2016 Intl. Conference on Advances in Computing, Communications and Informatics (ICACCI), Sept.
21-24, 2016, Jaipur, India
Finite Element Analysis of Composite Overwrapped
Pressure Vessel for Hydrogen Storage
Takalkar Atul S.1, Shantanu S Bhat, Shubham S Chavan, Swapnil B Kamble, Arpit P Kulkarni, Sandesh B Sangale
Department of Production Engineering
KIT’s College of Engineering, Kolhapur, India
1
takalkaratul6070@gmail.com
Abstract—This paper investigates the effect of winding angle on
composite overwrapped pressure vessel (COPV) manufactured by
filament winding process where continuous fibers impregnated in
resin and wound over a liner. Three dimensional shell model is
considered for the structural analysis of pressure vessel. The study
on COPV is carried out by considering carbon T300/epoxy
material. The thickness of composite vessel is calculated by using
netting analysis. The study focused on optimum winding angle,
total deformation, stress generation and failure analysis of
composite pressure vessel. The failure of COPV is predicted by
using Tsai-Wu failure criteria. The classical laminate theory (CLT)
and failure criteria is considered for analytical method and
obtained results are compared with numerical results which are
obtained from ANSYS workbench (ACP) for validation. This
comparison further helps in predicting behavior of COPV for
change in winding angle and operating internal pressure.
Keywords—Composite overwrapped pressure vessel, classical
laminate theory, angle ply, winding angle, stacking sequence
I. INTRODUCTION
Pressure vessel is a closed container to store the liquid or
gases at higher pressure which had application as space habits,
nuclear reactors and submarines etc. The pressure vessels are
manufactured by considering a higher factor of safety so as to
prevent the bursting which is caused by material failure. Now a
day, the pressure vessels are used in automotive sector to large
extent to carry the hydrogen gas. To fullfil the requirement such
as light weight and high strength, the composite materials are
used for the manufacturing of pressure vessel. The composite
overwrapped pressure vessel is specially designed to sustain the
fluid pressure. The manufacturing of such kind of pressure vessel
is carried out by using liner which is inner part to avoid the
leakage on which filament is wound. The strength of composite
material can be maintained by proper selection of layups and
fiber orientation. From last decade lot of research work had been
carried out on the design and manufacturing of pressure vessel.
Shafique M.A. Khan [1] investigated the effect of various
geometric parameters and changing load on stress distribution in
horizontal pressure vessel and saddle support. The
recommendations were made to optimize the ratio of distance of
support from end of vessel to length of vessel and the ratio of
978-1-5090-2029-4/16/$31.00 @2016 IEEE
length of vessel to radius of vessel. The study on elastic stress
distribution was done at cylinder to cylinder junction which is
caused due to misalignment in circumferential joints [2]. The
cylindrical pressure vessel was considered with shell structure for
finite element analysis. The stress measurement was done by
Yashar Javadi et al [3] through thickness of stainless steel
pressure vessel by using ultrasonic method. The ultrasonic
transducers are used for evaluation of Hoop and axial residual
stresses. The welding residual stresses were measured by
employing longitudinal critical refracted waves.
The failure prediction of composite laminate was done by
using Tsai-Wu failure criteria. E.S. Barboza Neto et al [4] carried
out the study on behavior of pressure vessel liner which was
made up of 95 wt.% low liner density polyethylene (LLDPE) and
5 wt.% high density polyethylene, under burst pressure testing.
The actual liner models were used for experimental tests and
failure prediction of polymeric liner and composite laminate shell
was done by using Von Mises and Tsai-Wu criteria. The same
failure criteria can be applied on filament wound composite
pressure vessel. The orientation of optimal angle-ply of
symmetric and anti-symmetric shell design was studied [5] for
maximum burst pressure. The alternating internal pressure was
applied on filament wound composite pressure vessel and the
effect of temperature and winding angle was studied. The burst
failure of pressure vessel was predicted by using Lekhnitskii’s
theory where as burst failure pressure of tubes was predicted by
Tsai-Wu failure criterion. The non-linear axial behavior of
composite filament wound pressure vessel due to thermal
expansion was demonstrated by P. Nimdum et al [6]. The
experimental and numerical simulation was performed to
investigate the effect of initial pressure loading and local bending
on dome area. The different test were carried out on composite
pressure vessel to check its rigidity and mode of failure. Jerome
Mespoulet et al [11] carried out numerical study to analyze the
effect of hypervelocity impact on pressurized composite-Al
vessels. The numerical investigation of various impact conditions
for carbon-fiber overwrapped pre-stressed Al vessel was done
which were difficult to analyze by experimental test. The analysis
