Blade Root Research Articles

Development of ultrasonic phased array technique for inspection of fir-tree type turbine blade root and disc-rim in nuclear power plant

Development of ultrasonic phased array technique for inspection of fir-tree type turbine blade root and disc-rim in nuclear power plant

Electromechanical modelling and vibration control analysis of cyclic symmetric structures with a piezoelectric vibration absorber

This study explored the application of piezoelectric vibration absorbers (PVAs) equipped with synthetic circuits for the vibration control of cyclic symmetric structures. A cyclic symmetric electromechanical model (CSEM) integrated with PVAs was introduced to facilitate the design and optimization of the PVAs. This model was formulated analytically based on the circulant matrix theory, and the dynamic response was computed using the complex mode superposition method with explicit consideration of the intrinsic resistance within the PVA. A case study involving a simplified blisk model and an experimental test rig was conducted to validate the proposed CSEM. The validity of the model was confirmed through a comparative analysis of both the natural and dynamic characteristics obtained using the finite element model and experimental results. Furthermore, the impact of synthetic circuit parameters (inductance and negative capacitance values) and the placement of piezoelectric patches on the vibration control performance of PVA were investigated. The results suggested that the optimal inductance coincide with the analytical value, whereas the optimal negative capacitance of the series was slightly greater than the intrinsic capacitance of the patch. Additionally, mounting the piezoelectric patch on the blade root improved the vibration control.

Numerical investigation on boiling crisis characteristic of a 7-rod HCF assembly in hexagonal lattice

Helical cruciform fuel (HCF) has the advantages of larger heat transfer area, enhanced coolant mixing and self-supporting, which contribute to increasing power density and safety margins. Compared with the square lattice configuration, the hexagonal arrangement of HCF assembly is more compact, which can help achieve a higher power density. In this paper, the flow characteristics and heat transfer behaviors of HCF in hexagonal lattice were predicted at high and low vapor quality during boiling crisis based on Eulerian two-fluid model. The influence of twist pitches and cross-sections of the fuel rod on heat transfer efficiency and fuel temperature was also studied. The cross-flow intensity changed periodically with a 30° cycle at low vapor quality, and did not fluctuate periodically at high vapor quality, which decreased with the increase of flow resistance. The highest heat flux of HCF rod was the at the blade root and the lowest was at the blade tip, and the maximum to average heat flux ratio was about 1.8. The peak vapor fraction and temperature occurred at leeside side of the fuel rods. The increase of the twist pitch reduced the critical heat flux (CHF), and the increase of blade length enhanced the non-uniformity of heat flux distribution. During boiling crisis, the maximum temperature of the fuel was lower than the phase transition temperature of U-50 wt%Zr alloy, which means the cladding meltdown caused by boiling crisis will occur before phase transition of the fuel.

Deep analysis of power regulation on fatigue loads and platform motion in floating wind turbines

The fatigue loads experienced by components and the motion of the platform in floating wind turbines are likely influenced by their operation within a limited power state; however, the corresponding effects remain inadequately understood. This study investigates a 5 MW semi-submersible floating wind turbine, aiming to provide a comprehensive analysis of fatigue loads on critical components and platform motion under various power regulation modes. To achieve this objective, we employed the NREL 5 MW semi-submersible wind turbine model, generated three-dimensional wind fields using TurbSim, and conducted dynamic simulations with OpenFAST, utilizing MLife software for post-processing of fatigue load analysis. We assessed the fatigue loads of four key components—the blade root, tower base, drivetrain, and mooring cables—alongside the platform motion under varying generator speeds, yaw angles, and active power levels. Additionally, correlation analysis was performed to explore the relationship between component fatigue loads and platform motion under different yaw conditions. The results demonstrate that both generator speed and yaw angle significantly influence fatigue loads and platform motion, while the effect of active power appears to be relatively minor. Specifically, an increase in generator speed markedly elevates fatigue loads on the blade root and drivetrain, while concurrently reducing loads on the tower base and certain mooring lines. The analysis further reveals that, under various yaw angles, the fatigue loads on symmetrically positioned mooring cables exhibit a symmetric response, impacting fatigue damage in the blade root and tower base moments. Moreover, the relationship between maximum horizontal platform displacement and fatigue loads varies. The findings of this study provide critical insights into the operational optimization of floating wind turbines.

