Impact of stacking sequence on burst pressure in glass/epoxy Type IV composite overwrapped pressure vessels for CNG storage

The shift from metallic to composite pressure vessels for storing compressed natural gas (CNG) is driven by the goal of reducing environmental impact by using lighter higher-performing structures. This work focuses on enhancing the internal pressure strength of a type IV composite overwrapped pressure vessel (COPV) by optimising the stacking sequence of the overwrapping composite layers. Parametric finite element (FE) models are developed to reveal symmetry effects. In these models, both the thickness build-up and fibre angle variation at the turnaround zones are accurately modelled. Subsequently, the stacking sequence is optimised with the objective function of maximising burst strength. The parametric modelling demonstrates that representing the COPV as an axisymmetric continuum reduces computational costs in 5400× while yielding results comparable to full 3D continuum models. Experimental burst tests are carried out to validate the numerical predictions, and the difference in pressure between them is 12.6 %.