Simulation Analysis and Optimization Design of Dome Structure in Filament Wound Composite Shells.

Carbon fiber-reinforced composites are widely used in the aerospace industry due to their exceptional mechanical properties. However, the dome region of composite pressure vessels is prone to stress concentrations under internal pressure, often resulting in premature failure and reduced burst strength. This study developed a finite element model of a reinforced dome structure, which showed excellent agreement with hydrostatic test results, with less than 5.9% deviation in strain measurements. To optimize key reinforcement parameters, a high-accuracy surrogate model based on a backpropagation neural network was integrated with a multi-objective genetic algorithm. The results indicate that compared to the unreinforced dome, the optimized structure reduced the maximum fiber-aligned stress in the dome region by 6.8%; moreover, it achieved a 9.3% reduction in overall mass compared to the unoptimized reinforced configuration. These findings contribute to the structural optimization of composite pressure vessel domes.