Reduced-order peridynamics for efficient simulation of fracture in a turbine blade root

This paper introduces an adaptive partitioned reduced-order model (ROM) of peridynamics for the efficient simulation of fracture in a gas turbine blade root. The computational domain is divided into an ROM subdomain and a full-order model (FOM) subdomain. The subdomains adaptively evolve to ensure that the FOM domain covers the fractured area. The proposed model is used to investigate the failure of a gas turbine blade root under static and fatigue loads, respectively. The simulation results coincide well with the actual fracture morphology. In addition, in the three-dimensional case, the computational efficiency can be improved by approximately 300 times

Studying and analysis of deformation and stresses in horizontal-axis wind turbine using fluid-structure interaction method

Fluid-structure interaction (FSI) studies have become an important tool in the development of wind turbine blades as well as for analyzing and optimizing Horizontal Axis Wind Turbine (HAWT). The most essential elements for estimating the turbine blade strength to withstand extreme wind loads and aerodynamic performance are the blade deformation and the associated stresses. This study aims to compare the strength and analyze the deformation behavior of two models of HAWT blades. A three-dimensional model was created and loaded into a Finite Element (FE) model for analysis. The Computational Fluid Dynamics (CFD) investigation was coupled with the structural model using one-way FSI. In this article, the effect of the aerodynamics on the blade surface of a small HAWT has been studied numerically and experimentally. The airfoil used for the blade profile is S826 airfoil. To provide an appropriate displacement for static measurements, the blade in the experimental investigation is made of thermoplastic polyurethane material (TPU). It is noted that the current experimental findings verify the simulation results, and a comparison between the simulations and the experimental findings reveals a reasonable agreement. The numerical simulations are also implemented on a HAWT epoxy E-glass unidirectional (EEGUD) material. It can be concluded from this study that the blade deformation and stress on the blades are related to the wind speed. The deformation along the span length exhibits nonlinear variation that gradually increases from the blade root and reaches its maximum at the blade tip position. The tip deflection and equivalent stress were found to increase with an increase in wind speed. The dynamic analysis at different tip speed ratios shows the highest deformation at λ = 4, for wind speed of 20 m/s.

Probabilistic Modeling Geometric Tolerance and Low Cycle Fatigue Life of Gas Turbine Compressor Blade

Abstract This paper presents a probabilistic low cycle fatigue (LCF) assessment for geometric tolerances on high load contact surfaces of gas turbine compressor blades. The typical patterns of the geometric deviations for the root contact flank of the compressor blades are identified and characterized according to coordinate measurement machine (CMM) measurements of the blade root. These typical patterns are closely related to the root form manufacture tools and process. Finite element (FE) models for the typical geometric deviation patterns are created based on nodal coordinates transformation of the surface nodes on the blade root contact flanks and radius. An optimized blade root profile tolerance is established, which enables significant cost saving. The elastic-plastic FE analysis with nonlinear contact model, material strain-life test, response surface, and constrained Monte Carlo simulation are used to create a probabilistic LCF life model for the optimized tolerance. The model quantifies the effect of the geometric deviations, blade mass, and material property on the blade LCF life. The result shows that with the optimized tolerance, the probability of blade LCF failure is very low and acceptable. It is also shown that the strain life material property is the most critical factor for the LCF failure. The root profile tolerance and blade mass are seen to have a much weaker effect on the blade LCF life.

