A seminar presentation for major or minor project for BTech/MTech students on design of pressure vessels using composite materials. for complete presentation log on to www.mechieprojects.com

1. DESIGN OF COMPOSITE
PRESSURE VESSELS
JJ TECHNICAL SOLUTIONS
(www.mechieprojects.com)

2. The pressure vessels are used in various applications
these days such as, aerospace, automobiles, aeronautics,
chemical engineering industries etc.
The pressure vessels have suddenly become an attraction
for the piping and sewage as well as oil and gas transport
industries.
These pressure vessels have a special Characteristics of
lightweight and high strength because of which the
demands for these pressure vessels are increasing
drastically in applications where, the weight is a very
important concern.
1.INTRODUCTION

3. These pressure vessels provide an excellent compromise
between high mechanical properties and low weight.
In most of the applications composite pressure vessels are
subjected to very high-pressure during their service life.
High Pressure vessels are used for a pressure range of 15
N/mm2 to a maximum of 300 N/mm2
But Now the high pressure Vessels are extended up to
350 MPa.

4. 2.PROBLEM STATEMENT
The objective of this project is to model and analyze the
existing solid pressure vessel made of SA515 Gr70 for internal
pressure of 30 MPa and thereby find the stresses and deflection
induced in the component.
In order to reduce the thickness of the pressure vessel without
affecting the performance of the vessel composite material
were used.
The composite materials chosen for modeling and analysis of
pressure vessel are carbon fiber reinforcement polymer
(CFRP) and HM carbon epoxy. These composite material
vessels are modeled using software Solid Works and analysis
is done on software ANSYS 14.5 to obtain a pressure vessel
with less weight, deflection and maximum stability.

5. The following dimensions are from an existing solid wall
pressure vessel:
Design Pressure P - 21 N/mm2,Hydrostatic
Design Temperature T - 210C
Design Code C - ASME Sec.VIII div-1
Inside Radius of vessel Ri - 1143 mm
Inside Diameter of vessel Di - 2286 mm
Outside Radius of vessel Ro - 1305 mm
Outside Diameter of vessel Do - 2610 mm
Joint Efficiency J - 1
Safety Factor F.S - 3
Corrosion Allowance, C.A - 3.0 mm

6. Thickness 6 mm – 300 mm
Width 1500 mm – 4050 mm
Length 3000 mm – 15000 mm
MATERIAL PROPERTIES: SA515 Grade 70 Steel Material
Commercially Available of SA515 Grade 70 Material
S.No Properties Units Steel
1 Young’s Modulus (Ex) GPa 140
2 Density Kg/ m3 7850
3 Poisson Ratio --------- 0.3
4 Shear Modulus (G) GPa 80
5 Yield Strength MPa 260
Mechanical Properties SA515 Grade 70 Materials
Chemical Composition of SA515 GR 70 Material
C Mn P S Si Fe
0.30% 1.30% 0.035% 0.035% 0.13-% 0.98%

7. S.No Properties Units
T300/LY5052
carbon/Epoxy
1 Young’s Modulus Ex GPa 135
2 Young’s Modulus Ey = Ez GPa 8
3 Density Kg/m3 1760
4 Shear modulus Gxy = Gxz GPa 3.8
5 Shear modulus Gzx GPa 2.6845
6 Poisson ratio xy = xz ------ 0.27
7 Poisson ratio yz ------ 0.49
8 Longitudinal Tensile Strength (Xt) Mpa 1210
9 Transverse Tensile Strength (Yt) Mpa 76
10 Longitudinal Compressive Strength (Xc) Mpa 900
11 Transverse Compressive Strength (Yc) Mpa 85
12 Plane Shear Strength (S) Mpa 98
MATERIAL PROPERTIES : CFRP

8. MATERIAL PROPERTIES : HM Carbon Epoxy
S.No Properties Units
HM
carbon/Epoxy
1 Young’s Modulus Ex GPa 190
2 Young’s Modulus Ey = Ez GPa 7.7
3 Density Kg/m3 1600
4 Poisson ratio ------ 0.3
5 Shear modulus(G) GPa 4.2
6 Longitudinal Tensile Strength (Xt) Mpa 1000
7 Transverse Tensile Strength (Yt) Mpa 54
8 Longitudinal Compressive Strength (Xc) Mpa 850
9 Transverse Compressive Strength (Yc) Mpa 94
10 In Plane Shear Strength (S) Mpa 60

