Optimal Design of Composite Water Tank by Using Finite Element Analysis

Software

By Tamrat Yimer
Submitted to Dr. Ermeas G. Koricho
For the course Selected topics on Advanced Mechanics of Materials
Addis Ababa Institute of Technology (AAIT)
Addis Ababa University

Abstract
Composite made tankers in Ethiopia uses in the last decade increase rapidly. Steel and plastic
made tankers replaced by these fiber glass tankers and many companies produce these tankers.
But on this fiber E-glass, epoxy matrix tankers detected some failures due to many seasons. The
main target of this paper reduces the failures shown on these tankers by creating suitable fiber
angles of orientation produced optimal design of composite structure to with stand these failures.
On this work the mathematical model of composite shell structure created. The solid modeling of
twenty five thousand litters tanker is created by AutoCAD 2007 exported to ABQUS commercial
software to analyses the model. ABAQUS result shows on these fiber orientation composite
structure some failures will be on the joint between the dome and cylinder areas. This has to
solve by strengthen the joint structure.

1. Introduction
Over the last two decades the strived for lighter and stronger structures has resulted in an
increasing use of composite materials. In particular, fiber reinforced polymers (FRP) have gained
an ever increasing popularity due to their very high strength to weight ratio. In structural
applications fiber reinforced polymers are usually stacked in a number of layers, each consisting
of strong fibers bonded together by a resin, to form a laminate. The fibers may be uniformly
oriented in typically one or two directions or they may be oriented in no particular ordered
fashion. The best use of the material is achieved when ordering the fibers in specific directions to
obtain high stiffness in the loading directions and lower stiffness in other directions. Exploiting
this “directionality” of the material is at the core of efficient design with laminated composites.
Furthermore, to obtain an optimal design the engineer must choose where to put material and
which materials to use – both in general and in individual layers. However, proper choice of
material layout, materials, stacking sequence and fiber orientation is a far from simple task since
laminates can often consist of as many as 500 or more different layers.

Composite materials play an important role in modern industry through the design and
manufacture of advanced materials capable of attaining higher stiffness/density and
strength/density ratios. These ratios allow composite materials to be used in various applications
where the weight and strength of the structure are highly significant design parameters (e.g.
aircraft, pressure vessel, liquid tank and aerospace shuttle industries). Composite materials
dramatically enhance the performance and increase the efficiency of such structures. In order to
insure structural integrity and safe performance, through understanding of the behavior of these
materials under arising loads must be established.

The use of filament-wound composite construction has long been established in the corrosion
and storage tank industry. Composite construction provides a long-lasting solution for liquid
storage, where corrosion has often shortened the life of steel tanks and piping. For the storage or
transport of highly corrosive liquids, an inert corrosion barrier material is used on the inside of
the tank to shield the outer structure from the corrosive influences of the liquid [7].

Power tech lab. company works on Compressed Natural Gas (CNG) & Hydrogen Tank Safety,
R&D, and Testing presented there are four basic types of CNG pressure vessels tank
Type 1 – all metal

Type 2 – metal liner with hoop wrapped composite

Type 3 – metal liner with fully wrapped composite

Type 4 – Plastic liner with fully wrapped composite

The company reported on November 2009 Type 1 steel cylinders involved in nearly 50% of
failure incidents and the other shows on the graph below [10].
Fig. 1 cylinder type vs number failure graph
By these reasons now a day in Ethiopia steel and plastic water tanks are completely replaced by
fiber glass tankers, there are many producers are there but their products investigated some
failure‟s specially huge capacity tanks like tankers greater than 10,000 lt. this paper focuses on
25,000 lt. tanker, these failures come from different reasons. This paper aim to crate the optimal
design of composite water tank by using finite element based analysis commercial software ie
ABAQUS.

Design of blast Resistant Composites is made by using multi-objective genetic topological

optimization this work was done by the use of multi-objective genetic topological optimization
to design blast resistant composites. The fundamental problem of the design of a two-layer
composite plate that is subjected to blast is considered using the finite element method. Two
materials are used to form the microstructure of each layer. The microstructure and thickness of
each layer is optimized for the two-layer plate to minimize the weight and stress-to-strength
ratio. A set of optimal blast resistant composite microstructures that meet design requirements is
demonstrated [1].

