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Optimisation of the Filament Winding Approach Using a Newly Developed In-House Uncertainty Model

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Optimisation of the Filament Winding Approach Using a Newly Developed In-House Uncertainty Model Article Optimisation of the Filament Winding Approach Using a Newly Developed In-House Uncertainty Model Nada Aldoumani 1, Cinzia Giannetti 2, Zakaria Abdallah 3,*, Fawzi Belblidia 1, Hamed Haddad Khodaparast 1 , Michael I. Friswell 1 and Johann Sienz 1 1 The Advanced Sustainable Manufacturing Technologies (ASTUTE) Project, Faculty of Science and Engineering, Swansea University, Swansea SA1 8EN, UK; [email protected] (N.A.); [email protected] (F.B.); [email protected] (H.H.K.); [email protected] (M.I.F.); [email protected] (J.S.) 2 The Future Manufacturing Research Institute (FMRI), Faculty of Science and Engineering, Swansea University, Swansea SA1 8EN, UK; [email protected] 3 The Steel and Metals Institute (SaMI), Faculty of Science and Engineering, Swansea University, Swansea SA2 8PP, UK * Correspondence: [email protected]; Tel.: +44-1792-6043-95 Received: 15 September 2020; Accepted: 10 October 2020; Published: 13 October 2020 Abstract: The device under investigation in this paper consists of a float used to capture tidal energy, which is tethered by multiple flexible cables to a large barge-like reactor. The proposed float is made of a continuously wound glass-reinforced composite shell with stainless steel bolting plates integrated into the float walls to allow the connection of 5 stainless steel cables. Numerical computations are required to assess whether a delamination of the composite layers in the float is likely. The manufacturing of the device has various potential uncertainties that should be investigated, such as the number of the plies, the bond strength between the composite layers, and the fibre orientations of the composite material relative to the applied load. This paper provides a multi-level strategy to optimise the composite float system, which is manufactured from glass-reinforced plastic (GRP). In contrast to previous publications on the topic, the current work uses an efficient link between ANSYS Workbench and MATLAB through an in-house code that has been developed over 3 years. This allowed the whole process to be fully automated and to reduce the time and cost of the simulations. Previously, ANSYS APDL was linked to MATLAB, but limitations in terms of the geometry and boundary conditions made it impractical when compared to ANSYS Workbench for the simulation of complex features. This makes the current approach unique and rare when compared to the published work in the field. This approach allows the use of a huge number of trials and is able to reduce the number of parameters to be studied by selecting the most sensitive ones. Additionally, the developed tools may be used for the efficient, robust optimisation of the proposed structure. The current study has focused on exploring the effects of the fibre orientations and the optimum number of plies on the overall performance of the structure. Keywords: robust design; floating systems; bond strength; composites; filament winding; uncertainty; ANSYS; MATLAB 1. Introduction 1.1. Background The device under investigation consists of a float that is tethered by multiple flexible cables to a large barge-like reactor to harvest tidal energy. The cables are attached to a hydraulic power take-off Eng 2020, 1, 122–136; doi:10.3390/eng1020008 www.mdpi.com/journal/eng Eng 2020, 1, FOR PEER REVIEW 2 of 15 Eng 2020, 1 123 The device under investigation consists of a float that is tethered by multiple flexible cables to a large barge-like reactor to harvest tidal energy. The cables are attached to a hydraulic power take-off system that captures the energy from the relative movement between the float float and and the the reactor, reactor, which is then converted to electricity. The proposed device has the potentialpotential to compete favourably with other available renewable technologies, since since the the proposed device relies on sea waves waves,, which are more consistent consistent than than wind wind and and offer offer an an average average power power density density of 2 of–3 2–3 W/m W2/,m which2, which is superior is superior to that to ofthat wind of wind (0.5 (0.5W/m W2)/ mand2) and solar solar energy energy (0. (0.1–0.31–0.3 W W/m/m2) 2[1])[1 Although] Although several several experiments experiments have have been conducted onon the the system, system, computational computational modelling modelling of the of devicethe device immersed immersed in sea waterin sea is water also required. is also required.The proposed The proposed float is made float of is a made continuously of a continuously wound glass-reinforced wound glass-reinforced composite composite shell with shell stainless with stainlesssteel bolting steel plates bolting integrated plates integrated into the floatinto the walls float to walls connect to connect the float the to afloat large to bargea large on barge the seabedon the seabedusing 5 using stainless 5 stainless steel cables, steel ascables, shown