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AberdeenUniversityPhDResearchProposal"OptimalDesignofFibreReinforcedCompositePipes"

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[Type text] Page 1

Optimal Design of Fibre Reinforced Composite Pipes

June 21, 2013

PhD Candidate

Saeed KIA

Supervisors

Dr Oleksandr Menshykov

Professor Igor Guz

Graduate School

College of Physical Sciences

The University of Aberdeen


Research Proposal Page 2

Contents1. Introduction................................................................................................................................. 3

1.1. Background of the Study...................................................................................................... 4

1.2. Problem Statement ............................................................................................................... 5

1.2.1. Research Questions........................................................................................................ 6

1.3. Objectives............................................................................................................................. 6

1.4. Significance of Study ........................................................................................................... 6

2. Methodology ............................................................................................................................... 7

2.1. Research Design................................................................................................................... 7

2.2. Formulation of the objective function .................................................................................. 7

2.3. Optimization Variables ........................................................................................................ 7

2.4. Optimization procedure........................................................................................................ 8

2.5. Timescale ............................................................................................................................. 9

3. Conclusion ................................................................................................................................ 11

References..................................................................................................................................... 12

List of Figures

Figure 1: Timescale from September 2012 to December 2013 .................................................... 10Figure 2: Timescale from January 2014 to December 2014......................................................... 10Figure 3: Timescale from January 2015 to December 2015......................................................... 11



1. Introduction

Nowadays, the fibre reinforced composite pipes have been widely employed in various fields

including the airplane, fuel cell vehicle, and electricity generation and communication power

systems due to their advantages such as high strength and stiffness to weight ratio, excellent

resistance to fatigue and corrosion as well as satisfactory durability. In general, the fibre

reinforced composite pipes are used to manufacture the laminated composites by deploying the

fibers in several unidirectional layers and all fibers have a common orientation in each layer, and

these layers are stacked in angled orientations to achieve high stiffness and strength in different

directions. Since the stiffness and strength of an individual layer are much higher in the fiber

direction than in the transverse direction, the designable composite layers sufficiently bring the

mechanical performance in the fibre reinforced composite principal orientations into play in

order to suit the anticipated load-bearing distributions.

The design of the fibre reinforced composite pipes associates the physical and mechanical

properties of materials with the geometry shapes of structure. Before the composite pipes

optimization which aims to achieve the perfect matching between the mechanical performance,

thickness of layers and weight, an initial exploration of the composite pipes load carrying

capacity which is represented by the structural failure and damage behavior is required for

reliable and economical design of this structure. Various failure modes may be provoked under

complex loading and these failure modes may continue to evolve with external loads, and the

damage evolution behavior of composite laminates depends on these failure modes to some

extent. Thus, the knowledge of the damage mechanisms of composite pipes plays an important

role in instructing the practical design and optimization of composite structures.



Although fiber reinforced composite materials are demanded by oil and gas industry because of

their high specific stiffness or strength especially for applications where weight reduction is

critical. By using composites, weight of a structure can be reduced significantly. Further

reduction is also possible by optimizing the material system itself such as fiber orientations, ply

thickness, stacking sequence, etc. Many researchers attempted to make a better use of material

either by minimizing the laminate thickness, thus reducing the weight, or by maximizing static

strength of composite laminates for a given thickness. By this research proposal, researcher is

going to find optimized fibre reinforced composite pipes for the oil and gas industry, onshore and

offshore. The most significant criteria have been made in the areas of composite pipe work and

fluid handling, driven by light weight and corrosion resistance compared to metals. Based on this

optimization of fibre reinforced composite pipes in many cases the purchase cost of composite

components exceeds that of their metallic counterparts. However, because of their relative ease

of handling the installed cost, especially of composite pipe systems, is often lower than that of

conventional steels. The cost advantages are even greater when composites replace expensive

corrosion resistant metals such as copper nickel alloys, duplex or super duplex stainless steel or

even titanium. Their corrosion resistance also improves reliability and leads to lower through-life

costs.