9. SOLID WALL PRESSURE VESSEL 2D
AND 3D VIEWS
MATERIAL: SA515 GR. 70 STEEL
Fig1: 2D solid wall pressure vessel

10. Fig 2: 3D solid wall pressure vessel (Pro/E)

11. Proposed Composite Pressure vessel 2D and
3D views
Material: CFRP (carbon fiber reinforcement polymer)
Fig 3: 2D CFRP Multilayer Composite pressure vessel

12. Fig 4: 3D CFRP Multilayer Composite pressure vessel

13. Proposed Composite Pressure vessel 2D
and 3D views
Material: HM carbon epoxy
Fig 5: 2D HM carbon epoxy Multilayer Composite pressure vessel

14. Fig 6: 3D HM carbon epoxy Multilayer Composite pressure vessel

15. 3.SOLUTION METHODOLOGY
The Main aim of this Project is to replace Solid walled Pressure
Vessel with a suitable composite material so as to model a
pressure vessel with less weight, deflection without affecting the
performance of pressure vessel.
To obtain the governing equations for the pressure vessel made
of structural steel replacing with composite materials CFRP, and
HM carbon epoxy and thereby determine the stresses and
deflections induced.
To Model and analyze using ANSYS Software
To find the Structural analysis when the pressure 27.3 N/mm2 is
applied on inner surface and outer end is fixed

16. 4.Theoretical Calculations:
CASE-1: MATERIAL OF CONSTRUCTION FOR
SOLID PRESSURE VESSELS.
Description Material UTS MPa
(min)
YS MPa
(min)
Vessel SA 515 GR 70 492 260
Dished Ends SA 515 GR 70 492 260

17. DESIGN OF VESSEL THICKNESS (t):
The thickness (t) of the Vessel is calculated from the
equation
= 162 mm (Factors of safety 3)
Thickness of Solid Wall Vessel, (t) = 162 mm
C.A
P0.6JS
RP
t
i



3.0
21x0.61x164
1143x21
t 



18. DESIGN OF HEMISPHERICAL DISHED END:
The thickness of the dished end is given by
C.A
P0.2JS2
RP
t
i
d 


= 77.12 mm
Adopted Thickness of the dished end is, td = 162 mm
0.3
21x0.21.0x164x2
1143x21
td 



19. Calculation of Hydrostatic Test Pressure:
Hydrostatic Pressure is taken as 1.3 times design pressure.
PH = 1.3 X Design Pressure
= 1.3*21
PH = 27.33N/mm2.
Stress Developed during Hydrostatic Test

20. STRESS DEVELOPED (S): vessel
S = 208.99 N/mm2
The stress developed (208.99 N/mm2) which is less then
the yield stress value (260 N/mm2 ).
t
tP0.6RP
S HiH
H


162
162x27.3x0.61143x27.3
SH


The Stress developed inside the shell is given by the equation,

21. STRESS DEVELOPED (S): In Dished End
t*2
P2.0RP HiH
Hd
t
S


= 99.03 N/mm2
The stress developed (99.03 N/mm2) which is less then the
yield stress value (260 N/mm2 ).
The Stress developed In Dished End is given by the
Equation:
162x2
162x27.3x0.21143x27.3
SHd



22. CALCULATION OF BURSTING PRESSURE (PB)
Ultimate Tensile Strength of the material = 492 N/mm2
K = Outer Diameter / Inner Diameter = 2610 / 2286
= 1.141
Bursting Pressure,
2
2
2
B N/mm52.64
1K
1-K
xU.T.SP 



23. STRESS DEVELOPED DURING BURSTING
TEST:
The Stress developed inside the dished ends is given by the
equation,
x t2
tP0.2RP
S BiB
Bd


162x2
162x64.52x0.21143x64.52
SBd


S = 234.06 N/mm2
The stress developed (234.06 N/mm2) is less than the
Ultimate Tensile stress value (492 N/mm2)