Analysis and Optimization of Laminated Composite Shell Structures generated this work
presented the development of finite element based optimization techniques for laminated
composite shell structures. The platform of implementation is the finite element based analysis
and design tool MUST (Multidisciplinary Synthesis Tool) and a number of features have been
added and updated. This includes an updated implementation of finite elements for shell
analysis, tools for investigation of nonlinear effects in multilayered topology optimization and a
novel framework called Discrete Material Optimization (DMO) for solving the material layout
and orientation problem [2].

Design and finite element analysis of Fiber Reinforced Polymer (FRP) Liquid Petroleum Gas
(LPG) cylinder viewed under this title. This paper entails the design and finite element analysis
(FEA) of a LPG cylinder made of E-glass fiber, vinyl ester resin and HDPE plastic composite,
the liner of the cylinder is made of HDPE plastic (blow molding grade) and wound with
continuous fiber E-glass composite with vinyl-ester polymer matrix. The cylinder cover is also
made of HDPE plastic. The LPG cylinder was designed and tested for burst pressure of 3 MPa.
The thickness of the cylinder was established to be 3.5 mm (1.5 mm of liner and 2 mm of FRP
composite layer) using Abaqus software based FEA. Various design concepts were worked out
along with a financial viability analysis. A strong, light, rust proof and semi-transparent LPG
cylinder was aimed to be designed in this paper focusing on the use in the South African context
[3].

Honeycomb Fiber-Reinforced Polymer Sandwich Composites for Development of Aquaculture

Raceway Systems presented. Fiber-Reinforced Polymer (FRP) sandwich materials offer an
economical option for production of light, transportable and durable fish culture raceway
systems. This study is concerned with the development and evaluation of prototype fish culture
tanks using a Honeycomb FRP, termed HFRP, sandwich panel with sinusoidal core geometry
[4].

Optimal design of filament wound type 3 tanks under internal pressure using a modified genetic
algorithm considered. In this research, the optimal design algorithm includes the semi-geodesic
path algorithm, progressive failure analysis and genetic algorithms. In addition, a modified sub-
string genetic operator that improves the genetic algorithm was newly suggested and verified
through a basic design. The optimal design algorithm was applied to a representative filament
wound type 3 tank - high pressure hydrogen storage tank [5].
An Integrated Systematic Approach to Linerless Composite Tank Development presented. The
paper describes a program currently underway at Composite Technology Development, to
dramatically improve the design and capabilities of lightweight linerless composite tanks. The
program integrates material development and characterization, micromechanics-based analyses
of composite materials and structural design and fabrication of prototype tanks. This integrated
systematic approach, addresses the multi-scale and multi-disciplinary issues that are critical to
linerless composite tank design by looking concurrently at material requirements, capabilities
and tailoring, refinement of fabrication process, and structural design optimization [6].

The use of filament-wound composite construction has long been established in the corrosion
and storage tank industry. Composite construction provides a long-lasting solution for liquid
storage, where corrosion has often shortened the life of steel tanks and piping. For the storage or
transport of highly corrosive liquids, an inert corrosion barrier material is used on the inside of
the tank to shield the outer structure from the corrosive influences of the liquid [7].

Development of CNG Tanks Type 3 is developed. In this paper using Composite Star™
software, designed the laminate structure and determined the properties of the tanks as per the
requirement stated in ISO 11439 (2003). The tanks consist of 24 layers of laminates, with
various winding pattern from 8o to 90o. By maintaining all the parameters, using the 4-axis,
single spindle filament winding machine, aluminum vessel 6061-T6 as the liner, carbon fiber
T700S-12k-50C as reinforcement, and epoxy resin as polymer matrix, manages to produce a few
prototypes for this purposes. As for the weight of the tanks, the prototype produced is lighter by
50% of weight reduction compared to the type-1 and type-2 tanks with the same volume capacity
[8].

