Research on Fatigue Damage Behavior of Main Beam Sub-Structure of Composite Wind Turbine Blade

Given the difficulty in accurately evaluating the fatigue performance of large composite wind turbine blades(referred to as blades),this paper takes the main beam structure of the blade with a rectangular cross-sectionas the simulation object and establishes a composite laminate rectangular beam structure that simultaneouslyincludes the flange,web,and adhesive layer,referred to as the blade main beam sub-structure specimen,throughthe definition of blade sub-structures.This paper examines the progressive damage evolution law of the compositelaminate rectangular beam utilizing an improved 3D Hashin failure criterion,cohesive zone model,B-K failurecriterion,and computer simulation technology.Under static loading,the layup angle of the anti-shear web hasa close relationship with the static load-carrying capacity of the composite laminate rectangular beam;under fatigueloading,the fatigue damage will first occur in the lower flange adhesive area of the whole composite laminaterectangular beam and ultimately result in the fracture failure of the entire structure.These results provide a theoreticalreference and foundation for evaluating and predicting the fatigue performance of the blade main beamstructure and even the full-size blade.

Stiffness Degradation Modeling for Composite Wind Turbine Blades Based on Full-Scale Fatigue Testing

In order to provide more insights into the damage propagation composite wind turbine blades(blade)under cyclic fatigue loading,a stiffness degradation model for blade is proposed based on the full-scale fatigue testing of a blade.A novel non-linear fatigue damage accumulation model is proposed using the damage assessment theories of composite laminates for the first time.Then,a stiffness degradation model is established based on the correlation of fatigue damage and residual stiffness of the composite laminates.Finally,a stiffness degradation model for the blade is presented based on the full-scale fatigue testing.The scientific rationale of the proposed stiffness model of blade is verified by using full-scale fatigue test data of blade with a total length of 52.5 m.The results indicate that the proposed stiffness degradation model of the blade agrees well with the fatigue testing results of this blade.This work provides a basis for evaluating the fatigue damage and lifetime of blade under cyclic fatigue loading.

Hashin Failure Theory Based Damage Assessment Methodology of Composite Tidal Turbine Blades and Implications for the Blade Design

A damage assessment methodology based on the Hashin failure theory for glass fiber reinforced polymer(GFRP)composite blade is proposed. The typical failure mechanisms including the fiber tension/compression and matrix tension/compression are considered to describe the damage behaviors. To give the flapwise and edgewise loading along the blade span, the Blade Element Momentum Theory(BEMT) is adopted. In conjunction with the hydrodynamic analysis, the structural analysis of the composite blade is cooperatively performed with the Hashin damage model. The damage characteristics of the composite blade, under normal and extreme operational conditions,are comparatively analyzed. Numerical results demonstrate that the matrix tension damage is the most significant failure mode which occurs in the mid-span of the blade. The blade internal configurations including the box-beam, Ibeam, left-C beam and right-C beam are compared and analyzed. The GFRP and carbon fiber reinforced polymer(CFRP) are considered and combined. Numerical results show that the I-beam is the best structural type. The structural performance of composite tidal turbine blades could be improved by combining the GFRP and CFRP structure considering the damage and cost-effectiveness synthetically.

Optimization of Composite Wind Turbine Blade Based on Modal Sensitivity

This study develops a method for the full-size structural design of blade,involving the optimal layer thickness configuration of the blade to maximize its bending stiffness using a genetic algorithm.Numerical differentiation is employed to solve the sensitivity of blade modal frequency to the layer thickness of each part of blade.The natural frequencies of first-order flapwise and edgewise modes are selected as the optimal objectives.Based on the modal sensitivity analysis of all design variables,the effect of discretized layer thickness on bending stiffness of the blade is explored,and 14 significant design variables are filtered to drive the structural optimization.The best solution predicts an increase in natural frequencies of first-order flapwise and edgewise blade modes by up to 12%and 10.4%,respectively.The results show that the structural optimization method based on modal sensitivity is more effective to improve the structural performance.