of space debris of Aluminum composite vessel is done by Pierre-
Louis Hereil et al [12] which is subjected to high velocity impact.
The pressure vessel was made up of CFRP (carbon fiber
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reinforced plastics) overwrapped technique. The obtained result dimensional finite element model to calculate stress value due to
implies that the failure of composite pressure vessel was due to orthotropic behavior. B. Gentilleau et al [23] presented a
catastrophic damage. composite behavior law to account the variability of material
parameters used in type IV hydrogen storage vessel. The
In many cases the failure of pressure vessel is caused due to experimental results were used to compare the model with the
bursting. The manufacturing of high pressure vessel was carried behavior of composite with wound notch structure to verify the
out by Yongzheng Shao et al [13] from vinylester and epoxy capabilities of law. Parametric identification, modeling and
reinforcement with carbon fibers. The pressure vessel with experimental validation of type IV hydrogen high pressure
winding lamination of 90ࡈ and ±15ࡈ was tested experimentally up storage vessel was done by B. Magneville et al [24]. The thermo-
to burst pressure. The obtained result shows that the higher mechanical behavior law is used to predict the burst behavior to
ultimate pressure obtained for carbon/vinylester than epoxy account several physical phenomena. The experimental tests
reinforced. The experimental study on effect of repeated loading were carried out on wound carbon-epoxy samples and validation
was done by Ibrahim Demir et al [14] on composite pressure of wound carbon-epoxy semi-structures was done. The present
vessels to test burst pressure. The manufacturing of vessel was study concentrate on the effect of change in winding angle on
carried out by using filament winding method where epoxy resin type IV composite overwrapped pressure vessel for storage of
and E-glass was used for glass fiber reinforced vessels. The result hydrogen. The purpose of this study was to design a COPV with
indicates that the burst pressure increases with increase on impact increased storage capacity and burst pressure by altering the
load and water temperature. The experimental and numerical stacking sequence, winding angle and shell thickness keeping the
simulation of high pressure hydrogen storage vessel was done by dimensional constraints constant. The method opted was to use a
Juan Pedro Berro Ramirez et al [15]. The burst simulation was numerical simulation to design and alter the parametric entities of
further used for the prediction of behavior of pressure vessel and the COPV and later validate the results using analytical method.
damage modes at the ply scale. The obtained result predicts the
non linearity and leaks due to gap between liner and composite
shell. The burst simulation was carried out by D. Leh et al [16] II. METHODOLOGY
on hydrogen pressure vessel which is manufacture by using The procedure followed for numerical analysis is as shown in
filament winding. Fig.1. where FE software tool is used to generate the results for
In filament wound composite the stacking sequence is altered various parameters like winding angle, stacking sequence,
to increase the mechanical properties. The investigation of stack- thickness, pressure. Further the results are evaluated by varying
based layering was done by Hassen Taher Dorrah et al [17] the parameter values to optimize the results.
during system change pathway. The stack based configuration in
multi stacking network was proposed. The study on effect of
stacking sequence on behavior of filament wound composite
cylinder was done [18] which were subjected to impact loading.
The carbon fiber reinforced plastics was used for the
manufacturing of cylinder which was further used to relate the
damage with the absorption energy and damage depth ratio.
Maxime Bertin et al [19] investigated the effect of thermo-
mechanical cyclic loading on stacking sequence of
polymer/composite multilayer. The quasi-static tensile tests and
fatigue test of staking sequence was carried out to analyze the
behavior of material under cyclic loading. The composite made
up of filament winding method with an optimum stacking layer
has a vast applications in automotive industries for storage of
hydrogen. The multi-sequence dome lay-up simulation by
changing the winding angle and thickness was carried out for
hydrogen hyper-bar composite pressure vessels [20]. The method
was proposed for the calculation of prediction of geometrical
characteristics of the end-closures which is used for hydrogen
storage. The optimization of the composite stacking sequence
was investigated by D. Leh et al [21] for type IV hydrogen
pressure vessel which is manufactured by using filament winding
technique. The different optimization methods were applied by
considering composite damage and dome multi sequencing.
Benoit Gentilleau et al [22] studied the stress analysis in multi-
layer polymer/composite of type IV high-pressure hydrogen Fig. 1. Methodology for pressure vessel analysis
storage vessel. Tsai-Wu criterion is applied on a three-

