Wind turbine rotor blades are sophisticated, multipart, lightweight structures whose aeroelasticity-driven geometrical complexity and high strength-to-mass utilization lend themselves to the application of glass-fibre or carbon-fibre composite materials. Most manufacturing techniques involve separate production of the multi-material subcomponents of which a blade is comprised and which are commonly joined through adhesives. Adhesive joints are known to represent a weak link in the structural integrity of blades, where particularly, the trailing-edge joint is notorious for its susceptibility to damage. Empiricism tells that adhesive joints in blades often do not fulfil their expected lifetime, leading to considerable expenses because of repair or blade replacement. Owing to the complicated structural behaviour-in conjunction with the complex loading situation-literature about the root causes for adhesive joint failure in blades is scarce. This paper presents a comprehensive numerical investigation of energy release rates at the tip of a transversely oriented crack in the trailing edge of a 34m long blade for a 1.5MW wind turbine. First, results of a non-linear finite element analysis of a 3D blade model, compared with experimental data of a blade test conducted at Danmarks Tekniske Universitet (DTU) Wind Energy (Department of Wind Energy, Technical University of Denmark), showed to be in good agreement. Subsequently, the effects of geometrical non-linear cross-section deformation and trailing-edge wave formation on the energy release rates were investigated based on realistic aeroelastic load simulations. The paper concludes with a discussion about critical loading directions that trigger two different non-linear deformation mechanisms and their potential impact on adhesive trailing-edge joint failure.
This study demonstrates an advanced blade modelling approach based on a combination of shell and solid elements which can enhance the reliability of structural predictions for wind turbine blades. The advanced blade modelling approach is based on a shell element model where the adhesive bondline in the trailing edge region is discretised by means of solid brick elements which are connected via Multi-Point-Constraint to the shell elements. The new approach overcomes the drawbacks of pure shell element simulations and can reliably predict the response of wind turbine blade structures which are exposed to ultimate loads. The prediction accuracy of the numerical simulations was compared to a certication load case and a full-scale ultimate limit state test of a 34m wind turbine rotor blade. The displacements, stresses and strains show reasonably good agreement and demonstrate the capabilities of the advanced blade modelling approach.
Wind turbine blades are exposed to numerous impact risks throughout their lifetimes. The impact risks range from bird collisions during operation to impacts with surrounding structures at the time of transportation and installation. Impact loads on the fibre composite blades can induce several complex, simultaneously interacting and visually undetectable damage modes and have a high potential to reduce the local and global blade sti↵ness. An assessment of such impact-induced damages is therefore necessary and usually involves high computational costs using numerical procedures, especially when analysing large composite components. To minimise this computational expense, di↵erent numerical impact modelling techniques are utilised, primarily shell-element-based approaches and multiscale-modelling-based global-local approaches. In this article, a comparison between (1) pure shell, (2) shellto-solid coupling, and (3) submodelling finite element modelling techniques using Abaqus/Explicit is presented for a case where an impactor hits the leading edge of a blade. A high-fidelity local solid finite element model is developed for the leading edge of a DTU 10 MW blade at the region of impact and its sti↵ness is compared with baseline. A user material subroutine VUMAT for the intralaminar damage mode based on the Hashin failure criterion is formulated and then validated via an experiment from the literature. Finally, based on di↵erent numerical modelling techniques, impact investigations are performed, and the impact responses, damage to the blade and computational analysis durations are compared. It is found that the submodelling-based global-local approach is the most e cient analysis technique for this case, capturing failure modes including delamination, core crushing and local surface indentation in the blade. The findings of this study can be used to develop accurate and computationally e cient tools for modelling impact-induced damage to a blade.
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