as inshown Figure in1 .Figure The barge 1. The hosts barge the hosts energy the harvesting energy harvesting devices devicesthat depend that ondepend the variation on the variation of the tension of the loads tension in the loads cables in the due cables to the due constrained to the constrained float movement. float Amovement. sub-modelling A sub technique-modelling is introducedtechnique withis introduced a layered (float)with a model layered and (float) a solid model (anchoring and system)a solid (anchoringmodel to fully system) explore model and to assess fully explore the stress and levels assess within the stress each oflevels the within winding each layers of the of thewinding float. layersThe integrity of the float. of the The bonding integrity between of the bonding the cable between connectors the cable and connectors the composite and layersthe composite under normal layers underoperation normal will operation also be investigated, will also be as investigated it represents, as a majorit represents potential a major weakness potential in the weakness integrity in of the integritystructure. of In the other structure. words, In the other existence words, of the high existence stress levels of high at stress the boundary levels at betweenthe boundary the anchoring between thesystem anchoring and the system float under and normalthe float operation under normal is one ofoperation the issues is thatone mightof the beissues encountered that might in thebe encounteredstructure. In additionin the structure. to locally In altering addition the to design locally in altering these zones the design to improve in these the zones structural to improve response, the it structuralis necessary response, to perform it is furthernecessary computations to perform further to assess computations if a delamination to assess of theif a floatdelamination layers is of likely, the floattaking layers into is account likely, taking the variable into account wave loading, the variable i.e., thewave development loading, i.e., of the faults development due to fatigue, of faults which due tois beyondfatigue, the which scope is of beyond the current the paper.scope Theof the system current suff erspaper. from The various system uncertainties, suffers from such various as the uncertaintiesnumber of plies, such in theas the top number and bottom of plies shells, in the the top strength and bottom of the steel shells, cable, the thestrength bond of strength the steel between cable, the steelbond plates strength and between the composite the steel layers, plates the and bond the strength composite between layers, the the composite bond strength layers, between and the fibre the comporientationsosite layers, of the and composite the fibre material orientations relative of to the the composite applied load. material The current relative study to the will applied concentrate load. Theon exploring current study the eff willects concentrate of the fibre orientationson exploring and the the effects number of the of pliesfibre onorientations the overall and performance the number of ofthe plies structure. on the overall performance of the structure. FiFiguregure 1. TheThe floating floating device in the energy harvesting system. The filamentfilament winding winding process process consists consists of two of main two elements: main elements: a filament- a or filament tape-type- reinforcementor tape-type reinforcementand a matrix or and resin. a matrix The process or resin. wraps The aprocess band ofwraps continuous a band resin-impregnated of continuous resin fibres-impregnated around a rotating mandrel, which is then cured at room temperature or in an oven under prescribed pressure 2 EngEng 2020,, 1, FOR PEER REVIEW 3 of124 15 fibres around a rotating mandrel, which is then cured at room temperature or in an oven under prescribedand temperature, pressure as shownand temperature, in Figure2. as The shown mechanical in Figure properties 2. The ofmechanical the final product properties depend of the on final the productmaterial, depend winding on angle, the material, fibre strength, winding resin angle, chemistry, fibre strength, and curing resin cycleschemistry [2]., The and filament curing cycles winding [2]. processThe filament has become winding very process popular has due become its the very attractive popular properties, due its the such attractive as its high properties stiffness-to-weight, such as its highratios. stiffness Such properties-to-weight have ratios. made Such this processproperties widely have used made in many this applications,process widely such used as in aerospace,in many applicationshydrospace,, andsuch military as in aerospace, applications. hydro Thespace reinforcement, and military and applications the matrix. canThe be reinforcement tailor-made inand order the matrixto satisfy can particular be tailor-made properties. in order The to windingsatisfy particular pattern isproperties. controlled The through winding the pattern rotational is controlled speed of throughthe mandrel the rotational and the movement speed of the of mandrel the fibre and feed the mechanism movement [3 of].
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