Integrated analysis of compaction, edge distortion and residual deformation of wind-turbine thick composite spar-cap

Ammasai Sengodan, G; Joshi, SC; Chen, Z

Abstract

A scaled model of a unidirectional glass/epoxy wind turbine spar cap measuring 7.5 mm thick was cured in a vacuum assisted oven and noticed a non-uniform thickness along its length. Even though, a vacuum pressure of 1 bar applied to the laminate, the edge deformation was severe leading to edge curvature. These shortcomings cannot be dealt separately in a single manufacturing process because of the coupled nature of the entire processing physics. Even though considerable research efforts are made to predict the process induced shape distortion and residual stress, only thermo-mechanical modeling was focused in the past. The flow-compaction induced deformation was either studied separately or not included in the numerical process modelling of deformation studies. In this work, resin flow-induced compaction; edge distortion and residual deformation was simulated for a scaled wind turbine spar cap. For this purpose, a coupled numerical simulation procedure was established and implemented in a multi-physics finite element software package. This simulation results indicate that even though the distorted edge of the laminate is trimmed off; there will exist some curvature within the remaining part. Further, the residual deformation and related stresses can be determined from this single simulation procedure. Such fully coupled and integrated procedure may useful to select optimized process conditions to achieve intended final part dimensions with minimal manufacturing-induced effects.

Citation

Ammasai Sengodan, G., Joshi, S., & Chen, Z. (2015, July). Integrated analysis of compaction, edge distortion and residual deformation of wind-turbine thick composite spar-cap. Presented at ICCM International Conferences on Composite Materials, Copenhagen, Denmark

• Presentation Conference Type: Other
• Conference Name: ICCM International Conferences on Composite Materials
• Conference Location: Copenhagen, Denmark
• Start Date: Jul 19, 2015
• End Date: Jul 24, 2015
• Publication Date: Jul 1, 2015
• Deposit Date: Sep 29, 2022
• Publisher URL: http://www.scopus.com/inward/record.url?eid=2-s2.0-85033462150&partnerID=MN8TOARS
• Additional Information: Event Type : Conference; Funders : Energy Research Institute, Nanyang Technological University;Nanyang Technological University