Design optimization of type 4 composite pressure vessel considering the effects of fabrication conditions

This study presents a computational method for thermo-structural and free vibration analysis of type-4 composite pressure vessels that explicitly incorporates the effects of fabrication conditions. The method is based on the principle of minimum total energy and enables calculation of residual stresses from manufacturing processes, failure indices under operational loads, and natural frequencies. Validation of the method is demonstrated by comparison with numerical analyses from other studies on type-4 composite pressure vessels. An optimization approach is proposed to achieve a lightweight design while considering residual stresses and operational constraints. The resulting optimal vessel design ensures structural integrity under operational conditions with a mass of 23.55 kg. The framework could serve as a foundation for building a database of structural and vibrational characteristics for mechanical and aerospace applications. The validation results demonstrate that the proposed approach is suitable for such applications due to its relative simplicity and computational efficiency. • Proposed framework for thermo-structural and vibration analysis of type-4 vessels. • Optimization minimizes weight considering residual stresses and operational limits. • 3D FE analyses evaluate thermo-mechanical and vibrational properties of optimized vessel. • Validation confirms high efficiency, making it useful for advanced design and analysis.