Design study of composite sandwich truck tank using a high-order sandwich theory approach
considered on the following paper. In this paper the use of sandwich construction for a truck tank
structure has been investigated by using a high-order sandwich theory approach. In order to
improve the efficiency of the structure, the sandwich was allowed to take on a mid-plane
asymmetric configuration where one face could be thicker than the other, involve different
materials or different stacking sequences. Different material combinations for the faces were
investigated to determine the choice that results in the lightest structure [9].
On this Paper creating different fiber orientations to develop optimal design of the fiber E-glass,
epoxy matrix water tank. The mathematical model of composite shell structure created. The
solid modeling of twenty five thousand litters tanker is created by AutoCAD 2007 exported to
ABQUS commercial software to analyses the model. ABAQUS result shows on these fiber
orientation composite structure some failures will be on the joint between the dome and cylinder
areas. This has to solve by strengthen the joint structure.
The main objective of this work is
To develop the optimal design of the composite water tank by using finite element analysis
software.
2. Mathematical Model of Cylindrical Shells
The governing equations for the cylindrical shells are quite similar to the governing equations for
plates and the development is entirely analogous. The one consider a circular cylinder of radius r
in cylindrical coordinates x, , z as shown the figure below.

Fig. 2 cylindrical shell coordinates

The strain displacement relations can then be shown to be

 x   x  k x 
0

    0   z k 
        
 x   x0  k x 
 

Where
 x 
   Normal and shear strains
  
 x 

 u 0 
 x 
 x0   
 0   1  v0 
    Strains at the geometrical mid plane =    w 
 0  r  v 

 x   v0 1 u 0 
 x  r  

uo , vo , w  Mid plane displacements in the x, , z directions

2w 
 2 
k x   x 
k     1  w 
2

    r 2  2 
k x   
 2 2w 
 r 2 x 
 

For shell such that z/r can be neglected with respect to 1, the stress and moment resultants for the
cylindrical shell are identical to the plate.

 N x  h / 2  x  A16   x   B11
0
 A11 A12 B12 B16  k x 
N    dz   A  
       12 A22 A26   0    B12 B22 B26  k 
 N x  h / 2
 x   A16 A26 A66   x0   B16 B26 B66  k x 
 
 M x  h / 2  x  B16   x   D11
0
 B11 B12 D12 D16  k x 
M    zdz   B  
       12 B22 B26   0    D12 D22 D26  k 
 M x  h / 2
 x   B16 B26 B66   x0   D16 D26 D66  k x 
 
or
 N   A B   0 
M    B D  
    k 
where
n
Aij   (Q ij ) k (hk  hk 1 )
k 1
 1 n
Bij  
2 k 1
(Q ij ) k (hk2  hk21 )

1
Dij 
3
 (Q ij ) k (hk3  hk31 )

3. Finite Element Analysis of the water tank

The twenty five thousand liters composite tanker made of E-glass model is done by AutoCAD
2007 and exported to Abaqus, analysis is done by this software. Material properties of E-glass
fiber, Epoxy matrix as follows on the following tables [11].

Elastic properties of E-glass fiber

Ex (GPa) Ey (GPa) Poisons ratio G12 (GPa) G13 (GPa) G23 (GPa)
38.6 8.27 0.26 4.14 2 2

Hashin Damage of E-glass fiber

Longitudinal Longitudinal Transverse Transverse Longitudinal Transverse

Tensile compressive Tensile Tensile Shear Shear
Strength (X) Strength (X‟) Strength (Y) Strength (Y‟) Strength MPa Strength MPa
MPa MPa MPa MPa
1062 610 31 118 72 72