24. CASE-2: COMPOSITE PRESSURE VESSEL FOR
CFRP MATERIAL.
Description Material UTS MPa
(Min)
YS MPa
(Min)
Shell Liner S2 GLASS 2297 -
Shell Layers CFRP 1210 -
Dished Ends CFRP 1210 -

25. DESIGN OF VESSEL THICKNESS (t):
The thickness of the shell is calculated from the ASME
modified membrane theory equation as:
C.A
P0.6JS
RP
t
i



3.0
21x0.61x403
1143x21
t 


t = 64 mm (Factors of safety 3)

26. DESIGN OF HEMISPHERICAL DISHED END:
The thickness of the dished end is given by
C.A
P0.2JS2
RP
t
i
d 


0.3
x212.01.0x403x2
1143x21
td 


= 32.93 mm
Adopted Thickness of the dished end is, td = 64 mm

27. STRESSES DURING HYDROSTATICE TEST:
IN SHELL
The Stress developed inside the shell is given by the equation,
t
tP0.6RP
S HiH
H


= 503.94 N/mm2
The stress developed (503.94 N/mm2) is less than the
Ultimate Tensile stress value (1210 N/mm2).
64
64x27.3x0.61143x27.3
SH



28. STRESS DEVELOPED (S): In Dished End
t*2
P2.0RP HiH
HD
t
S


64x2
64x27.3x0.21143x27.3
SHD


= 246.5 N/mm2
The stress developed (246.5 N/mm2) is less than the Ultimate
Tensile stress value (1210 N/mm2).
The Stress developed in side the Dish during Hydrostatic Test
is given by the equation:

29. CALCULATION OF BURSTING PRESSURE (PB)
Intentionally Kept Blank

30. STRESS DEVELOPED DURING BURSTING TEST:
The Stress developed inside the dished ends is given by the
equation,
x t2
tP0.2RP
S BiB
Bd


64x2
64x64.72x0.21143x64.72
SBD


= 584.4 N/mm2
The stress developed (584.4 N/mm2) is less than the
Ultimate Tensile stress value (1210 N/mm2)

31. CASE-3: COMPOSITE PRESSURE VESSEL FOR
HM Carbon Epoxy MATERIAL.
Description Material UTS MPa
(Min)
YS MPa
(Min)
Shell Liner S2 GLASS 2297 -
Shell Layers HM C.E 1000 -
Dished Ends HM C.E 1000 -

32. DESIGN OF VESSEL THICKNESS (t):
The thickness of the shell is calculated from the ASME
modified membrane theory equation as:
C.A
P0.6JS
RP
t
i



3.0
21x0.61x333
1143x21
t 


t = 78 mm (Factors of safety 3)

33. DESIGN OF HEMISPHERICAL DISHED END:
The thickness of the dished end is given by
C.A
P0.2JS2
RP
t
i
d 


0.3
x212.01.0x333x2
1143x21
td 


= 39.26 mm
Adopted Thickness of the dished end is, td = 78 mm

34. STRESSES DURING HYDROSTATICE TEST:
IN SHELL
The Stress developed inside the shell is given by the equation,
t
tP0.6RP
S HiH
H


78
78x27.3x0.61143x27.3
SH


= 416.43 N/mm2
The stress developed (416.43 N/mm2) is less than the
Ultimate Tensile stress value (1000 N/mm2).

35. STRESS DEVELOPED (S): In Dished End
The Stress developed in side the Dish during Hydrostatic Test
is given by the equation:
Intentionally Kept Blank

36. CALCULATION OF BURSTING PRESSURE (PB)
U.T.S is Ultimate Tensile Strength of the material = 1000 N/mm2
K = Outer Diameter / Inner Diameter = 2442/ 2286
= 1.068
Bursting Pressure,
2
2
2
B N/mm69.65
1K
1-K
xU.T.SP 



37. STRESS DEVELOPED DURING BURSTING TEST:
The Stress developed inside the dished ends is given by the
equation,
x t2
tP0.2RP
S BiB
Bd