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 2016 Intl. Conference on Advances in Computing, Communications and Informatics (ICACCI), Sept. 21-24, 2016, Jaipur, India

III. GEOMETRY FOR PRESSURE VESSEL
The pressure vessel with a single port as shown in Fig. 2 (a) is
consider for structural analysis. The single port with a diameter
of 34 mm [4] functions as a both inlet and outlet port. Two fix
supports are used to provide stability to pressure vessel. To avoid
leakage, liner is used as inner element of pressure vessel where as
shell forms the outer layer to sustain the inner pressure.
node which possess six degrees of freedom at each node. By
using SHELL181 element type free meshing is carried out. Two
cylindrical fixed type supports are used as a boundary condition
to constrain the displacement of pressure vessel as shown in Fig.
3. The internal pressure of 40 MPa is applied on inner wall of
pressure vessel which is equally distributed and normal to the
surface of the walls.
V. THEORETICAL ANALYSIS

A. Thickness Calculation
The cylindrical filament wound pressure vessel consists of
helical and hoop layers. For cylindrical part helical and hoop
layers are used whereas only helical layers are used for end
domes. Further netting analysis is used to determine the
(a) minimum thickness by considering inner pressure loading. The
effect of the matrix is not considered while calculating thickness.
The calculation of thickness for helical layer [25] which is wound
on cylindrical and dome part is as shown below
Pi .r
t fθ =
2.σ f θ .cos 2 θ
(1)
also the thickness for Hoop layer which is wound on cylindrical
(b) part can be calculated as below
Fig. 2. Axis-symmetry model of the pressure vessel, (a) Schmetic diagram, P .r
(b) Dimensioned diagram [4] t f 90 = i .(2 − tan 2 θ )
2.σ f 90
(2)
The simulation is carried out by using T300 carbon/epoxy Finally the total thickness by considering the fiber volume ration
material. The material properties for analytical calculation are can be calculated as below
referred from composite material data book. The liner is wound
with 10 helical winding layers and 20 Hoop layers. The thickness t fθ t f 90
tc = +
for helical winding layer and Hoop layer is calculated by using f v ( helical ) f v ( hoop )
Eqn. 1, 2 and 3. The simulation is carried out by varying stacking (3)
where R- inner radius of filament wound cylinder (mm), Pi -
sequence which is in order of [( ±θ )/90t/90t] as shown in Fig 7.
internal pressure (MPa), (±ș) - winding angle ( ࡈ ), (tfș) - helical
IV. FINITE ELEMENT MODEL OF PRESSURE VESSEL fiber thickness (mm), fV - fiber volume fraction.