1.1. Background of the Study

Fibre reinforced composite pipes have been commonly used in many engineering applications

because of their high specific strength and stiffness, fatigue and corrosion resistances. In some

applications these pipes are exposed to hostile environmental conditions which cause

degradation of their material properties. These composite pipes may be subjected to transverse

impact loading, which causes various damages in the pipe such as matrix crack, delamination,



fiber breaking, fiber matrix de-bonding and fiber pull out. These damages may cause

considerable reduction in structural stiffness of composite pipes.

During recent years, many researchers have made efforts to analyze the impact behavior of

composite structures. However, so far, only a few studies have been devoted to investigate

optimization and or impact effects on cylindrical curved composite structures. Some researches

just studied effects of an optimization procedure is proposed to minimize thickness (or weight) of

laminated composite plates subject to complex load combinations. Composite fiber shape and

layer thickness are chosen as design variables by optimization search algorithm to simulate pipe

which lead to reliable optimal design.

1.2. Problem Statement

Currently, the application of composite materials in oil and gas industry lacks proven test

methodologies and understanding of technical and fundamental issues relevant specifically to

composite materials and structures. Thus, the main academic challenge and key aspect to the

success of the project is the transfer of composite materials knowledge (theoretical and

numerical models very successfully used in the modern aerospace industry), into the demanding

oil and gas sector. This extremely interesting and challenging project will deal with the

assessment of composite pipes subjected to a combination of complex loading and harsh

environmental conditions (such as high temperature, high pressure and exposure to corrosive

fluids’). In order to move the technology forward it is necessary to have a detailed understanding

of the pipes properties from manufacture and over its entire life cycle.



1.2.1. Research Questions

The overall aim of this research project will be optimal design of thick and thin walled composite

pipes. The developed numerical model should be able to predict the deformation and damage

under tension, compression and bending, as found in service (during installation in oil wells).

1. Find appropriate optimization algorithm for optimal design of thick and thin walled

composite pipes.

2. Find optimization procedure to propose maximize safety factor subjected to complex load

combination and structural design criteria.

3. Find heuristic optimization algorithm procedure between structural design and complex

loading with harsh environmental conditions.

1.3. Objectives

The objectives of the research project are to find optimization algorithm based on complex

structural loading with relation of these constrains:

1. Different types of the matrix and the reinforcement used

2. Different fibre volume fractions

3. Different layouts of the reinforcement (unidirectional versus multidirectional, etc.)

4. Combinations of laminas with different reinforcement directions

1.4. Significance of Study

The significance of the study will be to:

1. Find and improve optimal design of thick and thin walled composite pipes.

2. Find and improve appropriate relation between objective constrains and composite pipes

mechanical analysis.



2. Methodology

This section presents an overview of the methods to use in the study. Areas covered include there

search design, population, sample and sampling techniques, data collection and analysis

2.1. Research Design

The study will involve the evaluating the optimal design of fibre reinforced composite pipes.

Consequently, the research will be designed to achieve the objectives set out by the researcher.

2.2. Formulation of the objective function

Objective function is a function used to classify designs. For every possible design, it returns a

number which indicates the goodness of the design. Usually we choose such that a small value is

better than a large one (a minimization problem). Frequently it measures weight, displacement in

a given direction, effective stress or even cost of production. So failure of any signals inception

in optimized fibre reinforced composite pipes by defined objective function will be failure of the

whole structure, even though its ultimate load bearing capacity may not be exceeded. For this

reason, this is considered as a design limit. Accordingly, the first failure approach is adopted in

the design optimization and safety of each lamina in a composite pipes design generated during

the optimization process is checked using maximum stress failure criteria. If a configuration

generated during the optimization procedure leads to failure according to the failure criteria, a

penalty value is calculated and added to the cost function. The overall objective function may

then be expressed by theoretical an experimental researches.