Fig. 3 CAD modeling of the water tank

Fig. 4 the deformed and undeformed shape of the water tank

The entire CAD modeling done by AutoCAD 2007 and FEA simulation were carried out using
the commercial FEA software Abaqus [13]. Composite laminate of thickness 10mm was
modeled using eight symmetric plies total of sixteen plies in the composite layup module of
Abaqus keeping the orientation angle arranged symmetrically like 0o, 300,45°,60°0o, 300,45°,60°
for each layer. The engineering constants option was invoked for assignment of composite
material properties. The hydrostatic Pressure is the designated pressure acting on the inner layer
is applied. The value assigned to the hydrostatic pressure is 0.0062 MPa and is applied as a
uniform pressure load. 3-d linear hexahedral (brick) elements (total number 5414) were chosen
for the FEA meshing. Fig. 4 shows the Tersca stress deformed and undeformed contour plot of
the composite water tank after Static FEM analysis. The results show no signs of immediate
failure. The maximum operating water tank pressure is less than 0.0062 MPa and the analysis
was done at above 0.0062MPa in the present study. Hence, a factor of safety 2 was established.
 Fig. 5 stress vs strain graph

4. Conclusion
In this paper fiber E-glass, epoxy resin tanker is done by using suitable angles of fiber
orientations. The solid modeling of twenty five thousand litters tanker is created by AutoCAD
2007 exported to ABQUS commercial software to analyses the model. ABAQUS result shows
on these fiber orientation composite structure some failures will be on the joint between the
dome and cylinder areas. This has to solve by strengthen the joint structure. From this the one
conclude that by adjusting angles fiber orientation create optimal composite structure.

5. References
1. M. P. Sheyka & A. B. Altunc & M. M. Reda Taha(2012) 'Multi-objective Genetic
Topological Optimization for Design of Blast Resistant Composites' Published online:
21 January 2012 Springer Science+Business Media B.V. 2012
2. Ph.D. Thesis by Jan Stegmann „Analysis and Optimization of Laminated Composite
Shell Structures‟, Institute of Mechanical Engineering, Aalborg University
Pontoppidanstræde 101, DK-9220 Aalborg East, Denmark e-mail: js@ime.aau.dk, May
2005
3. Moyahabo, Bradley Moketla & Mukul shukla „Design and Finite Element Analysis of
FRP LPG cylinder‟ , Department of Mechanical Engineering Science, University of
Johannesburg, Johannesburg, South Africa Email: brmmoketla@gmail.com,
mshukla@uj.ac.za,mukulshukla2k@gmail.com
4. Msc thesis by Avinash Vantaram „Honeycomb Fiber-Reinforced Polymer Sandwich
Composites for Development of Aquaculture Raceway Systems‟, College of Engineering
and Mineral Resources at West Virginia University 2004
5. Cheol-Ung Kim, Chang-Sun Hong, Chun-Gon Kim and Jung-Yub Kim ‘Optimal Design
of Filament Wound Type 3 Tanks Under Internal Pressure Using a Modified Genetic
Algorithm‟, Department of Mechanical Engineering, Division of Aerospace Engineering
Korea Advanced Institute of Science and Technology
6. Kaushik Mallick, John Cronin, Kevin Ryan, Steven Arzberger, Naseem Munshi Chris
Paul, Jeffry S. Welsh „An Integrated Systematic Approach to Linerless Composite Tank
Development‟ Published in the proceedings of the 46th AIAA/ASME/ASCE/AHS/ASC
Structures, Structural Dynamics, and Materials Conference, 18 – 21 Apr 05, Austin, TX
14.
7. Innovation Sandwich Technology News F a l l 2 0 0 9
8. H.F.A.Marzuki, R. Razak, M.F.Z. Abidin, E.A.E. Ubaidillah, I.N.Ismail, M.A. Baharom
„Development of CNG Tanks Type 3‟, Advanced Polymer and Composites Programme
9. Jack R. Vinson and Ole T. Thomsen „Design study of composite sandwich truck tank
using a high-order sandwich theory approach‟ March 2003 Delaware center for
transportation, University of Delaware.
10. Power lab Inc. report in 2009 on Compressed Natural Gas (CNG) & Hydrogen Tank
Safety, R&D, and Testing
11. Stephen W. Sai 'Theory of Composite Design' 2008 Stanford University
12. John C. Halpin 'Primer on Composite Materials Analysis' 2nd Edition Air Force
Materials Center Wright-Paterson AFB, Ohio
13. Abaqus Version 6.10 – User‟s Manual.