Optimization of Fiber Winding Angles for Enhanced Structural Performance of Composite Pressure Vessels Using Finite Element Analysis

Abstract

From the experiments carried out on pressure vessels, it was clearly observed that composite materials provide superior quality and safety compared to steel-made vessels However, a major challenge remains in determining the optimum fiber winding angles, since most composite vessels are manufactured using the Filament Winding technique..This study investigates the optimization of fiber winding angles in composite pressure vessels (CPVs) with the aim of improving structural performance without increasing thickness or weight. Composite materials have been shown to provide superior safety and reduced weight compared to conventional steel vessels, justifying their slightly higher costs. Building upon the previous study , where a winding layers configuration of [0,66,0,-66,0]α in composite gas cylinder was employed, this study evaluates four alternative configurations: [45,-45,0,65,-65]α, [0,75,0,-75,0]α, [0,50,0,-50,0]α, and [0,90,0,90,0]α, using finite element analysis (FEA) in ANSYS Workbench. Results reveal that the [0,50,0,-50,0]α configuration demonstrates the best performance, achieving Hoop Stress = 18 MPa and Axial Stress = 5 MPa while maintaining identical geometry and weight. This confirms that optimization of winding orientations enhances the mechanical performance of CPVs without compromising their lightweight advantage.

Mesh independence and Tsai-Wu failure criterion were used to ensure result reliability. The findings provide valuable insight for industrial designers seeking lightweight, high-strength vessel configurations.