2.3. Optimization Variables

The following function and variables are always present in a fibre reinforced composite pipes

problem:



Design variable which are function or vector that describes the design, and which can be

changed during optimization. It may represent geometry or choice of material. When it

describes geometry, it may relate to a sophisticated interpolation of shape or it may

simply be the area of a bar, or the thickness of a sheet. Is this problem are:

Different types of the matrix and the reinforcement used

Different fibre volume fractions

Different layouts of the reinforcement

Combinations of laminas with different reinforcement directions

State variable: For a given structure for a given design is a function or vector that

represents the response of the structure. For a mechanical structure, response means

displacement, stress, strain or force such as:

Deformation and damage under tension

Compression

Bending

Service Loads during installation in oil wells

2.4. Optimization procedure

In research, a variant of methods of operations research algorithm such as ‘‘Mathematical

Programming Techniques” will used to minimize the thickness of laminated composite structures

subject to complex load combinations. The application of heuristic optimization search algorithm

to optimization of composite materials was explained and find suitable one for this project. Main

algorithms which I use in my M.Sc. thesis about “Durability-Based Optimization of Reinforced

Concrete Reservoirs” are:

Particle Swarm Optimization Algorithm



Ant Colony Optimization Algorithm

Artificial Bee Colony Algorithm

Genetic Algorithm

Neural Networks Algorithm

Nonlinear Programming

Multi-Objective Programming

So by using optimization algorithm and the measures on structural performance indicated are

purely mechanical will lead to make clear the position of fibre reinforced composite pipes

optimization in relation to such, usually not mathematically defined, factors, we give a short

indication of the main steps in the process of designing a product in general. For mechanical

structures of fibre reinforced composite pipes performed by means of computer based methods

like the Finite Element Method (FEM) or Multi Body Dynamics (MBD) such as ANSYS and

ABAQUS software packages with MATLAB optimization algorithm programming. These

methods imply that all design iteration can be analyzed with greater confidence and probably

every step can be made more effective. However, they do not lead to a basic change of the

strategy.

2.5. Timescale

Approximate timetable for the research proposal illustrated as figure 1 to 3 which divided in to

three years from September 2013 to December 2015.



Figure 1: Timescale from September 2012 to December 2013

Figure 2: Timescale from January 2014 to December 2014

Jan. Feb. March April May Jun July Aug. Sep. Oct. Nov. Dec.

1 Review of literature

2 Draft literature review

3 Agree research strategy with supervisors

2013SubjectNo


4Agree about structural modeling and analysiswith supervisors

5Agree about find best and suitableoptimization algorithm with supervisors

6Agree about find related objective functionand variables with supervisors

7Agee about optimization MATLAB codingwith supervisors with supervisors

8Compare theoretical research results withoperational by other researchers

9Compare theoretical research results with finallaboratory composite pipe models

2014No Subject



Figure 3: Timescale from January 2015 to December 2015

3. Conclusion

In this research proposal, an optimization methodology for shape design and weight

minimization of fibre reinforced composite pipes under complex loading and harsh

environmental conditions (such as high temperature, high pressure and exposure to corrosive

fluids’, etc.). Methods were proposed in order to overcome the difficulties faced by the previous

researchers and introduce new way of optimization. The mentioned optimization algorithm was

adopted as search algorithm to find relation between structure shape and variables such as

material matrix and the reinforcement, fibre volume fractions, layouts of the reinforcement and

combinations of laminas with different reinforcements. The optimization algorithm proved to be

quite reliable in locating these designs for different materials, fiber orientation and different for

the loading combinations. In optimization cases, the optimal designs can be counter intuitive so

sometimes, when one component of loading is increased, load bearing capacity of the optimized


10 Invesitage results with supervisors

11

Back and forward process to find global bestpoint position for Fibre Reinforced CompositePipes based on variables and objectivefunction

12Check final optimization application coding,review analysis and optimization algorithm

13 Final writing of project report

14 Final Presentiona and related documentaion

No Subject2015



laminate may increase. Therefore, a design process for composite materials should be based on

theoretical with intuition or laboratory experiences.

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