Design optimization for filament wound cylindrical composite internal pressure vessels considering process-induced residual stresses

The manufacturing process has significant influence on the product quality of filament wound composite parts. The aim of this work is to provide an analytical and optimization tool to find the optimal winding parameters to obtain better mechanical performance of the filament wound composite internal pressure vessels accounting for the process-induced residual stresses. First, the winding process model is established to calculate the winding process-induced residual stresses based on the three-dimensional thick cylinder theory. Then, an analytical model is constructed to predict the cure-induced residual stresses considering the thermo-viscoelastic effects based on linear thermo-viscoelastic constitutive model. Moreover, the optimization model is established to maximum the failure pressure based on proposed winding and curing process model. A novel iterative algorithm is given to determine the failure pressure based on the Tsai-Wu failure criterion and vonmises strength theory. The winding and curing process models are verified by the results of FEA and other work. The simulation results show that it is feasible to find the optimal winding angels and tensions to improve the load capacity of the filament wound cylindrical composite internal pressure vessels with aid of the proposed process analysis and optimization model.