Residual Axial Deformation and Buckling Analysis of Thin-Walled Carbon Fiber Fully Wound Composite Gas Cylinders
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摘要: 针对钛合金薄壁内胆碳纤维全缠绕复合材料气瓶水压试验后轴向缩短及内胆局部发生屈曲失稳现象，开展了试验研究及有限元分析. 结果表明：自紧加卸载后，封头靠近极孔区域沿轴向向内凹陷，封头靠近赤道区域沿径向向外扩张，封头整体沿轴向变短，试验和有限元计算的轴向缩短量为6.15 mm和6.363 mm，误差为3.46%，有限元计算结果与试验结果具有很好的一致性. 最后，采用多极孔法优化封头纤维层厚度分布，封头厚度极值降低32.6%，过渡更加均匀，优化后的气瓶沿轴向略有伸长，平均伸长为0.6 mm，采用CT和内窥镜检测，内胆均未出现屈曲失稳，有效地解决了水压试验后轴向缩短及内胆屈曲问题.Abstract: Experimental research and finite element analysis were carried out to study the phenomenon of axial shortening and buckling instability of carbon fiber fully wound composite gas cylinders with titanium alloy thin-wall liners after hydraulic test. The results show that, after self-tightening and unloading, the area near the polar hole of the head will be concave axially, the area near the equator of the head will expand radially, and the whole head will become shorter axially. The axial shortening of the head will be 6.15 mm and 6.363 mm, respectively, and the error of the finite element calculation will be 3.46%. The finite element simulation results are in good agreement with the experimental results. Finally, the multi-pole hole method was used to optimize the thickness distribution of the fiber layer of the head, and the extreme thickness of the head was reduced by 32.6%, and the transition was made smoother. After the optimization, the gas cylinder will be slightly extended along the axis, with an average elongation of 0.6 mm. By CT and endoscope detections, no buckling instability would appear in the liner, which means an effective solution of the problems of axial shortening and liner buckling after hydraulic tests.
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Key words:
- composite gas cylinder /
- thin-walled liner /
- titanium alloy /
- residual deformation /
- buckling
edited-byedited-by1) (我刊青年编委田阔推荐) -
图 6 水压试验压力卸载后轴向位移云图
注 为了解释图中的颜色，读者可以参考本文的电子网页版本，后同.
Figure 6. The contour of axial displacements after unloading of hydraulic test pressure
图 7 52.5 MPa时，内胆等效应力云图
Figure 7. The equivalent stress contour of the inner liner at 52.5 MPa
图 8 52.5 MPa时，内胆等效塑性应变云图
Figure 8. The equivalent plastic strain contour of the inner liner at 52.5 MPa
图 9 52.5 MPa时，内胆径向位移云图
Figure 9. The contour of radial displacements of the inner liner at 52.5 MPa
图 10 水压卸载后的内胆径向应变云图
Figure 10. The radial strain contour of the inner liner after hydraulic unloading
图 11 封头曲面加卸载前后轮廓变化
Figure 11. Profile changes before and after loading and unloading of the head surface
图 12 水压卸载后内胆等效应力云图
Figure 12. The equivalent stress contour of the inner liner after hydraulic unloading
图 13 水压卸载后内胆等效塑性应变云图
Figure 13. The equivalent plastic strain contour of the inner liner after hydraulic unloading
图 15 刚度优化后的封头有限元网格模型
Figure 15. The finite element mesh model of the head after stiffness optimization
图 16 扩孔前后纤维厚度随平行圆变化曲线
Figure 16. Curves of fiber thicknesses with the parallel circle before and after reaming
图 18 内胆内壁水压时内胆径向位移分布
Figure 18. Radial displacement distributions under pressure on inner wall of the liner
图 19 内胆内壁水压卸载后的内胆轴向位移分布
Figure 19. Axial displacement distributions of the inner liner after water pressure unloading
图 20 内胆内壁水压时内胆等效塑性应变分布
Figure 20. Equivalent plastic strain distributions under pressure on inner wall of the liner
图 21 内胆内壁水压卸载后的内胆等效塑性应变分布
Figure 21. Equivalent plastic strain distributions of the inner liner after hydraulic unloading
图 22 封头曲面加卸载前后轮廓变化
Figure 22. Profile changes before and after loading and unloading of the head surface
表 1 气瓶水压试验数据
Table 1. Water pressure test data of the gas cylinder
cylinder number residual deformation after loading and unloading dR/mm is the liner buckling and instable? C1 -6.20 yes C2 -6.00 yes C3 -6.10 yes C4 -6.30 yes 
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表 2 钛合金试样拉伸性能测试数据
Table 2. Tensile property test data of titanium alloy specimens
number yield strength Rp0.2/MPa tensile strength Rm/MPa elastic modulus E/GPa S1 328.43 451.06 102.91 S2 322.39 447.26 101.65 S3 325.09 447.29 109.58 S4 321.63 446.45 105.57 S5 343.99 458.51 108.03 S6 348.93 465.95 107.41 S7 350.12 470.68 106.83 S8 347.16 465.40 108.16
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表 3 钛内胆主要性能参数(前封头、前筒身段)
Table 3. Main performance parameters of the titanium liner (front head, front cylinder section)
elastic modulus E/GPa Poisson’s ratio μ yield strength Rp0.2/MPa tensile strength Rm/MPa elongation after fracture δ/% 104.9 0.3 324 448 32
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表 4 钛内胆主要性能参数(后封头、后筒身段)
Table 4. Main performance parameters of the titanium liner (rear head, rear cylinder section)
elastic modulus E/GPa Poisson’s ratio μ yield strength Rp0.2/MPa tensile strength Rm/MPa elongation after fracture δ/% 107.6 0.3 347 465 34
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表 5 T1000级碳纤维/环氧树脂层性能参数
Table 5. T1000 carbon fiber/epoxy resin layer performance parameters
E1/GPa E2/GPa E3/GPa μ12 μ23 μ13 G12/GPa G23/GPa G13/GPa 193.1 11.41 11.41 0.33 0.49 0.33 7.09 3.79 7.09
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表 6 水压压力加卸载后各部分变形计算值
Table 6. Calculated deformation values of each part after hydraulic pressure loading and unloading
front head dFH/mm front body section dFB/mm rear body section dRB/mm rear head dRH/mm total dT/mm -3.297 1.318 1.530 -3.340 -6.363
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