The Effect of Composite Flexures on Aeroelastic Stability of a Hingeless Rotor Blade

The effects of ply orientation angle of composite flexures on stability of hingeless rotor blade system are studied.The composite hingeless rotor blade system is simplified as a hub,a flap flexure and a lag flexure.pitch bearing and main blade.The kinematics formulations are inferred by employing the moderate deflection beam theory.The shear deformation and warping related to torsion are considered.The quasi-steady strip theory with dynamic inflow effects is applied to obtain the aerodynamic loads acting on the blade.Based on these.the set of finite element formulations of a hingeless rotor blade system is worked out.The numerical results show that the ply angle of the composite flexures has great effects on the aeroelastic stability of rotor blade.

Strength, Fatigue Strength and Stiffness of High-Tech Bamboo/Epoxy Composites

A major problem in the strength data available for cellulose fibre-based materials is that the moisture content of the test specimens is rarely measured, and yet it is the dominant variable in the tests. Detailed strength and stiffness results are presented for Brazilian Dendrocalamus Giganteus bamboo at a wide range of moisture contents down to 2% and the fatigue curve is given for Chinese Moso bamboo at 4% moisture content. Techniques are described for handling the variability of these natural materials, both in design and in manufacturing quality control, for the mass production of large, high-tech composites wind turbine blades.

Geometrically exact nonlinear analysis of pre-twisted composite rotor blades

Modeling of pre-twisted composite rotor blades is very complicated not only because of the geometric non-linearity, but also because of the cross-sectional warping and the transverse shear deformation caused by the anisotropic material properties. In this paper, the geometrically exact nonlinear modeling of a generalized Timoshenko beam with arbitrary cross-sectional shape,generally anisotropic material behavior and large deflections has been presented based on Hodges＇ method. The concept of decomposition of rotation tensor was used to express the strain in the beam. The variational asymptotic method was used to determine the arbitrary warping of the beam cross section. The generalized Timoshenko strain energy was derived from the equilibrium equations and the second-order asymptotically correct strain energy. The geometrically exact nonlinear equations of motion were established by Hamilton＇s principle. The established modeling was used for the static and dynamic analysis of pre-twisted composite rotor blades, and the analytical results were validated based on experimental data. The influences of the transverse shear deformation on the pre-twisted composite rotor blade were investigated. The results indicate that the influences of the transverse shear deformation on the static deformation and the natural frequencies of the pre-twisted composite rotor blade are related to the length to chord ratio of the blade.

基于CLD的风电叶片挥舞疲劳试验寿命预测方法

随着风电叶片长度的不断增加,挥舞疲劳测试时叶片自重和夹具重量对叶片产生的影响已无法忽略。本文以株洲时代新材料科技股份有限公司某90 m级叶片挥舞疲劳试验主梁失效为研究对象,测试了主梁拉挤板在不同应力比情况下的疲劳S-N曲线,基于Goodman等寿命图提出一种新的复合材料疲劳寿命预测方法。通过考虑平均应力对主梁疲劳寿命的影响,文章对比分析理论试验预测损伤及疲劳试验实际损伤,得出两个重要结论:(1)现有不考虑叶片自重的挥舞疲劳试验载荷等效方法已不能反映叶片的实际受载情况;(2)本文提出的考虑均值的Goodman疲劳寿命计算方法能够较准确地预测叶片的疲劳试验寿命。

低肋与V形肋复合结构在双通道中的强化换热数值研究

随着燃气轮机内涡轮入口温度的升高,燃气轮机会出现热障问题,为保证燃气轮机安全运行,复合结构能够有效提高通道的冷却性能来解决此问题。采用SST k-ω湍流模型对带有低肋与V肋复合结构双通道的流动与传热特性进行了数值模拟,将圆形肋复合结构、扇叶形肋复合结构和葫芦形肋复合结构与纯V形肋在雷诺数为10 000~60 000时的传热性能进行比较,探索出综合换热效果最佳的复合结构。发现相比于纯V形肋通道,复合结构双通道的综合传热性能均得到提升,其中葫芦形肋与V形肋组成的复合结构的综合换热效果最好。葫芦肋复合结构的Nu相比于纯V形肋提高了4.33%~6.6%,f提高了0.04%~4.48%,η最佳值达到了2.13。葫芦形肋复合结构的η比45°斜方形肋和45°斜花形肋分别增大了25.51%~32.98%和4.73%~10.51%,同时,低肋与V形肋组成的复合结构综合换热性能要优于凹坑与V形肋组成的复合结构。葫芦肋复合结构有效增强通道的换热效果且压力损失增长较小,可显著提升涡轮内部冷却通道的综合换热性能。