78x2
78x65.69x0.21143x65.69
SBD


= 487.87 N/mm2
The stress developed (487.87N/mm2) is less than the
Ultimate Tensile stress value (1000 N/mm2)

38. Element Type : SOLID 187
Real Constants:
Total Thickness = 162mm.
Material Properties : STEEL SA515 Gr.70
Ex, Ey, Ez, PRxy, PRyz, PRxz, Gxy, Gyz, Gzx.
Degrees of Freedom:
UX, UY, UZ, ROTX, ROTY, ROTZ.
5.RESULTS AND INTERPRETATION
CASE-1: STRUCTURAL ANALYSIS OF SOLID
PRESSURE VESSELS

39. Steel solid wall pressure vessel model
Modeling:

40. Meshed model of steel solid wall pressure vessel
Meshing model: Free mesh

41. B .C of steel solid wall pressure vessel 27.3 Mpa
Apply load : Boundary conditions

42. Results: shell Deformations
X-direction 1.57mm Y-direction 1.58mm
Z-direction 2.18mm Maximum Deformation 2.18mm

43. Results: Dish End Deformations at Burst pressure 64.52 Mpa
X-direction 0.619mm Y-direction 0.623mm
Z-direction 1.141mm Maximum Deformation 1.14mm

44. Results: Dish End Stresses at Burst pressure 64.52 Mpa
X- direction 130.32N/mm2 Y- direction 130.26N/mm2
Z- direction 383.49N/mm2 Von Mises Stresses 357.538 N/mm2

45. CASE-2: STRUCTURAL ANALYSIS OF CFRP PRESSURE
VESSELS
Element Type : shell181
Real Constants:
No of layers = 27
Total Thickness = 64mm.
Liner thickness = 10mm & each shell thickness = 2mm.
Material Properties : Carbon Fiber Reinforced Polymer
Ex, EY, EZ, PRXY, PRYZ, PRxz, GXY, GYZ, GZX.
Degrees of Freedom:
UX, UY, UZ, ROTX, ROTY, ROTZ.

46. Layer Stacking sequence:
Layer stacking sequence for 28 layers

47. Meshed model for 27 – layers and 1-liner

48. Results: Shell Deformations (0 º /+45º/-45 º/+90 º)
X-direction 2.798mm Y-direction 2.793mm
Z-direction 4.288mm Maximum Deformation 4.29039mm

49. Results: Shell Stresses (0 º /+45º/-45 º/+90 º)
Intentionally Kept Blank

50. Results: Dish End Deformations (0 º /+45º/-45 º/+90 º)
X-direction 0.855mm Y-direction 0.849mm
Z-direction 1.060mm Maximum Deformation 1.11699mm

51. Results: Dish End Stresses (0 º /+45º/-45 º/+90 º)
X- direction 188.63N/mm2 Y- direction 186.69N/mm2
Z- direction 271.18N/mm2 Von Mises Stresses 241.272N/mm2

52. Results: Dish End Deformations at Burst pressure 64.72 Mpa
Intentionally Kept Blank

53. Results: Dish End Stresses at Burst pressure 64.72 Mpa
X- direction 508.21N/mm2 Y- direction 502.97N/mm2
Z-direction 730.60 N/mm2
Von Mises Stresses 650.021N/mm2

54. CASE-3: STRUCTURAL ANALYSIS OF HM Carbon Epoxy
PRESSURE VESSELS
Element Type : shell181
Real Constants:
No of layers = 34
Total Thickness = 78mm.
Liner thickness = 10mm & each shell thickness = 2mm.
Material Properties : HM carbon Epoxy
Ex, EY, EZ, PRXY, PRYZ, PRxz, GXY, GYZ, GZX.
Degrees of Freedom:
UX, UY, UZ, ROTX, ROTY, ROTZ.

