A Critical Evaluation of Structural Analysis Tools used for the Design of Large Composite Wind Turbine Rotor Blades under Ultimate and Cycle Loading

Rotor blades for 10-20MW wind turbines may exceed 120m. To meet the demanding requirements of the blade design, structural analysis tools have been developed individually and combined with commercial available ones by blade designers. Due to the various available codes, understanding and estimating the uncertainty introduced in the design calculations by using these tools is needed to allow assessment of the effectiveness of any future design modification. For quantifying the introduced uncertainty a reference base was established within INNWIND.EU in which the several structural analysis concepts are evaluated. This paper shows the major findings of the comparative work performed by six organizations (universities and research institutes) participating in the benchmark exercise. The case concerns a 90m Glass/Epoxy blade of a horizontal axis 10MW wind turbine. The detailed blade geometry, the material properties of the constitutive layers and the aero-elastic loads formed the base by which global and local blade stiffness and strength are evaluated and compared. Static, modal, buckling and fatigue analysis of the blade were performed by each partner using their own tools; fully in-house developed or combined with commercially available ones, with its specific structural analysis approach (thin wall theory and finite element models using beam, shell or solid elements) and their preferable analysis type (linear or geometrical non-linear). Along with sectional mass and stiffness properties, the outcome is compared in terms of displacements, stresses, strains and failure indices at the ply level of the blade structure, eigen-frequencies and eigen-modes, critical buckling loads and Palmgren-Miner damage indices due to cycle loading. Results indicate that differences between estimations range from 0.5% to even 40%, depending on the property compared. Modelling details, e.g. load application on the numerical models and assumptions, e.g. type of analysis, lead to these differences. The paper covers these subjects, presenting the modelling uncertainty derived

A Benchmark on Lifetime Prediction of Composite Materials under Fatigue

The present paper describes a benchmarking programme to compare different lifetime prediction methodologies. Lifetime prediction is still a complex task and the results depend on many factors. Thus, it is very important to know which factors have a decisive effect on the results. The main objective of this investigation is not to proof the validity of a certain prediction model, but to quantify the influence of each step of the prediction process on the results using different methodologies

Structural optimization of wind turbine rotor blades by multilevel sectional/multibody/3D-FEM analysis

The present work describes a method for the structural optimization of wind turbine rotor blades for given prescribed aerodynamic shape. The proposed approach operates at various description levels producing cost-minimizing solutions that satisfy desired design constraints at the finest modeling level. At first, a "coarse"-level constrained design optimization is performed by using a 1D spatial geometrically exact beam model for aero-servo-elastic multibody analysis and load calculation, integrated with a 2D FEM cross sectional model for stress/strain analysis, and the evaluation of the 1D model fully-populated cross sectional stiffness matrices. Next, a "fine"-level 3D FEM model is used for the refinement of the coarse-level solution. Improved results obtained at the level of the 3D model are utilized at the following coarse-level iteration through a heuristic modification of the design constraints. In addition, a buckling analysis is performed at the fine description level, which in turn affects the nonstructural blade mass. The updated constraint bounds and mass make their effects felt at the next coarse-level constrained design optimization, thereby closing the loop between the coarse and fine description levels. The multilevel optimization procedure is implemented in a computer program and it is demonstrated on the design of a multi-MW horizontal axis wind turbine rotor blade