A multi-scale fatigue life prediction methodology of composite pressure vessels subjected to multi-axial loading has been proposed in this paper. The multi-scale approach starts from the constituents, fiber, matrix and interface, leading to predict behavior of ply, laminates and eventually the composite structures. The life prediction methodology is composed of two steps: macro stress analysis and micro mechanics of failure based on fatigue analysis. In the macro stress analysis, multiaxial fatigue loading acting at laminate is determined from finite element analysis (FEM) of composite pressure vessel, and ply stresses are computed using a classical laminate theory (CLT). The micro-scale stresses are calculated in each constituent (i.e. matrix, interface, and fiber) from ply stresses using a micromechanical model. Micromechanics of failure (MMF) was originally developed to predict the strength of composites and now extended to prediction of fatigue life. Two methods are employed in predicting fatigue life of each constituent, i.e. an equivalent stress method for multi-axially loaded matrix, and a critical plane method for the interface. A modified Goodman diagram is used to take into account the generic mean stresses. Damages from each loading cycle are accumulated using Miner’s rule. Each fiber is assumed to follow a probabilistic failure depending on the length. Using the overall micro and macro models established in this study, Monte Carlo simulation has been performed to predict the overall fatigue life of a composite pressure vessel considering statistical distribution of material properties of each constituent and manufacturing winding helical angle.

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