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Composite Structures
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Article history:
Available online 7 August 2015
Keywords:
Fatigue
Failure
Delamination
Wind turbine blade
Bumping motion
a b s t r a c t
As blade failures at wind farms have increased, the structural safety of composite wind turbine blades is
ever more important. The recent implementation of considerably larger blades has made the problem
even more crucial. One of the critical failure modes is the blade root failure, which can result in the blade
being pulled out from its wind turbine during operation. In this study, we experienced delamination failure at the blade root during fatigue testing of a 3 MW full-scale wind turbine blade according to international standard IEC 61400-23: full-scale structural testing of rotor blades. Comparing the measured data
with the FE analysis results, we simulated the situations the blade had experienced, and then found what
caused the delamination failure as well as the problem of the conventional design approach. The bumping motions of the blade shell caused by geometric complexities between the maximum chord and the
root alter significantly the load distribution at the end of the blade root. Therefore, to enhance the structural safety of a large composite wind turbine blade, a more detailed FE analysis on the blade root in the
design stage is needed.
2015 Elsevier Ltd. All rights reserved.
1. Introduction
With the recent trend toward large slender wind turbine blades,
questions are being raised regarding their reliability. In order to
evaluate the static strengths and fatigue lives of these larger
blades, static and fatigue tests of full-scale prototype blades should
be conducted according to international standards or equivalent
guidelines [14]. Testing methodologies developed so far are well
described in the two review papers of Malhotra et al. [5] and
Yang et al. [6].
Previous studies pertaining to static strength of a full-scale
wind turbine blade are as follows. Jensen et al. [7] tested a 34 m
composite wind turbine blade until its structural collapse.
Debonding of the outer skin was the initial failure mechanism, followed by delamination buckling which led to the blades collapse.
Jensen et al. believed the main root cause was the Braizer effect of
the shell structure due to bending. Overgaard et al. [89] carried
out a static flapwise bending test of a 25 m wind turbine blade
to collapse. The Brazier effect had a large influence on the local
out-of-plane deflection, but its influence on the longitudinal strain
level in the primary load-carrying laminate was insignificant.
Overgaard et al. assert that the structural stability of the generic
wind turbine blade has been governed by buckling and the
delamination phenomena. Yang et al. [10] conducted a static test
Corresponding author. Tel.: +82 55 280 3261; fax: +82 55 280 3498.
E-mail address: hakgulee@kims.re.kr (H.G. Lee).
http://dx.doi.org/10.1016/j.compstruct.2015.08.010
0263-8223/ 2015 Elsevier Ltd. All rights reserved.
dealt with small wind turbine blades that have relatively higher
fatigue margins than the large slender wind turbine blades
presently in development.
Another approach to enhance the reliability of a wind turbine
blade is an FE fatigue simulation for the blade. Kong et al. [17,18]
designed a 750 kW wind turbine blade, factoring in its fatigue life
of 20 years based on the well-known SN linear damage equation,
the load spectrum, and Speras empirical equations. Shokrieh et al.
[19] performed a case study with a 23 m wind turbine blade. Using
its FE shell model with a stochastic approach on fatigue loads, the
fatigue life was bounded between 18.66 years and 24 years as
lower and upper limits. Toft et al. [20] estimated the reliability of
a wind turbine blade for a single failure mode, considering statistical uncertainties.
Despite such contributions by many researchers, about 30 blade
failures are occurring per year throughout the world, and the number of blade failure are increasing over time [21]. There have been
blade failures not observed in previous studies which have
occurred in the field at Eclipse wind farm and Ocotillo wind farm
in 2013. In these instances, the wind turbine blades were pulled
out from the wind turbines due to delamination at the root. The
authors of this paper have also experienced a similar phenomenon
during fatigue testing of a 3 MW full-scale wind turbine blade. To
find a root cause of the phenomenon, loading conditions calculated
by its FE shell model were applied to the more detailed FE solid
model of the root subcomponent. Comparing the analysis results
with measured strain data of the T-bolt, we adjusted loading conditions of the FE solid model to simulate deformations and stress
distributions of the blade root. Based on the simulation results, this
study has found one of the plausible root causes able to incur
delamination at the root of a wind turbine blade.
879
880
Table 1
Specifications of the M36 T-bolt used in this study.
Grade
Min. diameter
[mm]
Pretension
[kN]
Prestress
[MPa]
10.9
28
340
552
940
Fig. 6. Strain values measured by two different strain gages attached at the same cross section of the T-bolt: (a) strain gage 1 and (b) strain gage 2.
881
Fig. 8. Flowchart of the root cause analysis taking the fatigue testing conditions into account.
882
Table 2
FE shell model for the test blade.
Element type
No. of the
elements
Boundary condition
ABAQUS
6.13
57,969
Clamped condition at
the root
G23
E2
21 v 23
Element type
No. of the
elements
Boundary conditions
ABAQUS 6.13
8 node solid
element(C3D8I)
53,629
the FE shell model, which were applied to the cross section of the
blade root part along the spanwise direction and the hoop direction, respectively.
Equivalent orthotropic properties of the blade root laminate
whose stacking sequence is [45/0/45]n were generated for the
convenience of FE modeling with solid elements. Classical laminated plate theory (CLPT) cannot calculate whole equivalent orthotropic properties because even interlaminar stresses at the
interface of two laminae are discontinuous [23]. CLPT gives us only
in-plane laminate properties such as Ex, Ey, vxy, and Gxy and
through-thickness Poissons ratios such as vxz and vyz, which are
calculated from Eqs. (2)(4) [22].
FE solver
FE solver
v xz
v yz
Fi
1
1
A1
11 F 1 A12 F 2 A16 F 6
2HA1
11
1
1
A1
21 F 1 A22 F 2 A26 F 6
2HA1
22
N
X
k k
S Q
k k k k
i 1; 2; 6
13 1i S23 Q 2i S36 Q 6i t k
k1
E2
[GPa]
E3
[GPa]
v12
v13
v23
G12
[GPa]
G13
[GPa]
G23
[GPa]
40.14
12.30
12.30
0.26
0.26
0.38
3.40
3.40
4.44
Table 5
Properties of the [45/0/45]n laminate.
Ex
[GPa]
Ey
[GPa]
Ez
[GPa]
vxy
vxz
vyz
Gxy
[GPa]
Gxz
[GPa]
Gyz
[GPa]
30.69
13.44
12.70
0.42
0.21
0.34
6.26
3.55
4.21
883
Fig. 11. Comparison between the results of the FE shell model and those of the conventional approach: (a) axial force distribution and (b) local moment distribution.
Fig. 12. Bumping motion of the blade shell during the fatigue testing.
5. Analysis results
Fig. 13. Comparison between the measured and the calculated strain ranges.
884
Fig. 14. Partial separation between the blade root and the pitch bearing.
Fig. 15. Stress distributions that incur delamination at the end of the blade root.
Fig. 16. Schematic diagram of the blade root failure caused by delamination followed by crack propagation.
885
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