钛合金包边复合材料风扇叶片的鸟撞数值仿真

为降低鸟体撞击航空发动机中带钛合金包边树脂基复合材料风扇叶片的试验成本,开展了数值仿真研究,为钛合金包边在航空发动机风扇叶片上的应用提供参考和依据。对风扇叶片进行简化,采用ABAQUS有限元软件构建了鸟撞带钛合金包边和不带钛合金包边的风扇叶片模型,其中,钛合金包边和复合材料叶片之间用粘结界面单元进行粘接,研究了不同鸟体冲击角度和速度下2种风扇叶片的损伤。结果表明:在鸟体冲击速度相同时,随着冲击角度的增大,风扇叶片的损伤增大且能量吸收率提高,在冲击角度也相同时,带钛合金包边的风扇叶片损伤更小且能量吸收率更高;在鸟体冲击角度相同时,随着冲击速度的加快,风扇叶片的损伤增大且能量吸收率提高;在鸟体冲击下,粘结界面单元最终发生拉伸破坏,在低速度冲击下还会发生剪切损伤。

基于声发射b值分析的风力机叶片材料损伤特性研究

风力发电机叶片主要材料玻璃纤维环氧树脂增强复合材料(GFRP)的损伤,会造成叶片寿命减少甚至断裂,必须进行损伤检测。采用声发射方法可分析GFRP复合材料损伤特性,实现在线监测叶片性能。该文采用声发射b值特征来表征GFRP损伤程度,并通过主成分分析和k-均值++算法进行声发射参数聚类来分析GFRP损坏模式。结果表明:1)对整个声发射事件进行b值分析,观察到GFRP试样在断裂前b值呈明显下降趋势,表明b值的变化率可作为材料断裂的预警信号。2)根据主成分分析9种声发射参数所占主成分比重,选择声发射信号的幅度、峰值频率两个特征参数。通过k-均值++算法对特征参数进行聚类分析,发现拉伸过程的声发射信号分为了4个簇,并找到每个簇的特征频率。3)通过使用扫描电子显微镜(SEM)对GFRP试样拉伸断口进行观察,得到4个簇分别对应于基体开裂、纤维/基体脱粘、分层和纤维断裂4种损伤模式。基于声发射b值分析方法适用于GFRP损伤特性研究,可在风力发电机叶片损伤检测领域推广。

基于哨兵函数和S变换的风力机叶片材料损伤特性研究

利用声发射检测技术研究玻璃纤维增强环氧树脂复合材料的损伤特性,在此过程中,采用哨兵函数来表征该材料的损伤程度,并通过S变换和模糊C均值(FCM)聚类来分析声发射信号,从而获得材料的损伤特征。三点弯曲实验结束后对试件断口进行扫描电子显微镜(SEM)拍照来验证,可得:通过对SEM照片的分析得到基体开裂、纤维脱粘、分层破坏、纤维断裂4种损伤模式;对整个声发射事件进行哨兵函数分析,观察到试件在弯曲过程中哨兵函数曲线呈明显下降趋势;对依据哨兵函数划分的不同阶段的信号进行VMD降噪处理,然后采用S变换进行时频分析得到不同损伤的特征频率,最后采用FCM聚类进行验证。结果表明:哨兵函数值的突变可作为材料断裂的预警信号,材料损伤类型的识别可依据S变换的频率分布结果进行确定。

极端运行阵风下风电叶片动力学响应特性流固耦合分析

基于CFD及有限单元法,利用ANSYS Workbench平台的Fluent与Transient Structural模块,对NREL 5 MW风电机组复合材料叶片在极端运行阵风下的气动特性及结构力学特性进行研究。结果表明:风轮气动载荷受极端运行阵风的影响较大,极端运行阵风作用下,风力机转矩及轴向推力等随风速的变化出现较大幅值的响应且响应峰值较阵风峰值均有所提前;叶片位移随风速的变化在峰值风速的前后出现大小两个峰值;在风速达到峰值时,与均匀来流阶段相比,叶片表面应力整体增幅较大。

