FEA Design Optimization of Multi-layered Pressure and Tensile Armour for Internal Pressure Loading

Project Overview

This project focused on ensuring the structural integrity of a multi-layered cylindrical Pressure Armour system subjected to internal pressure. The objective was to understand how material properties and geometry influence stress distribution for optimal design and durability. A finite element analysis (FEA) model was developed in ANSYS, comprising a cylindrical core and two helical wire-wrapped outer layers. Parametric studies evaluated the impact of Ultimate Tensile Strength (UTS) and Outer Diameter (OD) on average equivalent (von Mises) stress. Response surface modeling and sensitivity analysis mapped the design space and identified critical drivers. The analysis conclusively demonstrated that outer diameter is the most dominant factor in reducing structural stress. An optimal design strategy involves maximizing OD within practical limits and carefully selecting materials with a moderate UTS (around 950-970 MPa), as excessively high UTS can lead to stiffness mismatch. This approach significantly enhances the system's structural integrity.