Effects of Inflow Turbulent Coherent Structures on a Small-Scale Wind Turbine in the Atmospheric Boundary Layer of Long Corridor Terrains: An Example Study in the Hexi Corridor

Considering its Venturi effect, long corridor terrain is considered as one of the outstanding wind-energy resources, but has not been developed due to unclear inflow turbulence effects on wind turbines. To advance the wind-power technology in long corridors and reveal the physics behind it, we conducted a series of data-fusion analyses combining field measurements in the Hexi Corridor, Gansu, China, and numerical simulations and summarize the effort here. In this study, the classical spectrum for the atmospheric boundary layer for wind-energy research, the IEC Kaimal spectrum (also known as IECKwind, International Elector technical Commission 61400-1) cannot describe the wind profile in corridors. Here, we proposed a new spectrum to describe the wind in the Hexi Corridor by modifying the IEC Kaimal spectrum, and we call it the IECK-HX spectrum. The results demonstrate that it preferentially resides at lower frequencies (larger spatial scales) compared with IECKwind. Large-scale motions (LSMs) and very large-scale motions (VLSMs) coexist in the Hexi Corridor atmospheric boundary layer, which can be well described by the IECK-HX spectrum, and these two dominate the large fluctuations in the power, thrust, and blade root flapwise moment of wind turbines, while the high-frequency small-scale coherent structures mainly cause high-frequency fluctuations in wind-turbine load. Furthermore, IEC Kaimal spectrum can not describe the VLSMs, and the generated flow presents significant fluctuations and thereby reduces the power output in high wind-speed regions. This study provides fundamental support for wind-energy scientists and engineers who are interested in wind energy in corridor terrains. Published by the American Physical Society 2024

Dynamic strain distribution monitoring and fatigue damage analysis on a 100 kW wind turbine blade based on field aerodynamic measurements

Abstract Operation and maintenance (O&M) costs can account for 10%–20% of the total costs of electricity for a wind project. Structural health monitoring method is a form of preventive maintenance consisting of regular monitoring of the wind turbine components to detect potential faults. The strain measurements on the blades are typically used for load monitoring and damage detection, but only obtain a small amount of concentrated load information. In this work, a strain distribution monitoring method was proposed and validated based on aerodynamic measurements in the field. Then the contribution and evolution of the strain distribution from the aerodynamic load, gravity load, inertial load, and centrifugal load in the complex start-up process of the wind turbine were analyzed. The results shows that the mean value of the synthetic strain is mainly determined by the aerodynamic load and the centrifugal load, while the fluctuation amplitude is mainly determined by the gravity and the aerodynamic load. Furthermore, the fatigue damage of the blade root was evaluated based on strain extrapolation, rainflow cycle-counting algorithm, Goodman diagram and Miner’s linear superposition principle. It is found that the fatigue damage is generally greatest near the pressure side and suction side, and least near the leading edge and trailing edge. The strain distribution monitoring method can capture the location of maximum stress and the most severe fatigue damage on the blade, which are helpful for damage detection and load control, and further reduces O&M costs.

Lifing Assessment of Gas Turbine Blade Root Affected by Out-of-Tolerances.

Current and future heavy-duty gas turbines (GTs) are being developed as an alternative or support to renewable energy sources (RESs). Therefore, GTs are subjected to several instances of being switched on and off; thus, the material fatigue limit can be reached in a short time. In such a scenario, possible out-of-tolerances (OoTs) in critical components must be considered. In this paper, OoTs related to critical parameters in the attachment geometry of a rotor blade are considered to estimate their impact on component life through a 2D finite element (FE) analysis. First, a mesh refinement is performed to obtain mesh-independent results; second, OoT geometries are simulated to determine stresses and strains at the blade attachment and disc groove. The mesh refinement process is critical to ensure model accuracy for both nominal and OoT geometries. The results show that OoTs can lead to important reductions in the life of the intended component, both on the blade and disc sides. These results could be useful in updating the maintenance plan for components and could be used for future insights, with further work extending the study to 3D geometry, for example, and evaluating the effect of other geometries.

