Analysis of cross axis wind turbine blades designed and manufactured by FDM based additive manufacturing

Abstract

Additive manufacturing is emerging as a preferred approach to manufacture complex three dimensional components easily within a short span of time. In this study, cross axis wind turbine blades and its components are produced using fusion deposition modeling using Acrylonitrile Butadiene Styrene (ABS) material. The 3D CAD models are converted into .STL file which are processed further in “Slicer” freeware software. This convert the model into series of thin layers and creates G-code file which acts as an input to automated 3D printing machine to lay layers of loaded thermoplastic material successively to build the model from series of cross sections. The components produced by additive manufacturing is assembled and the obtained cross axis wind turbine (CAWT) is investigated using an open jet wind tunnel for wind velocities varying from 4 m/s to 10 m/s. The dimensionless performance parameters i.e., coefficient of power (Cp) and tip speed ratio (λ) are plotted. In general, the Cp value of CAWT increases gradually and reaches the maximum value around λ = 1.20. A maximum Cp value of 0.02385 is observed for wind velocity Vα = 10 m/s. Thus, the 3D printed components by additive manufacturing can be used to produce small wind turbines.