Optimum Design And Analysis Of Filament Wound Composite Tubes In Pure And Combined Loading

Optimum Design And Analysis Of Filament Wound Composite Tubes In Pure And Combined Loading

1. atheesh Kumar Reddy1, Ch.Nagaraju 2, T.Hari Krishna3

   1. Senior assistant professor, 2.Professor, 3.Assistant Professor Department of Mechanical Engineering,

V.R.siddhartha Engineering College, Vijayawada,

Andhra Pradesh INDIA

Abstract

This is the investigation of the design and analysis processes of filament wound composite tubes under pure and combined loading. The problem is studied by using a computational tool based on the Finite Element Method (FEM). Filament wound tubes are modeled as single layered orthotropic tubes. Several analyses are performed on layered orthotropic tubes by using FEM. Results of the FEM are examined in order to investigate characteristics of filament wound tubes under different combined loading conditions. Winding angle, number of layers, level of orthotropy and various combined loading conditions were the main concerns of the study. The results of the FEM analysis are discussed for each loading condition. Both pure loading and combined loading analysis results were consistent with the ones mentioned in literature, such as optimum winding angles, optimum loading and optimum level of orthotropy. Finally, the required data is obtained for the design of filament wound composite tubes under combined loading.

Key words: Filament wound, Winding angle, FEM

1. Introduction

   Composites are the materials that are composed of at least two components and form a new material with properties different from those of the components. Most composites are composed of a bulk material and a reinforcement material, generally fibers. The reinforcement materials usually have extremely high tensile and compressive strength. However, these theoretical values are not achieved in structural form. This is due to the surface flaws or material impurities, which results in crack formation and failure of the piece below its theoretical strength [1].

   In order to overcome this problem, reinforcement is produced in fiber form, which prevents crack formation through the whole body. However, a matrix should be used to hold these fibers together, and improve material properties in the transverse direction of the fiber. The matrix also protects the fiber from damage, as well as spreading the load equally to each individual fiber.

   The material properties of a composite are determined by the properties of matrix and fiber, volumetric ratio and orientation of the fibers. The volumetric ratio of fibers is mainly determined by the manufacturing method used. The higher the volumetric ratio, the closer will be the properties of composite and fiber. Orientations of the fibers are also important, since fibers have superior mechanical properties along their lengths. Composites have an increasing popularity in engineering materials, with their stiffness and strength combined with low weight and excellent corrosion resistance [1]. By studying the variable properties of composite materials, engineers use the advantage of anisotropy included within composite materials. By building a structure by properly selected resin, fiber, layer orientation and curing, optimization is successful in most cases

2. Modeling of composite tubes

   Structural analysis is performed in order to investigate the behavior of layered orthotropic tubes with different materials in Table 1. Under pure and combine loading. The model is prepared with Shell 99 element with rigid region at other end with Mass 21 element in Ansys. As shown in Fig.1 this model is constraint with for all degrees of freedom at one end and load applied to the rigid region of the tube at other end as shown in Fig 2. The internal pressure is applied on the inner surface of the tube. Dimensions of the tube used in the study are given in Table 2.

   Fig 1. Finite element model of composite tube

   Carbon-Epoxy

   7 EGlass-Epoxy

   Aramid-Epoxy

   6

   5

   4

   3

   2

   1

   0

   0 10 20 30 40 50 60 70 80 90

   Fig.2 Boundary conditioned for composite tube.

3. Materials used for analysis

   Fig 3. Axial deformation vs winding angle

   Carbon-Epoxy

   80 EGlass-Epoxy

   Table.1 Materials used for analysis

   70

   60

   50

   40

   30

   Mechanical Properties of Fiber Glass Epoxy Resins	Carbon / Epoxy (MPa)	E-Glass / Epoxy (MPa)	Aramid / Epoxy (MPa)
   Elastic Constants
   Elasticity Exx	127700	45600	83000
   Elasticity Eyy	7400	16200	7000
   Elasticity Ezz	7400	16200	7000
   Poisson ratio xy	0.330	0.27	0.41
   Poisson ratio yz	0.188	0.27	0.4
   Poisson ratio zx	0.188	0.27	0.4
   Shear modulus – Gxx	6900	8500	2100
   Shear modulus – Gyy	4300	5500	1860
   Shear modulus – Gzz	4300	5500	1860
   Strength Constants
   Tensile stress Sxx	1717	1243	1377
   Tensile stress Syy	30	40	18
   Tensile stress Szz	30	40	18
   Compressive stress xx	1200	525	235
   Compressive stress yy	216	145	53
   Compressive stress zz	216	145	53
   Shear Stress Sxy	33	73	27
   Shear Stress Syz	33	73	34
   Shear Stress Szx	33	73	34

   20

   10

   0

   0.02

   0.015

   0.01

   0.005

   0

   Aramid-Epoxy

   0 10 20 30 40 50 60 70 80 90

   Fig 4. Lateral deformation vs winding angle

   Carbon-Epoxy EGlass-Epoxy Aramid-Epoxy

   0 10 20 30 40 50 60 70 80 90

   Fig 5. Angle of twist vs winding angle

   Table.2 Dimensions for composite tube

   1.5

   1

   Length of the tube (mm)	400 mm
   Fixing length at end	Rigid
   Average radius (mm)	25 mm
   Tube thickness (mm)	1 mm