Measurement of unsteady force on rotor blade surfaces in axial flow compressor

To assess the aerodynamic performance and vibration characteristics of rotor blades during rotation, a study of unsteady blade surface forces is conducted in a low-speed axial flow compressor under a rotating coordinate system. The capture, modulation, and acquisition of unsteady blade surface forces are achieved by using pressure sensors and strain gauges attached to the rotor blades, in conjunction with a wireless telemetry system. Based on the measurement reliability verification, this approach allows for the determination of the static pressure distribution on rotor blade surfaces, enabling the quantitative description of loadability at different spanwise positions along the blade chord. Effects caused by the factors such as Tip Leakage Flow (TLF) and flow separation can be perceived and reflected in the trends of static pressure on the blade surfaces. Simultaneously, the dynamic characteristics of unsteady pressure and stress on the blade surfaces are analyzed. The results indicate that only the pressure signals measured at the mid-chord of the blade tip can distinctly detect the unsteady frequency of TLF due to the oscillation of the low-pressure spot on the pressure surface. Subsequently, with the help of one-dimensional continuous wavelet analysis method, it can be inferred that as the compressor enters stall, the sensors are capable of capturing stall cell frequency under a rotating coordinate system. Furthermore, the stress at the blade root is higher than that at the blade tip, and the frequency band of the vibration can also be measured by the pressure sensors fixed on the casing wall in a stationary frame. While the compressor stalls, the stress at the blade root can be higher, which can provide valuable guidance for monitoring the lifecycle of compressor blades.

Influence of tip air injection on the unsteady blade force under circumferential pressure distortion

In order to further understand the impact of tip air injection on compressor stability under circumferential pressure distortion, a series of experimental studies on tip air injection under uniform and circumferential distortion were conducted on a low-speed single rotor axial flow compressor. The unsteady measurements were carried out by use of microsensors and strain gauges bonded on the rotor blade surfaces, and a collection of dynamic pressure sensors installed on the casing wall. Results indicate that with the increase in the injected momentum ratio, the load at the leading edge near the rotor blade tip obviously decreases, thereby delaying the stall. By comparing the pressure distribution on the rotor blade surface under different injected momentum ratios, tip air injection can effectively suppress flow separation at the blade tip to enhance flow capability. In addition, it can also weaken the fluctuation of tip leakage flow and reduce the dynamic stress similar to natural vibration near the blade root both in stationary and rotating coordinate systems. Under the condition of inlet circumferential distortion, tip air injection can significantly reduce the load at the distorted region and suppress the low-frequency disturbances measured on the rotor blade surface caused by inlet distortion. In addition, the dynamic stress near the blade root can also be effectively reduced by tip air injection. It implies that tip air injection can both extend the stall margin and reduce blade vibration when suffering from circumferential distortion; thus, the compressor can safely operate.

The Wind Power Blade Spoiler Design and Validation Based on CFD

Abstract The power generation capacity of the wind turbine is derived from the aerodynamic properties of the blade, which can be characterized by the local flow state of the blade. In order to improve the aerodynamic performance of the blade and furthermore the power generation efficiency of the wind turbine, the top priority is to find the abnormal area of the local flow along the blade, and take relevant strategies to control the abnormal flow. The CFD-based blade spoiler design is carried out in both the blade root and the blade middlepiece respectively. Meanwhile, the influence of assembled spoilers on the local and whole performance of the blade is verified by the panel method and BEM method. The verification lays the foundation for further flow control optimization design.

Effects of multi-scale turbulent motions on aerodynamic performance of wind turbine under sand-laden conditions