B. Laminate Theory
The structural analysis of composite laminated is done by using
Classical Lamination Theory (CLT) [10]. As per the theory each
ply is assumed to be in state of plane stress and inter laminar
stresses are neglected. To obtain stress transformations, the
engineering stress & strain based matrices are used. The
stress/strain transformation matrix are as follows

§ cos2 α sin2 α sin2α ·

¨ ¸
M(α) = ¨ sin α
2
cos2 α −sin2α ¸
¨ −cossinα cosα sinα cos2α ¸
© ¹ (4)
Fig. 3. Finite element model of the pressure vessel (section view)
§ cos 2 α sin 2 α cos α sin α ·
The pressure vessel is categorized under thin type of ¨ ¸
structures. For the analysis of such structures SHELL181 element N (α ) = ¨ sin 2 α cos 2 α − cos α sin α ¸
type is used as it is well suited for linear, large rotation and large ¨ − sin 2α sin 2α cos 2α ¸¹
© (5)
strain nonlinear applications. The selected element is of four

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The manufactured laminate by using filament winding is further controlled which leads to reduction of weight and can be used in
considered as angle ply. By using stress/strain transformation vehicles for hydrogen storage. The FE simulation in ANSYS
matrix, compliance matrix (C) of a single orthotropic layer is workbench is performed by using ACP tool to analyze the stress
calculated as below and deformation. The preliminary structural analysis is
§ 1 − v1 2 · performed by using both isotropic and composite material. The
¨ 0 ¸ total displacement (mm) for varying pressure (MPa) observed in
¨ E1 E1 ¸
¨ − v1 2 1 ¸ case of composite material was much low as compared to the
C =¨ 0 ¸ isotropic material (Steel and Copper alloy) which can be
¨ E1 E2 ¸
¨ 1 ¸
identified from Fig.4.
¨ 0 0 ¸
© G1 2 ¹
(6)
The corresponding stiffness matrix S is obtained by inversion of
compliance matrix. The stiffness matrix of the resulting angle ply
laminate is calculated as below
1
S = ª¬ S (α ) + S ( −α ) º¼
2 (7)
The resultants of the stress components are further calculated by
the ABD matrix as follow
­ N ½ § A B · °­ ε 0 ½
® ¾=¨ ¸® ¾
¯ M ¿ © B D ¹ °¯ K ¿ (8)
Fig. 4. Effect of pressure (MPa) on total deformation (mm) for different
where Aij - extension stiffness matrix, Bij - extension bending materials
coupling matrix, Dij- bending stiffness matrix. This relationship The validation is carried out by using Tsai- Wu failure criteria
determines the mechanical behavior of fiber reinforced angle ply for selected geometry. The analytical results obtained for
laminate. different winding angle had good correlation with numerical
results. Form Fig.5. it is identified that the obtained curve for
C. Failure Theory
both Tsai- Wu (analytical) and Tsai- Wu (numerical) are within
The failure of orthotropic lamina is predicted by using Tsai Wu the limits. As the applied failure criteria consider stresses
Failure Criteria and Tsai-hill failure criterion. The Tsai-Wu developed lateral and longitudinal, it is preferred.
theory [7-9] predict the failure in orthotropic lamina under plane
stress condition as shown below
F11 ı12 + F22 ı22 + F66 IJ122 + F1 ı1 + F2 ı2 + 2F12 ı1ı2 = 1 (9)
Where Xt - longitudnal tensile strength (MPa), Yt - transverse
tensile strength (MPa), Xc - longitudnal compressive strength
(MPa), Yc - transverse compressive strength (MPa), S - in plane
shear strength (MPa). Also the elastic characteristics consist of
four independent elastic constants as E11, E22, G12, Ϝ12.
The strength coefficients are calculated by using the tensile,
compressive and shear strength properties in the principal
material directions as shown below Fig. 5. Effect of change in winding angle ( ࡈ ) on total deformation (mm)
1 1 1 1 1 1 F = 1
F1 = − F = F2 = − F =
X t X c ’ 22 YtYc ’ Yt Yc ’ 66 X 2 , 11 X t X c
1
F12 = − ( F11.F22 )
2 (10)
VI. RESULTS AND DISCUSSION
Earlier the pressure vessels were manufactured of isotropic
materials like Steel and Copper alloy. As this pressure vessels
were having redundant material along the longitudinal axis which
results in excess weight. This limitation is overcome by using
composite materials where filament winding is used for the
manufacturing of pressure vessel. The deposition of material is
Fig. 6. Effect of change in winding angle ( ࡈ ) on maximum failure stress (Pa)

