness of an arbitrary
composite pressure vessel is forecasted.
Then it is compared with the above
mentioned methods and actual
measured thickness. The results are
shown as bellow.
15.61%. As follows from Equation
(22), the maximum dome thickness is
10.16mm near one-band width. The
relative error is about 3.67%, which
is smaller than that from Gramoll and
Namiki’s methods.
Further, the thickness distribution
within two-band width obtained from
the cubic spline function and Gramoll
Figure 3. Dome thickness predicted by various methods
and Namiki’s methods are discussed.
The results are shown in Figure 4.
As can be seen in Figure 4, using
Gramoll and Namiki’s methods to
predict the dome thickness within
two-band width, it is noted that the
thickness equals zero at r = r0 and there
is a sharply thickness peak at about
one-band width. Predictive thickness

Parameters of an arbitrary composite

pressure vessel are: dome length
h=220 mm, fiber band b=12.5 mm,
thickness of a fiber band tp=0.48 mm,
polar radius r0=110 mm, diameter of
cylinder section R=375 mm. As follows
from Equations (22), A = -5368.19,
B = 126.65, C = -0.99, D = 0.0026.
The prediction results can be seen in
Figure 3.

In Figure 3, the diamond shape

corresponds to actual measured dome
thickness. The maximum actual dome
thickness value equals 9.8 mm near
one-band width. And the minimum
actual dome thickness value is about
0.96 mm at shell equator. The circle
shape corresponds to Equation (1). Figure 4. Dome thickness distribution within two-band width
It is found that outside of two-band
width, the predictive values could
reflect actual thickness well. But at the
polar radius, thickness is infinite, which
doesn’t correspond to real case. The
triangular shape means dome thickness
in according to Knoell equation. It
underestimates actual thickness. The
relative error is larger than the other
methods. The square shape means
thickness distribution in according to
the cubic spline function and inverted
triangular one corresponds to Gramoll
and Namiki’s methods. Both methods
have a good agreement with actual
measured thickness except within two-
band width. According to Gramoll and
Namiki’s methods, the maximum value
of dome thickness is 11.33 mm at one-
band width. The relative error is about

Polymers & Polymer Composites, Vol. 19, Nos. 2 & 3, 2011 231
 Rongguo Wang, Weicheng Jiao, Wenbo Liu, and Fan Yang
displays significant gradient. On the
other hand, using the paper’s method,
the cubic spline function, thickness
curve is smoothness and has a good
agreement with actual measured
value except at the polar radius. It
underestimates actual thickness at the
polar radius. The discrepancy may be
due to the resin movement during the
filament-winding process.
3.2 Finite Element Analysis
For the same pressure vessel mentioned
above, the finite element analysis
considering the dome thickness pre-
calculated by Gramoll and Namiki’s
methods and the cubic spline equation
were performed, respectively. In the
finite element modeling, shell91 type
elements with 8 nodes per element were
used. In order to study the effect of the
dome thickness on the finite element
model, the elements were refined
within two-band width. The model
has 4416 elements and 13440 nodes
and the two models were made in the
same manner except dome thickness is
different. Two finite models are shown
in Figure 5.
As can be seen in Figure 5, the finite
element models obtained by different
dome thickness forecasting methods
are very distinct. For Gramoll and
Namiki’s method, finite element model
show a sharp peak. Compared with this
Figure 5. Finite element models. (a) Model created by Gramoll and Namiki’s method (b) Model created by the cubic spline
equation
232
method, thickness of finite element
model created by the cubic spline
equation is continuous and smooth.
The internal pressure is 5 MPa and
material properties are shown in
Table 1. Water pressurizing test was
carried out and 12 strain gauges,
which were attached on the dome
section. The signals of each gauge and
pressure transducer were measured
simultaneously by an A/D converter.
The results of strain and stress
distribution are shown in Figure 6
and Figure 7 respectively. Figure 6a
and Figure 6b show the longitudinal
and hoop stress from the analysis
results. In Figure 6, no matter what
kind of dome thickness prediction
methods, the results of longitudinal
stress and hoop stress have the same
trend. But for strain results, it’s quit
different. In Figure 7a, comparing
with experiments data, both results are
overestimated duo to a rapid change in
curvature and thickness at the dome
region. Using Gramoll and Namiki’s
methods, the dome thickness changes
sharply. The maximum longitudinal
Table 1. Material property of composites
Item
Ex E y = Ez G12 = G13
T800/EP 191.3 GPa 8.820 GPa 5.331 GPa
Polymers & Polymer Composites, Vol. 19, Nos. 2 & 3, 2011
strain is 3855 µe. For the cubic spline
equation, the maximum longitudinal
strain is 3605 µe. The actual measured
maximum longitudinal strain is
3584 µe. Thus, the finite element
analysis relative error of Gramoll
and Namiki’s methods is larger than
that of the cubic spline function. It is
worth noting in Figure 7b, the hoop
strain of the theoretical values are
quite different from the measured
values. From Gramoll and Namiki’s
methods, the maximum positive hoop
strain is +4471 µe and the maximum
negative hoop strain is -1785 µe (sign
just only represent the direction of
deformation). It indicates that the larger
gradient of dome thickness predicted
by Gramoll and Namiki’s methods
leads to a larger change of stiffness for
composite structure. Then it causes a
large bending moment, which causes
a large deformation. This may lead to
premature destruction of the composite
structure. In order to satisfactory
deformation requirements, more fiber
is needed. In contrast, the hoop strain
distribution of cubic spline function
has a good agreement with the real
case. Finite element analysis results
G23 v12 = v13 v23
2.744 GPa 0.33 0.45
 Dome Thickness Prediction of Composite Pressure Vessels by a Cubic Spline Function and Finite Element Analysis

Figure 6. Comparison of the stress between experiment and analysis. (a) Longitudinal stress of dome section; (b) Hoop stress
of dome section

Figure 7. Comparison of the strain between experiment and analysis. (a) Longitudinal strain of dome section; (b) Hoop
strain of dome section

show that the cubic spline function
could provide a more accurate model
for finite element analysis than that of
using the other existing methods.
4. Conclusion
In this paper, a cubic spline function
was presented to predict the dome
thickness of composite pressure
vessels. Using this cubic spline
function, the dome thickness of an
arbitrary composite pressure vessel was
forecasted. The predictive results were
compared with the existing methods
and actual measured thickness.
The results showed that the cubic
spline function could improve the
prediction accurate of dome thickness
than the others. Finally, the finite
element analysis considering the dome
thickness pre-calculated by various
methods were performed. The results
showed that dome thickness obtained
from the cubic spline function could
provide an accurate model for structure
design and achieve the target of mass
reduction.
5. Acknowledgement
The work is supported by the National
Natural Science Foundation of China
(90916008).
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