激光能量密度对65Mn钢表面Ni60A/WC复合涂层摩擦磨损性能的影响规律

目的改善旋耕刀65Mn钢的摩擦磨损性能,提高农机触土零部件的使用寿命。方法采用激光熔覆技术在65Mn钢基体表面制备Ni60A/WC复合涂层。通过改变激光功率调节激光能量密度,在不同能量密度下制备Ni60A/WC复合涂层,观察并测试不同参数下复合涂层试样的宏观形貌、微观结构、物相组成、元素分布、显微硬度及摩擦磨损特性,研究激光能量密度对Ni60A/WC复合涂层组织演变及摩擦磨损性能的影响规律和机理。结果Ni60A/WC复合熔覆层顶部主要有胞状晶和树枝晶,分布较紧密,熔覆层中部主要有树枝状晶,熔覆层底部主要为胞状晶和垂直交界面生长的枝晶,且分布均匀致密。随着激光能量密度的升高,熔覆层的熔高和熔深增加显著,WC硬质相颗粒发生分解,硬质相的数量明显减少,涂层的平均显微硬度降低。在激光能量密度为120 J/mm^(2)时,熔覆层的平均显微硬度为587.1HV1.0,相较于基体,提升了约1.8倍。此时熔覆层的平均摩擦因数最小,为0.312,相较于基体,得到显著提升,摩擦磨损机制为轻微的磨粒磨损。经田间试验测试发现,在激光能量密度为120 J/mm^(2)时制备的带有熔覆层的旋耕刀相较于无熔覆层的旋耕刀,其磨损质量降低了63%。结论通过控制激光能量密度,可以有效调控Ni60A/WC熔覆层的硬度和耐磨性,可为农机触土易磨损件的减摩耐磨表面强化改性提供理论指导。

可回收热固性环氧树脂及其玻纤增强复合材料性能研究

为了研究可回收环氧树脂R与风电叶片中常规环氧灌注树脂的区别,采用真空灌注工艺制备了玻璃纤维增强可回收热固性复合材料,对比分析了树脂之间的材料性能以及其复合材料之间的力学性能。结果表明,可回收树脂R的粘度与常规灌注树脂相近,适用期长于常规灌注树脂,适用于风电叶片的真空灌注工艺;放热峰出现时间略早于常规灌注树脂,有利于减少生产工时;其本体性能、复合材料力学性能与常规灌注树脂大体相当;可回收树脂R与常规灌注树脂的之间具有良好的界面性能,表明该树脂可以通过先制备部件然后整体灌注成型的方式制造大型复合材料制件。

航空复合材料螺旋桨叶片制造工艺研究进展

螺旋桨推进方式在航空领域占有重要地位。复合材料具有高比强度、高比模量、高阻尼、可设计性等特性,复合材料螺旋桨叶片能够提升螺旋桨减重效率、推进效率、耐蚀性、降噪等方面性能,已成为大势所趋。本文对国内外航空复合材料螺旋桨叶片的研究成果进行回顾和总结,基于传统飞机螺旋桨叶片和旋翼桨叶,对航空螺旋桨叶片材料体系、结构设计和制造工艺进行分类阐述,重点总结复合材料螺旋桨制造工艺中的关键技术问题,概述桨叶制造工艺方面的仿真模拟研究,最后从健全材料体系、优化结构设计、深入工艺研究和加强数值模拟技术的工程化应用几个方面提出了国产化复合材料航空螺旋桨的未来发展方向。