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For determining the optimum winding angle the parametric
study is carried out for different winding angles. It is observed
that the deformation is maximum at the ends of pressure vessel
and minimum at the cylindrical portion which can be identified
from Fig.8. The deformation observed at the fixed support is 0.
For selected geometry of pressure vessel, inlet and outlet is
carried out by using same port. Hence it is identified that the
maximum deformation is at the inlet/outlet port. The total
deformation is minimum for winding angle ±35ࡈ with the stacking
sequence of [±35ࡈ/90ࡈ/90ࡈ]. The numerical simulation is carried out
for composite pressure vessel for different winding angles. The
obtained maximum failure stresses for different angles are
calculated and minimum stresses are developed for winding
angle ±35ࡈ as shown in Fig.6. The optimum winding angle is also
determined for the stress distribution for various winding angles
which are calculated numerically. Increase in winding angle
results in decrease in stress distribution which can be observed in
Fig.10. The obtained stress distribution contours for various
winding angles are shown below in Fig.9. where maximum stress
distribution is obtained for winding angle ±10ࡈ and minimum is
obtained for winding angle ±35ࡈ. Further ply-wise analysis was
carried out to reduce the stress distribution by changing the ply
orientation (Rosettes) for the helical layer, which improved the
results.

Fig. 7. Schematic diagram of different winding angle ( ࡈ ) sub laminates for COPV

(a) (b)

(c) (d)
Fig. 8. Deformation for variation winding angles ( ࡈ ) of COPV (a) 10ࡈ, (b) 35ࡈ, (c) 45ࡈ, (d) 70ࡈ

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(a)
(c)
Fig. 9. Stress distribution for various winding angles ( ࡈ ) of COPV (a) 10ࡈ, (b) 35ࡈ, (c) 45ࡈ, (d) 70ࡈ
Fig. 10. Stress (Pa) generation for different winding angles (ș) of COPV
Fig. 11. Total deformation (mm) for different winding angles ( ࡈ ) of COPV
Same parametric study is carried out to find the total
deformation for various winding angles. The minimum
deformation is observed for winding angle ±35ࡈ where as
435
(b)
(d)
maximum deformation at winding angle ±70ࡈ as shown in
Fig.11. After evaluating different numerical results a trade off
was taken between the total deformation and stresses
generated. Hence the optimum winding angle from overall
investigation is ±35ࡈ.
VII. CONCLUSION
The FE analysis is carried out for composite overwrapped
pressure vessel (COPV) by using ACP pre-post. The aim of
study was to design a COPV for hydrogen storage which had
application in fuel cell car. The operating pressure for
hydrogen storage tank was 20 MPa. Hence to be on safer side
the COPV was designed to sustain the pressure of 40 MPa. The
analytical results were accompanied with numerical simulation
to predict the complex mechanical failure of COPV more
accurately. Analytical results and numerical results showed a
good co-relation for Tsai Wu failure criteria. Altering the
stacking sequence by considering various ply angle was carried
out to find the most suitable ply angle for selected design. The
minimum stress and minimum total deformation is obtained for
winding angle of ±35ࡈ. The increase in winding angle results in
decrease in stress generation. The total deformation remains
constant as the winding angle increases till ±35ࡈ and further
increases with increase in winding angle. After carrying
analysis of various stacking sequence the optimum sequence
was ±35ࡈ. The analysis carried out ply wise which further
helped in reducing the stress and total deformation for selected
design.
 2016 Intl. Conference on Advances in Computing, Communications and Informatics (ICACCI), Sept. 21-24, 2016, Jaipur, India
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