55. Layer Stacking sequence:
Layer stacking sequence for 35 layers

56. Meshed model for 34 – layers and 1-liner

57. Results: Shell Deformations (0 º /+45º/-45 º/+90 º)
X-direction 2.347mm Y-direction 2.376mm
Z-direction 3.482mm Maximum Deformation 3.48285mm

58. Results: Shell Stresses (0 º /+45º/-45 º/+90 º)
X- direction 430.68N/mm2 Y- direction 445.27N/mm2
Z- direction 251.19N/mm2
Von Mises Stresses 403.481N/mm2

59. Results: Dish End Deformations (0 º /+45º/-45 º/+90 º)
X-direction 0.866mm Y-direction 0.856mm
Z-direction 1.152mm Maximum Deformation 1.2419mm

60. Results: Stresses of Dish End at Burst pressure 65.69 Mpa
X- direction 564.93N/mm2 Y- direction 567.09N/mm2
Z-direction 598.97 N/mm2 Von Mises Stresses 606.359 N/mm2

61. SOLID WALL
PRESSURE
Shell
Value from Ansys
Dished End
Value from
Ansys
Burst pressure
Value from
Ansys
Deformations
value (mm)
X 1.57 0.234 0.619
Y 1.58 0.231 0.623
Z 2.18 0.423 1.141
Max.Deformatio
n value (mm) 2.1846 0.42562 1.1459
Principle Stresses
value ( N/mm2)
X 214.97 48.40 130.32
Y 211.56 48.38 135.26
Z 124.31 142.43 383.49
Von Mises
Stresses
Maximum
value( N/mm2)
246.825 132.8 357.538
Theoretical
calculated
stresses value(
N/mm2)
208.99 99.03 234.06
SOLID PRESSURE VESSEL : TABULATED RESULT

62. Various orientations
Von Mises Stresses Ansys
values(N/mm2) CFRP
Von Mises Stresses Ansys
values(N/mm2) HM carbon epoxy
Shell Dished
End
Burst
pressure
Shell Dished End Burst
pressure
[0°/0°/0°/0°]
X 526.28 200.57 509.29 447.25 221.51 576.19
Y 528.91 198.50 504.04 462.41 245.84 578.40
Z 313.23 288.33 732.16 260.85 310.60 610.99
Von Mises Stresses
(N/mm2) 456.956 256.659 651.748 419.110 246.612 618.452
[0°/-45°/+45°/+90°]
X 520.83 188.63 508.21 430.68 233.05 564.93
Y 520.85 186.69 502.97 445.27 233.95 567.09
Z 321.17 271.18 730.60 251.19 247.10 598.97
Von Mises Stresses
(N/mm2) 451.029 241.272 650.021 403.481 250.15 606.359
[0°/-60°/+60°/+90°]
X 528.37 220.05 543.68 460.85 227.27 606.47
Y 531.37 217.78 538.07 476.46 239.45 608.79
Z 314.53 316.78 781.59 268.78 301.25 643.02
Von Mises Stresses
(N/mm2) 458.067 281.311 695.427 431.741 262.526 650.953
[0°/+25°/+45°/+90°]
X 482.632 193.56 511.38 455.88 219.70 592.71
Y 485.05 191.56 506.11 471.32 231.47 594.98
Z 287.29 278.26 735.16 265.88 291.21 628.43
Von Mises Stresses
(N/mm2) 418.924 247.687 654.426 427.085 254.057 636.184
[0°/+45°/+60°/+90°]
X 499.59 212.06 524.96 477.07 238.22 619.19
Y 502.1 209.87 519.54 493.22 250.98 621.56
Z 297.39 304.86 754.68 278.24 315.76 656.51
Von Mises Stresses
(N/mm2) 433.845 273.731 671.497 446.933 275.926 664.605
CFRP& HM C E PRESSURE VESSELS : 2mm thickness