   0.5

   0

   Carbon-Epoxy EGlass-Epoxy

   Aramid-Epoxy

   0 10 20 30 40 50 60 70 80 90

   Fig 6. Radial deformation vs winding angle

4. Results and discussion

   In this analysis, Carbon/Epoxy, EGlass/Epoxy

   350 Carbon-Epoxy

   330 EGlass-Epoxy

   and Aramid/Epoxy tubes are subjected to loading action in pure and multi-axial loading with magnitudes axial, transverse as 1000 kN, torsional 1000 N.mm and internal pressure 10 bar and the analysis is repeated for varying degrees of winding angles from zero to 900. All deformation and stresses in corresponding directions are collected for pure and combined loading. Multi-axial deformations and stress levels are shown in Figures 3 – 10

   310

   290

   270

   250

   230

   210

   190

   170

   150

   Aramid-Epoxy

   0 10 20 30 40 50 60 70 80 90

   Fig 7. Normal stress vs winding angle

   200

   150

   100

   50

   0

   200

   150

   100

   50

   0

   500

   400

   300

   200

   100

   0

   Carbon-Epoxy EGlass-Epoxy Aramid-Epoxy

   0 10 20 30 40 50 60 70 80 90

   Fig 8. Bending stress vs winding angle

   Carbon-Epoxy

   EGlass-Epoxy

   Aramid-Epoxy

   0 10 20 30 40 50 60 70 80 90

   Fig 9. Shear stress vs winding angle

   Carbon-Epoxy

   EGlass-Epoxy

   Aramid-Epoxy

   0 10 20 30 40 50 60 70 80 90

   Fig 10. Hoop stress vs winding angle

   Table.4 Optimum angles for Bi-axial loadings

   Loading Type	Parameter	Carbon	E Glass	Aramid	Material Selected
   Axial Transverse	Stiffness	900	900	900	Carbon
   	Stiffness	900	900	900
   	Stress	800	900	900
   	Stress	00	00	00
   Axial Torsional	Stiffness	900	900	900	Carbon
   	Stiffness	900	900	900
   	Stress	900	900	900
   	Stress	00	00	00
   Axial Internal Pressure	Stiffness	900	900	900	Carbon
   	stiffness	00	00	00
   	Stress	00	00	00
   	Stress	100	450	00
   Transverse Torsional	Stiffness	900	900	900	Carbon
   	Stiffness	00	00	00
   	Stress	00	00	00
   	Stress	00	00	00
   Transverse Internal Pressure	Stiffness	900	900	900	Carbon
   	Stiffness	00	00	00
   	Stress	00	00	00
   	Stress	00	00	00
   Torsional Internal Pressure	Stiffness	00	800	500	E-Glass
   	Stiffness	00	00	00
   	Stress	100	00	100
   	Stress	100	600	100

   Loading Type	Parameters	Carbon	EGlass	Aramid	Material Selected
   Axial Transverse Torsional	Stiffness	900	900	900	Carbon
   	Stiffness	900	900	900
   	Stiffness	800	900	00
   	Stress	800	900	900
   	Stress	00	100	00
   	stress	00	00	00
   Axial Transverse Internal Pressure	Stiffness	900	900	900	Carbon
   	Stiffness	900	900	900
   	stiffness	00	00	00
   	Stress	200	450	700
   	Stress	00	00	00
   	stress	00	00	00
   Axial Torsional Internal Pressure	Stiffness	900	500 900	500 900	Carbon E.Glass
   	Stiffness	400	500	400
   	stiffness	900	00	00
   	Stress	00	00	00
   	stress	00	900	00
   	stress	100	450	100
   Transverse Torsional Internal Pressure	Stiffness	900	900	900	Carbon E.Glass
   	Stiffness	400	00	00
   	stiffness	00	800	00
   	Stress	00	00	00
   	stress	00	00	00
   	stress	00	00	00

   Table.5 Optimum angles for Tri-axial loadings

5. Conclusions

   In order to investigate the effect of winding angle on pure and combined loading. Analyses are performed separately for pure and combined loadings. In the case of pure loading, the results of the analyses were in agreement with the ones given in the literature. Optimum winding angle and material selected is displayed in Table 3-6.

   Table.3 Optimum angles for Uni-axial loadings

   Loading Type	Parameters	Carbon	EGlass	Aramid	Material Selected
   	Stiffness	900	900	900
   Axial	Stiffness	900	900	900
   	Stiffness	800	900	00
   Transverse Torsional Internal					Carbon E.Glass
   	Stiffness	00	00	00
   	Stress	20	45	70
   	Stress	00	00	00
   Pressure
   	Stress	00	00	00
   	Stress	00	00	00

   Table.6 Optimum angles for Multi-axial loadings

   Loading Type	Parameter	Carbon	EGlass	Aramid	Material Selected
   Axial	Stiffness	900	900	900	Carbon
   	Stress	900	900	900
   Transverse	Stiffness	900	900	900	Carbon
   	Stress	00	00	00
   Torsional	Stiffness	00 / 900	450	450	E-Glass
   	Stress	00	900	00
   Internal Pressure	Stiffness	00	00	00	Carbon
   	Stress	00	00	00

6. Recommendations to tube/pipe manufacturer

   Pipe (or) Tubes manufacturing industries can look into this work for that there is lots of effect on the winding angle and level of orthotropy on deformation and level of stresses. The Schematic View of a Filament Winding Machineis shown in Fig11. Select by analysis of this type optimum winding angle and material, based on cost economy in mass production for actual loading condition on the pipe (or) tubes requirements. This presented winding angles and level of orthotropy are suitable for all lengths and loading magnitudes for them to be optimum for single layer. Fiber orientation for 450 and -450 are shown on the pipe in Fig 12

   Figure 11 Schematic View of a Filament Winding Machine

   Figure 12 – Fiber orientation for 450 and -450

7. Scope of Further work

   Above work is done only for single layer it can be extended for multi layer for better optimum winding angles and level of orthotropy.

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