Numerical Simulation and Characterization of Slurry Erosion of Laser Cladded Surfaces by Using Failure Analysis Approach

Yarrapareddy, Eswar; Kovacevic, Radovan

doi:10.1007/s11668-007-9083-8

Cited by 7 publications

(4 citation statements)

References 14 publications

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“…Some researchers have completely dismissed the option of analytical or numerical solutions and have adopted a fully probabilistic approach [26], while others have proposed expensive explicit dynamics simulations as a viable choice for the simulation of repeated impact scenarios [27] and protective coating evaluations [28]. Above all, it is apparent that raindrop impingement erosion should be looked at as a system's property rather than a material's property, in which the operational conditions of the wind turbine are taken into account as well [29].…”

Section: Introductionmentioning

confidence: 99%

A computational framework for the analysis of rain-induced erosion in wind turbine blades, part I: Stochastic rain texture model and drop impact simulations

Amirzadeh

Louhghalam

Raessi

et al. 2017

Journal of Wind Engineering and Industrial Aerodynamics

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In the past decade, the power output of wind turbines has increased significantly. This increase has been primarily achieved through manufacturing larger blades resulting in high blade tip velocities and increased susceptibility to rain erosion. This paper is the first part in a two-part paper that presents a framework for the analysis of rain erosion in wind turbine blades. Two ingredients of the framework are presented. A stochastic rain texture model is developed to generate three-dimensional fields of raindrops consistent with the rainfall history at the turbine location by integrating the micro-structural properties of rain, i.e. raindrops size and spatial distribution with its integral properties such as the relationship between the average volume fraction of raindrops and rain intensity. An in-house GPU-accelerated computational fluid dynamics model of free-surface flows and a multi-resolution strategy are used to calculate the drop impact pressure as a function of time and space. An interpolation scheme is finally proposed to find the time evolution of impact pressure profile for any given drop diameter using the high fidelity simulation results, significantly reducing the computational cost. Other ingredients of the framework pertaining to drop impact-induced stresses and the blade coating fatigue life are presented in part II.

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Section: Introductionmentioning

confidence: 99%

A computational framework for the analysis of rain-induced erosion in wind turbine blades, part I: Stochastic rain texture model and drop impact simulations

Amirzadeh

Louhghalam

Raessi

et al. 2017

Journal of Wind Engineering and Industrial Aerodynamics

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“…Furthermore, the possibility of thermal spikes during the material deposition (welding) process should be considered to prevent undesirable damage to the machine tools' controller. The Southern Methodist University in Texas have developed their own WHASP capability in the form of the MULTIFAB system [68], [69]. The MULTIFAB system comprises a multi-axis robot for material deposition and welding which is synergistically integrated into a 5-axis machine tool [70].…”

Section: Cnc Machining With Arc-based Directed Energy Depositionmentioning

confidence: 99%

Hybrid additive and subtractive machine tools – Research and industrial developments

Flynn

Shokrani

Newman

et al. 2016

International Journal of Machine Tools and Manufacture

373

160

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By synergistically combining additive and subtractive processes within a single workstation, the relative merits of each process may be harnessed. This facilitates the manufacture of internal, overhanging and high aspect ratio features with desirable geometric accuracy and surface characteristics. The ability to work, measure and then rework material enables the reincarnation and repair of damaged, high-value components. These techniques present significant opportunities to improve material utilisation, part complexity and quality management in functional parts. The number of single platform workstations for hybrid additive and subtractive processes (WHASPs) is increasing. Many of these integrate additive directed energy deposition (DED) with subtractive CNC machining within a highly mobile multi-axis machine tool. Advanced numerical control (NC), and computer aided design (CAD), manufacture (CAM) and inspection (CAI) software capabilities help to govern the process. This research reviews and critically discusses salient published literature relating to the development of Workstations for Hybrid Additive and Subtractive Processing (WHASPs), and identifies future avenues for research and development. It reports on state-of-the-art WHASP systems, identifying key traits and research gaps. Finally, a future vision for WHASPs and other hybrid machine tools is presented based upon emerging trends and future opportunities within this research area

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“…This step is taken since the plate is considered to be a small patch from a very large medium. The bottom face of the plate is fixed as this is a common approach for particle impact simulations [29,30,31,26,27,32] The stresses in the Gelcoat layer were calculated for two separate cases: 1) using the entire layup structure and 2) using only the Gelcoat layer with a rigid bottom face. It was observed that while the inclusion of the composite structure in the model increases the computational cost dramatically, it does not alter the stresses within the Gelcoat layer significantly.…”

Section: Transient Stress Analysis In the Blade Shellmentioning

confidence: 99%

A computational framework for the analysis of rain-induced erosion in wind turbine blades, part II: Drop impact-induced stresses and blade coating fatigue life

Amirzadeh

Louhghalam

Raessi

et al. 2017

Journal of Wind Engineering and Industrial Aerodynamics

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With the current trend in wind energy production, the need to manufacture larger wind turbine blades is on the rise. The high blade tip velocities associated with large blades subject them to various damages due to high speed impact with foreign objects such as raindrops. This paper is the second part in a two-part paper that presents a framework for rain erosion prediction in wind turbine blades. In part I, a stochastic rain texture model and multi-resolution simulation of raindrop impact on solid object were discussed. In part II, the predicted impact pressure profiles are imported into a finite element model of the wind turbine blade shell to analyze the raindrop impact-induced transient stresses within the blade coating and the ensuing fatigue damage pattern. The analysis is complemented with a fatigue stress-life estimation process that integrates elements of fatigue life calculation with 3D fields of raindrops generated from the stochastic rain texture model to relate damage accumulation rates to rain intensities. These accumulation rates, together with the statistics of rainfall history, provide a means for estimating the expected fatigue life of the blade coating as an indication of the onset of surface roughening or the end of the incubation period.

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Numerical Simulation and Characterization of Slurry Erosion of Laser Cladded Surfaces by Using Failure Analysis Approach

Cited by 7 publications

References 14 publications

A computational framework for the analysis of rain-induced erosion in wind turbine blades, part I: Stochastic rain texture model and drop impact simulations

A computational framework for the analysis of rain-induced erosion in wind turbine blades, part I: Stochastic rain texture model and drop impact simulations

Hybrid additive and subtractive machine tools – Research and industrial developments

A computational framework for the analysis of rain-induced erosion in wind turbine blades, part II: Drop impact-induced stresses and blade coating fatigue life

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