湿空气含湿量对燃气轮机透平叶片复合冷却性能影响的实验与数值研究

为了探究以湿空气作为冷却介质时透平叶片冷却的复合冷却性能,结合实验和数值方法探究了湿空气含湿量对透平叶片湿空气冷却性能的影响。以GE-E 3叶型为基础,建立了带有冲击冷却、U型带肋通道冷却、柱肋冷却、尾缘劈缝以及气膜冷却结构的复合冷却透平叶片。测量了不同冷气与主流质量流量比条件下,采用不同湿空气含湿量的湿空气作为冷却工质时50%叶高处叶片表面温度分布。实验结果表明,在不同的主流温度下,增加湿空气含湿量均能降低叶片表面温度。在主流进口温度分别为473、873 K条件下,采用含湿量分别为163.0、173.8 g/kg的湿空气作为冷却工质时,相较于17 g/kg的湿空气冷却工况,叶片表面冷却效率分别提高了9%~11%和7%~9%,叶片表面温度分别降低了4.1~5.2 K和19.0~21.3 K。数值研究结果表明:带γ-θ转捩模型的SST k-ω模型能够更为准确地预测湿空气冷却时的叶片表面的温度分布;湿空气含湿量的增加能够整体提高叶片表面冷却效率,叶片表面冷却效率的变化在气膜覆盖区域更为显著。

陶瓷基复合材料涡轮动叶榫头元件静强度实验及缺陷影响

陶瓷基复合材料(ceramic matrix composites,CMC)涡轮动叶榫头是动叶装配与承受离心载荷的关键。为了研究熔渗工艺制备CMC榫头在叶片旋转径向拉伸载荷下的力学行为,验证榫头内部质量对其静拉伸强度与破坏模式的影响,设计并制备燕尾形CMC高压涡轮动叶榫头元件试件,对其进行单轴静态拉伸实验,采用X射线CT无损检测对实验前试件内部质量进行扫描,采用DIC与声发射方法对实验过程进行监测。结果表明:燕尾形CMC榫头在单轴静态拉伸下保持完好接触,其静态拉伸强度与破坏模式对其内部质量(尤其是分层缺陷)非常敏感。试件不含分层缺陷时,损伤起始于榫头颈部,并迅速扩展,损伤起始载荷与最大破坏载荷接近,断口呈横向锯齿状;试件内部含分层缺陷时,损伤起始于缺陷,分层逐渐扩展并导致试件断裂,损伤起始载荷下降99.05%,最大破坏载荷下降14.29%,断口位置与分层缺陷一致。

复合材料风力机叶片参数化设计及优化

风力机叶片重量过大不仅会影响叶片的结构性能,还会增加运输、维修等成本。为解决叶片质量问题,本文选取经典的1.5 MW复合材料风力机叶片,叶片主梁、腹板、前缘和后缘分区铺设不同的复合材料。由于复合材料的铺设厚度从叶根向叶尖呈现递减趋势,且失效位置也多位于叶根处,故取距离叶根约1/3部分为研究对象来简化问题。为便于后期优化,采用ANSYS APDL参数化构建复合材料风力机叶片模型。考虑到陷入局部最优的情况,选择子集模拟优化方法进行随机优化。设计变量为腹板位置,约束函数为极限载荷下叶片满足位移及Tsai-Wu准则校核,目标为叶片重量最小。通过30组子集模拟优化统计结果可知:当腹板位置约在29.4%、53.3%弦长处时,相较于确定性设计,叶片减重约15.4%。最终结果表明,该优化方法在风力机叶片结构优化方面具有可行性,且优化结果对工程设计具有参考价值。

风力机叶片截面主刚度系数与横向剪应力分析

针对风力机复合材料叶片弯曲与扭转刚度计算,以及当叶片在横向剪力作用下对空心薄壁截面上剪应力的数值计算方法进行研究。现代风力机叶片呈细长扭曲形,翼型截面为薄壁且内部拓扑构型复杂,材料具有各向异性。在应用各类梁模型进行叶片气弹计算和强度校核等力学分析时,叶片截面的刚度系数和截面剪应力分布是必需参数。基于复合材料薄壁结构层合理论和加权平均方法,结合Bredt-Batho剪力理论,考虑了复合材料叶片的剪切腹板效应和翘曲效应,建立了复合材料层合板等效弹性常数与截面刚度系数数值分析算法;根据弹性力学板壳理论,考虑横向剪切和截面翘曲对截面变形的影响,建立了横向剪力引起的剪力流数值计算方法,并开发了相关算法的Matlab程序。分析10 MW风力机叶片主刚度系数和剪力流分布,并对比文献结果,验证了模型的正确性和算法的有效性。