Wind turbine installation in the desert and Gobi regions offers a promising approach for meeting long-term energy demands. However, the effect of multi-scale characteristics in sand-laden atmosphere flows on wind turbine aerodynamic performance has not been evaluated. In this study, wind velocity data collected from the Qingtu Lake Observation Array (QLOA) were employed to address this gap. Results show that up to 58% of the total turbulent kinetic energy (TKE) is accounted for by very large-scale motions (VLSMs), which make up a considerable portion of the TKE. The contributions of the large-scale motions (LSMs) and the small-scale motions (SSMs) to TKE are 36% and 6%, respectively. The contribution of multi-scale turbulent motions to the aerodynamic loads of wind turbine under sand-laden conditions has been quantified for the first time. The comparison demonstrates that while LSMs and SSMs exhibit a rapid drop in their contributions to wind turbine loads with height, VLSMs show a rapid increase. Wavelet analysis revealed a strong correlation between VLSMs and power, thrust, and blade root flapwise moment at periods ranging from 256 to 1024 s. This correlation weakens as the streamwise length scale of the turbulent coherent structure decreases. This study provides essential insights for optimizing wind turbine design and site selection in sand-laden environments.

Stability impact on wind turbine blades trailing edge from bonding zone modelling methods

Abstract The trailing edge of wind turbine blade will undergo a large deformation under the action of load, resulting in a higher risk of damage and failure. The finite element analysis modeling method directly affects the simulation result, furthermore impacts the result of blade structure design. Therefore, it is necessary to find out a modeling method, which is capable to reflect the stability of bonding regions more accurately. This paper aims to discuss the influences of different finite element modeling methods on the buckling stability of blade trailing edge. The influences of shell element, tetrahedron element and hexahedron element on the blade stiffness are considered. The bonding region were simulated separately by combining shell element with bonding web, shell element with tetrahedron element and shell element with hexahedron. The influences of different bonding region modeling methods on the trailing edge buckling factor were analyzed by using the eigenvalue buckling analysis method of finite element. The simulation results provided data support for the future validation of the blade trailing edge bonding area modeling method. The results show that, the tetrahedral mesh provides a higher stiffness, followed by the hexahedral mesh, and the adhesive web form has the smallest stiffness. In order to simulate the more realistic stiffness of the adhesive area at the trailing edge of the blade, adhesive web plates can be built in the flange area of the blade root and the core material area of the trial adhesive mold; The direct bonding area can be simulated employing the hexahedron mesh; The tetrahedral mesh has high stiffness and is not suitable for modeling the adhesive area at the trailing edge. Blade simulation modeling can flexibly use different adhesive forms according to actual situations, ensuring the reliability of the simulation model.

Fluid–acoustic–structure resonance mechanism of a plane cascade via a low-speed wind tunnel test

Acoustic resonance is an important factor that contributes to aeroengine compressor failure. In this study, a plane cascade of compressor blades was designed to reproduce acoustic resonance via a low-speed wind tunnel test. A high-frequency hot-wire, microphone and strain gauge were used to synchronously measure the fluid, acoustic and structural parameters. We analysed the variation in the amplitude and frequency of the multi-field parameters with increasing mean flow velocity and explored the multi-field interaction mechanism that induces the acoustic resonance of the plane cascade. The plane cascade effectively reproduced the acoustic resonance phenomenon. The first-order acoustic-mode frequency of the plane cascade flow duct, second-order torsional vibration mode frequency of the blade and shedding mode frequency of the tip clearance leakage vortex were equal under acoustic resonance. The fluid, acoustic and structural fields showed a strong interaction effect, achieving the maximum blade vibration amplitude and causing fatigue cracks of torsional vibration at the blade root. The frequency lock-in region of the compressor plane cascade was divided into an ‘acoustic–structure’ interaction region, a ‘fluid–acoustic–structure’ interaction region and a first-order acoustic-mode dominant region with increasing mean flow velocity, which demonstrates an interesting phenomenon in which the fluid–acoustic–structure modes compete: acoustic mode > blade vibration mode > vortex shedding mode. The results demonstrate a unique approach to the study of acoustic resonance that provides insight into the acoustic resonance mechanism in a cascade of compressor blades.