63. Various orientations
Von Mises Stresses Ansys
values(N/mm2) CFRP
Von Mises Stresses Ansys
values(N/mm2) HM carbon epoxy
Shell Dished
End
Burst
pressure
Shell Dished End Burst
pressure
[0°/0°/0°/0°]
X 522.85 191.49 505.60 437.31 211.12 567.99
Y 525.47 189.53 500.43 452.12 212.86 572.66
Z 311.47 274.20 723.98 235.05 213.42 574.17
Von Mises Stresses
(N/mm2) 453.721 243.723 643.561 409.689 227.613 611.159
[0°/-45°/+45°/+90°]
X 497.56 186.82 465.07 427.72 207.95 556.73
Y 499.99 184.91 460.31 442.20 209.66 561.31
Z 296.14 267.52 665.94 249.46 210.21 562.79
Von Mises Stresses
(N/mm2) 432.651 237.136 592.845 400.704 223.243 599.99
[0°/-60°/+60°/+90°]
X 516.94 201.62 512.32 422.75 224.27 597.38
Y 519.53 199.56 507.08 437.07 226.12 602.29
Z 307.72 288.71 733.61 246.56 226.71 603.88
Von Mises Stresses
(N/mm2) 448.956 256.891 652.568 396.048 241.361 643.374
[0°/+25°/+45°/+90°]
X 469.28 190.24 496.49 439.32 219.98 591.19
Y 471.64 188.29 419.41 454.19 221.79 596.05
Z 279.35 272.41 710.94 256.23 222.37 597.63
Von Mises Stresses
(N/mm2) 406.204 242.435 632.363 411.567 236.717 633.719
[0°/+45°/+60°/+90°]
X 489.30 196.96 506.63 454.44 238.02 610.96
Y 491.75 194.94 501.44 469.83 239.98 615.98
Z 291.27 282.02 725.44 256.04 240.61 617.61
Von Mises Stresses
(N/mm2) 424.212 250.316 645.537 425.983 256.747 657.312
: 1 mm Thickness Von Mises Stresses

64. Deformation, Von Mises stresses, F.S and Reduction in Thickness
Analysis Solid wall pressure vessel CFRP Multilayer pressure
vessel
HM Carbon Epoxy Multilayer
pressure vessel
Deformation
of Maximum
Value (mm)
Shell Dished
End
Burst
pressure
Shell Dished
End
Burst
pressure
Shell Dished
End
Burst
pressure
2.1846 0.425 1.1459 4.2903 1.1169 3.00933 3.4828 1.2419 3.01032
Von Mises
Stresses of
Maximum
Value
(N/mm2)
492/246.82 132.8 357.53 451.02 241.27 650.021 403.48 250.15 606.35
Factor of
safety
2 3.7 1.3 2.6 5.02 1.8 2.4 4 1.6
% Reduction
in Thickness ------- 60.49% 51.85%

65. CONCLUSIONS
Analysis is performed on pressure vessel made up of various materials (Steel,
CFRP and HM Carbon Epoxy.) and for various thicknesses (i.e.1mm&2mm) and
the following conclusions are drawn-
• Under steady statics analysis, composite material made of 1mm thickness
fared better than composite material made up of 2mm thickness.
• Composite materials made up of CFRP were found to better than the HM
Carbon Epoxy.
•
Intentionally Kept Blank

66. Future Scope
• Analysis on different layer material to reduce cost of production.
• Optimization of shell thickness for the given conditions.
• Transient analysis is to found.
• Effect of crack propagation in pressure vessel can be
determined.

67. REFERENCES
1. A.M.Butt and S.W. ul Haq:“Comparative Study for the Design of Optimal Composite
Pressure Vessels” International Journal of Space Technology Key Engineering Materials Vol
No.44 sept2010.
2. M. Madhavi1, K.V.J.Rao and K.Narayana Rao:“Design and Analysis of Filament Wound
Composite Pressure Vessel with Integrated-end Domes” Defenses science Journal, Vol No.1
January 2009.
3. Mohammad Amine and Sagheer Ahmed:“Finite Element Analysis of Pressure Vessel with
Flat Metal Ribbon Wound Construction under the Effect of Changing Helical Winding
Angle” Journal of Space Technology, Vol No.1, June 2011.
4. Mohammad Z. Kabir:“Finite Element Analysis of Composite Pressure Vessel with a load
Sharing Metallic liner composite Structures” International Journal of Engineering Trends
and Technology Vol No 49 Oct 2000.
5. Deepak Thomas:“Optimization of Pressure Vessel Using a Composite Material” Department
of Aeronautical Engineering Coimbatore International Journal of Advancements in Research
& Technology, Vol 3March-2014.

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69. This is purely an academic work and has no financial or other
interest.
The results achieved in this should be independently verified.