Research on the burst failure analysis method of type IV cylinders based on the fiber strength reduction effect
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摘要: 复合材料储氢气瓶是高压气态储氢最有效的解决方案，其中塑料内胆碳纤维全缠绕气瓶(Ⅳ型气瓶)是储氢气瓶发展的重要方向。精确预测Ⅳ型气瓶的爆破压力与失效方式是Ⅳ型气瓶轻量化设计的基础。目前气瓶失效预测方法多基于传统层合模型建立，未考虑螺旋缠绕过程中纤维交叉起伏形态影响。本文基于数值和实验方法，探究了纤维起伏形态对纤维拉伸强度的影响规律，进而发展了一种考虑纤维强度折减效应的Ⅳ型气瓶折减分析方法。使用该方法预测3种铺层IV气瓶的爆破压力和失效模式，并与不考虑纤维强度折减效应的传统分析方法进行对比。通过开展气瓶爆破实验，验证了考虑折减分析方法能更准确预测气瓶失效位置与形式，减小爆破压力预测误差，最大误差从+15.42%降低到+6.07%。Abstract: Composite material hydrogen storage cylinders are the most effective solution for high-pressure gaseous hydrogen storage. The carbon fiber fully wrapped plastic liner cylinder (Type IV cylinder) is the most important potential in the development of hydrogen storage. Accurately predicting the burst pressure and failure mode of Type IV cylinders is basement for the lightweight design of these cylinders. Current burst failure prediction methods are developed base on traditional laminated structural models, where the influence of fiber bundles cross undulation that occurs during the helical winding process are not considered. This paper comprehensively investigated the influence of fiber bundles cross undulation on the fiber strength by combining numerical and experimental approaches, and a failure prediction method which takes into account of the strength knock-down effect was developed for Type IV cylinders. The burst pressures and failure locations of three different types of IV cylinders were predicted and compared with the ones that predicted by traditional method which does not consider the strength knock-down effect. The physical bursting experiments were conducted, and the results validate that the numerical analysis method considering the strength knock-down effect can give more accurate prediction of the failure location and reduce the prediction error of the bursting pressure, the maximum error is reduced from +15.42% to +6.07%.
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Key words:
- composite /
- type IV cylinder /
- cross undulation feature /
- strength reduction /
- burst failure
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图 4 起伏角度随缠绕角度变化：(a)单层纤维的起伏形态；(b)2层纤维的起伏形态；(c)单层纤维变化规律；(d)2层纤维变化规律
Figure 4. Variations of undulation angle with the winding angle: (a) Undulation feature of single layer; (b) Undulation feature of 2 layer; (c) Variation curve of single layer; (d) Variation curve of 2 layer
图 6 FWC平板中纤维交叉起伏形态：(a)实验观测截面图；(b)建模示意图
Figure 6. Undulation of fiber bundle in FWC plate: (a) Experimental image; (b) Modeling image
图 7 不同缠绕角度FWC平板模型：(a)±10°；(b)±20°； (c)±30°；(d)±40°
Figure 7. FE models of FWC plates with different winding angles: (a) ±10°; (b) ±20°; (c) ±30°; (d) ±40°
图 8 FWC平板和SLC平板的位移-载荷试验曲线：(a)±10°；(b)±20°；(c)±30°；(d)±40°
Figure 8. Experimental displacement-load curves of FWC and SLC plate specimens: (a) ±10°; (b) ±20°; (c) ±30°; (d) ±40°
图 9 FWC平板和SLC平板长度方向DIC监测应变结果：(a)±10°；(b)±20°；(c)±30°；(d)±40°
Figure 9. Distribution of vertical strain of FWC and SLC plates monitored by DIC: (a) ±10°; (b) ±20°; (c) ±30°; (d) ±40°
图 10 FWC平板和SLC平板长度方向仿真应变结果：(a)±10°；(b)±20°；(c)±30°；(d)±40°
Figure 10. Numerical predicted distribution of vertical strain fields of FWC and SLC plates: (a) ±10°; (b) ±20°; (c) ±30°; (d) ±40°
图 11 仿真和实验位移-载荷曲线和FWC平板纤维拉伸失效演化：(a)±10°；(b)±20°；(c)±30°；(d)±40°
Figure 11. Simulation and experimental displacement-load curves and the evolution of fiber tensile failure in FWC plate: (a) ±10°; (b) ±20°; (c) ±30°; (d) ±40°
图 12
4000 N载荷下FWC平板+α层云图：(a)拉伸方向应变；(b)纤维方向应力Figure 12. FWC plate +α layer nephogram under
4000 N: (a) Strain in the tensile direction; (b) Stress in the fiber direction
图 13 仿真预测的FWC平板和SLC平板拉伸失效载荷对比：(a)单层厚度；(b)双层厚度
Figure 13. Comparison of tensile failure loads of FWC and SLC plates predicted by FEA: (a) 1-layer thickness; (b) 2-layers thickness
图 14 纤维强度折减系数随厚度和缠绕角度变化
