Mechanical performance and winding-angle optimization for high-pressure fracturing hose under internal pressure

High-pressure fracturing rubber hoses are key components in hydraulic fracturing systems, where they convey fracturing fluids under extreme internal pressures. Ensuring their reliability and performance remains challenge in structural hose design and optimization. This study examines the internal-pressure response and winding-angle optimization of an eight-layer steel-wire reinforced hose using full-scale experiments, analytical modeling, numerical simulation, and multi-objective optimization. Hydrostatic pressure tests with strain gauges and distributed fiber optic sensing (DFOS), together with burst testing, characterized hose behavior and validated a 3D model with hyperelastic rubber and embedded steel-wire reinforcement. The results indicate that under internal-pressure of the straight configuration, the conventional identical-angle design produces uneven load sharing and underutilizes the outer reinforcement layers. An ascending variable-angle design improves stress uniformity, increasing predicted burst pressure by 4.5% and steel-wire utilization by 65.7% at working pressure and 69.5% at burst pressure, while reducing axial deformation by 71.3%.