Impact of winding parameters on the fiber bandwidth in the cylindrical area of a hydrogen pressure vessel for generating a digital twin

Abstract The wet winding process is an established manufacturing technology for the production of rotationally symmetrical components made of fiber‐reinforced plastic (FRP), such as type‐IV hydrogen pressure vessels. In this process, the FRP laminate is produced by continuously depositing an impregnated fiber band on the winding core in a winding pattern adapted to the component stress. Despite a long history of the process, there are shortcomings in the understanding of the process, without which further optimization in terms of cost and material efficiency will reach its limits in the future. Currently, the fiber band is assumed to have a constant rectangular cross‐section in most simulations, which neglects manufacturing influences such as fiber spreading. The investigations carried out aim to extend the process understanding by a realistic description of the fiber bandwidth when deposited on the winding core. The investigations show that the fiber spreading, as well as the absolute fiber bandwidth, depend on the resin loading and the fiber band tension, independent of the winding pattern in the cylindrical area of a pressure vessel shaped winding core. In addition, the fiber bandwidth changes by 15%–20% during circumferential winding, depending on the machine movement.