Figure 14. Variation of strength reduction factors with winding angle and thickness
图 15 基于纤维强度折减效应的气瓶数值分析框架
Figure 15. Numerical analysis framework for cylinders based on the effect of strength reduction effect
图 17 IV型气瓶模型：(a)整体模型和载荷；(b)封头；(c)过渡区域
Figure 17. Type IV cylinder model: (a) Global model and loading; (b) Dome; (c) Transition region
图 19 气瓶水压实验及爆破失效形式：(a)试验装置；(b)A铺层；(c)B铺层；(d)C铺层
Figure 19. Pressure test and burst modes of type IV cylinders: (a) Burst test setup; (b) Layup-A; (c) Layup-B; (d) Layup-C
图 20 气瓶爆破失效前纤维应力云图：(a)A铺层-传统分析方法；(b)B铺层-传统分析方法；(c)C铺层-传统分析方法；(d)A铺层-折减分析方法；(e)B铺层-折减分析方法；(f)C铺层-折减分析方法
Figure 20. Fiber stress nephogram of cylinder before failure: (a) Layup A-traditional method; (b) Layup B-traditional method; (c) Layup C-traditional method; (d) Layup A-reduction modified method; (e) Layup B- reduction modified method; (f) Layup C- reduction modified method
图 21 气瓶爆破失效纤维拉伸损伤云图：(a) A铺层-传统分析方法；(b) B铺层-传统分析方法；(c) C铺层-传统分析方法；(d) A铺层-折减分析方法；(e) B铺层-折减分析方法；(f) C铺层-折减分析方法
Figure 21. Comparison of fiber tensile failure nephogram of cylinder: (a) Layup A-traditional method; (b) Layup B-traditional method; (c) Layup C-traditional method; (d) Layup A-reduction modified method; (e) Layup B- reduction modified method; (f) Layup C- reduction modified method
表 1 单向纤维束材料参数
Table 1. Material properties of unidirectional fiber bundle
Items Value Longitudinal modulus, E11/GPa 125.4 Transverse modulus, E22 =E33/GPa 7.7 In-plane shear modulus, G12=G13/GPa 3.8 Out-of-plane shear modulus, G23/GPa 4.8 Major Poisson's ratio, μ12 = μ13 0.33 Through-thickness Poisson's ratio, υ23 0.35 Longitudinal tensile strength, XT/GPa 2.18 Longitudinal compressive strength, XC/GPa 1.2 Transverse tensile strength, YT/MPa 60 Transverse compressive strength, YC/MPa 140 Density of laminate, ρ/(kg·m−3) 1600 Tensile fracture energy of fiber, Gft/(N·mm−1) 133 Compressive fracture energy of fiber, Gfc/(N·mm−1) 40 Tensile fracture energy of matrix, Gmt/(N·mm−1) 0.6 Compressive fracture energy of matrix,Gmc/(N·mm−1) 2.1 Elastic modulus of resin, E/GPa 3.0 Density of resin, ρr/(kg·m−3) 1200 Poisson's ratio of resin, μ 0.3 
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表 2 IV型气瓶材料力学性能参数
Table 2. Type IV cylinder material mechanical parameters
Items Value Longitudinal modulus, E11/GPa 154 Transverse modulus, E22 =E33/GPa 11.4 In-plane shear modulus, G12=G13/GPa 4.8 Out-of-plane shear modulus, G23/GPa 3.8 Major Poisson's ratio, μ12 = μ13 0.3 Through-thickness Poisson's ratio, υ23 0.33 Longitudinal tensile strength, XT/GPa 2.5 Longitudinal compressive strength, XC/GPa 1.2 Transverse tensile strength, YT/MPa 70 Transverse compressive strength, YC/MPa 180 Density of laminate, ρ/(kg·m−3) 1600 Tensile fracture energy of fiber, Gft/(N·mm−1) 133 Compressive fracture energy of fiber, Gfc/(N·mm−1) 40 Tensile fracture energy of matrix, Gmt/(N·mm−1) 0.6 Compressive fracture energy of matrix,Gmc/(N·mm−1) 2.1 Elastic modulus of HDPE, E/GPa 1.1 Poisson's ratio of HDPE, μ 0.38 Yield strength of HDPE, σs/MPa 22.9 Ultimate strength of HDPE, σb/MPa 25 Fracture elongation of HDPE, δ/% >600 Elastic modulus of BOSS, E/GPa 69 Poisson's ratio of BOSS, μ 0.324 Yield strength of BOSS, σs/MPa 298 Ultimate strength of BOSS, σb/MPa 330 Fracture elongation of BOSS, δ/% 12
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表 3 气瓶爆破失效结果对比
Table 3. Comparison of burst failure results of cylinders
Number Method Pressure/MPa Burst location Error A Test 62.86 Transition region − Traditional method 68.00 Cylinder body +8.18% Reduction modified method 59.60 Transition region −5.19% B Test 49.21 BOSS − Traditional method 56.80 BOSS +15.42% Reduction modified method 52.20 BOSS +6.07% C Test 52.95 Cylinder body − Traditional method 56.40 Cylinder body +6.52% Reduction modified method 56.40 Cylinder body +6.52%
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