Loads and fatigue characteristics assessment of wind farm based on dynamic wake meandering model

As the scale of wind farms continues to expand, the impact of the wake on the power generation and load of wind turbines is becoming increasingly prominent. This study delves into the wake characteristics, power generation, load, and fatigue behavior of an ideal layout wind farm using a dynamic wake meandering model, accounting for diverse spacing configurations, inflow conditions, and yaw angles. The findings reveal that increasing the axial spacing facilitates superior wake recovery, promoting a more evenly distributed load and reducing fatigue damage throughout the wind farm. Moreover, higher inflow wind speed or turbulence intensity exacerbates fatigue damage, especially at elevated wind, where the damage accumulates exponentially. Under yaw conditions, the wake deviates, reducing its adverse impact on downstream turbines and subsequently boosting the overall power generation of the wind farm. However, this deflection simultaneously introduces intricate and detrimental effects on the fatigue load. Notably, optimal yaw achieves a 7.9 % improvement in power generation, also resulting in the most significant fatigue damage at the blade root and tower base. This study provides theoretical and technical underpinnings for the layout optimization and control strategies of wind farms or wind farm clusters.

Transport helicopter blade root cuff attachment modernization concepts

The article discusses the issue of modernizing the blade root cuff attachment of the main rotor blade of a Mi-8 type transport helicopter. Several geometry options were designed and the stress-strain state of various options in a nonlinear formulation under the influence of operational loads was calculated using numerical methods. Conclusions are provided regarding the strength and mass of the blade root cuff attachment options under consideration. The influence of the tightening value of fasteners and the use of adhesive on the stress distribution along the connection is analyzed. Analytical methods were used to determine the optimal dimensions of fastening elements.

Strength and Vibration Analysis of Axial Flow Compressor Blades Based on the CFD-CSD Coupling Method

During the operational process of an axial-flow compressor, the blade structure is simultaneously subjected to both aerodynamic loads and centrifugal loads, posing significant challenges to the safe and reliable operation of the blades. Considering both centrifugal loads and aerodynamic loads comprehensively, a bidirectional CFD-CSD coupling analysis method for blade structure was established. The Navier–Stokes governing equations were utilized to solve the internal flow field of the axial-flow compressor. The conservative interpolation method was utilized to couple and solve the blade’s static equilibrium equation, and the deformation, stress distribution, and prestress modal behavior of compressor blades were mainly analyzed. The research results indicate that the maximum deformation of the blades occurred at the lead edge tip, while stress predominantly concentrated approximately 33% upward from the blade root, exhibiting a radial distribution that gradually decreased. As the rotational speed increased, the maximum deformation of the blades continuously increased. Furthermore, at a constant rotational speed, the maximum deformation of the blade exhibited a trend of first increasing and then decreasing with the increase in mass flow. In contrast, the maximum stress showed a trend of first increasing, then decreasing, and finally increasing again as the rotational speed continuously increased. Centrifugal loads are the primary factor influencing blade stress and natural frequency. During operation, the blades exhibited two resonance points, approximately occurring at 62% and 98% of the design rotational speed.

Application of Artificial Neural Networks to a Model of a Helicopter Rotor Blade for Damage Identification in Realistic Load Conditions.

Monitoring the integrity of aeronautical structures is fundamental for safety. Structural Health Monitoring Systems (SHMSs) perform real-time monitoring functions, but their performance must be carefully assessed. This is typically done by introducing artificial damages to the components; however, such a procedure requires the production and testing of a large number of structural elements. In this work, the damage detection performance of a strain-based SHMS was evaluated on a composite helicopter rotor blade root, exploiting a Finite Element (FE) model of the component. The SHMS monitored the bonding between the central core and the surrounding antitorsional layer. A damage detection algorithm was trained through FE analyses. The effects of the load's variability and of the damage were decoupled by including a load recognition step in the algorithm, which was accomplished either with an Artificial Neural Network (ANN) or a calibration matrix. Anomaly detection, damage assessment, and localization were performed by using an ANN. The results showed a higher load identification and anomaly detection accuracy using an ANN for the load recognition, and the load set was recognized with a satisfactory accuracy, even in damaged blades. This case study was focused on a real-world subcomponent with complex geometrical features and realistic load conditions, which was not investigated in the literature and provided a promising approach to estimate the performance of a strain-based SHMS.