基于内胆封头表面补强的Ⅳ型气瓶缠绕铺层分析

Analysis of Winding Layers for Type IV Cylinders Based on Dome Reinforcement of Liner

  • 摘要: 针对塑料内胆碳纤维缠绕气瓶(Ⅳ型瓶)阀座—内胆过渡区应力集中及轻量化问题,开展了在PA6内胆封头外表面铺设碳布的局部补强研究。建立基于Hashin准则和Camanho刚度退化的气瓶渐进损伤模型,并通过水压爆破试验进行模型验证。采用控制变量法研究局部补强范围、角度和厚度等因素对封头应力的影响规律,结果表明:扩大补强区域可减小阀座—内胆过渡区应力集中;补强角度主要影响补强层与原缠绕层之间的载荷分配,但不同角度方案间差异较小;补强厚度过小难以改变原薄弱位置,过大则会使载荷向过渡层及补强边界转移。通过综合分析得到推荐的补强范围、角度和厚度分别为38~111 mm、45°和2.1 mm,并在此基础上开展了局部补强气瓶的螺旋层减层设计(减少1组±17°螺旋铺层),最终气瓶质量储氢密度由6.04%提高至6.43%,失效位置由原方案气瓶的封头段变为筒身段。本文研究工作可为内压加载下的IV型气瓶封头外表面局部补强设计提供参考。

     

    Abstract: To address stress concentration in the boss–liner transition region and lightweight design requirements of Type IV carbon-fiber-wound pressure cylinders with plastic liners, local reinforcement was investigated by applying carbon cloth to the outer surface of the PA6 liner dome. A progressive damage model based on the Hashin failure criterion and the Camanho stiffness degradation model was established and validated through hydrostatic burst tests. The effects of the local reinforcement range, angle, and thickness on dome stresses were investigated using the control-variable method. The results show that enlarging the reinforcement region reduces stress concentration in the boss–liner transition region. The reinforcement angle mainly affects load sharing between the reinforcement layer and the original winding layers, although the differences among the investigated angles are relatively small. Insufficient reinforcement thickness has little effect on the original critical failure location, whereas excessive thickness causes load transfer toward the transition layer and the reinforcement boundary. Based on a comprehensive analysis, the recommended reinforcement range, angle, and thickness are 38–111 mm, 45°, and 2.1 mm, respectively. Helical-ply reduction was subsequently investigated for the locally reinforced cylinder by removing one pair of ±17° helical plies. The gravimetric hydrogen storage density of the cylinder increases from 6.04% to 6.43%, and the failure location shifts from the dome in the original design to the cylindrical section. This study provides a reference for local reinforcement design on the outer surface of the liner dome in Type IV pressure cylinders under internal pressure loading.

     

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