| The full-wrapped composite cylinders are mainly used as high-pressure hydrogen storage containers, respirators and compressed natural gas cylinders. The composite cylinder, which has been used to replace the steel cylinder in abroad, combines with the advantages of composite material, so it reaches the combination of excellent performances such as high pressure, high fatigue life, light weight, good corrosion resistance etc. In recent years, aluminum liner composite cylinder is researched in China and used in more fields step by step. At present, it has become an important research topic of both finite element analysis technology and structure optimization technology, which can improve the reliability of structural design and the performance of pressure vessels, effectively shorten design cycles and costs.Based on the subject of institute of winding equipment for composite filament, the research on the full-wrapped composite vessel is developed in this paper. The main research results are as follows:(1) The structure of the full-wrapped composite cylinder is designed based on the netting theory, techniques of filament-winding and volume constraint conditions. The dimension of aluminum liner and both wind angle and thickness of hoop and longitudinal orientation are calculated.(2) The filament winding layers are analyzed with the theory of elasticity mechanics and checked by the orthotropic failure criterion.(3) Finite element model, which has maximum consistency with the mechanical characteristic of the full-wrapped composite cylinder, is established with APDL language, and result analysis is done according to the design criteria of DOT-CFFC.(4) The method of parametric unitary optimization of composite cylinder is performed in this paper. The performance factors are studied. The object function of minimum mass of the cylinder and stress of liner under working pressure are solved to get the best design proposal according to the design criteria of DOT-CFFC.
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