DESIGN DEVELOPMENT AND TESTING OF MODELWIND MILL BLADE USING ADDITIVE MANUFACTURING PROCESS

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1 DESIGN DEVELOPMENT AND TESTING OF MODELWIND MILL BLADE USING ADDITIVE MANUFACTURING PROCESS PROJECT REFERENCE NO.: 40S_BE_1247 COLLEGE : SECAB INSTITUTE OF ENGINEERING TECHNOLOGY, VIJAYAPURA BRANCH : DEPRTMENT OF MECHANILCAL ENGINEERING GUIDES : PROF. SHASHIDHAR A.L. PROF. BASAVAROODH BADIGER STUDENTS : MR. JAMEER PASH HAVARGI MR. SIBGATULLA N.S. KHAN MR. AALAM MH. SHAMSHER SHAMSHAD MR. TAHA KHAN Keywords: qblade, 3d printing, fdm (fused deposition modeling), flexural stress. Introduction: The first wind turbine for electric power generation was built by the company S. Morgan-Smith at Grandpa s Knob in Vermont, USA, in The turbine (53.3 m rotor, 2 blades, power rating 1.25MW) was equipped with massive steel blades. One of the blades failed after only a few hundred hours of intermittent operation. Thus, the importance of the proper choice of materials and inherent limitations of metals as a wind blade material was demonstrated just at the beginning of the history of wind energy development. The next, quite successful example of wind turbine for energy generation is so called Gedser wind turbine, built by Johannes Juul for the electricity company SEAS at Gedser coast in The turbine was produced already with composite blades, built from steel spars, with aluminium shells supported by wooden ribs. The turbine (three blades, 24 m rotor,200 kw) war the first success story of wind energy: it has run for 11 years without maintenance. The additive manufacturing process along with some plastic materials showed some promises in fabricating the wind turbine blades. In the USA Stamper and Dekker fabricated a wing from ABS (Acylonitrile Butadiene Styrene) material in order to compare it with an aluminium one of the same cross-section. Because the ABS wing was built up in layers, it was rough compared to the aluminium one and its performance was not as good. However, once its surface had been smoothed, the lift and drag curves were found to approach those for the aluminium wing. In Germany, AM methods have been used to fabricate aerofoils with embedded sensors, to form aerodynamic components of racing cars. In this case, AM was used because it readily allowed the aerofoil profile to be altered to incorporate the sensors - but it is clear that the aerofoil functioned well even though it was made by a layer-lamination method, and as such its surface will have been relatively rough. At Lancaster University, a model of a vertical-axis tidal power device has been manufactured using the stereolithography AM technology, based on a multi-element aerofoil profile. In this case the multi-element profile was optimized using CFD, taking into account the very different Reynolds number value for tidal devices from the more familiar NACA aerospace geometries. The profiles were fabricated, with pressure tappings designed into the profiles and

2 incorporated at the outset. The final multi-element device was tested in a water flume in the Engineering Department s laboratory. Objectives: The main objective of the project is to design,develop and perform flexural test on 3D printed model wind mill blades manufactured by fused deposition modeling process using ABS plastic. The optimum chord length and twist distribution for the blades is to be obtained by wind mill calculator software and the data is input into QBLADE (open source) software to design the blade. The blades are to be 3D printed by fused deposition modeling process using ABS plastic material (provides good flexural strength). The flexural test is to be carried out on the blades to examine maximum bending stress induced. As the blade cross sectional area is varying continuously from root to tip the beam theory does not permit the manual hand calculation of flexural stresses. Therefore the numerical simulation is to be conducted using QFEM software for a rough estimate of stress. Based on the maximum load taken by the specimen the rough estimate of range of velocities a one meter blade can be operated is to be found out. Methodology: Initially a brief literature survey was conducted to select a particular aerofoil profile to be inculcated into blade root section to enhance structural properties of the blade. Also an airfoil section for good aerodynamic performance was selected. Wind blade calculator (open source software) was used to calculate optimum chord length and twist distribution for blade length of 0.85 meter. The blade was modeled in QBLADE software and was scaled by one fifth of the original dimensions due to manufacturing and cost constraints. The blades were saved in.stl format and input into 3D printer. The 3D printing machine used fused deposition modeling and ABS plastic material to print the blades. In UTM machine the blade root section was fixed to take the flexural stresses and incremental load was applied at the tip. The load at which the specimens failed and corresponding deflection was observed. Force vs Deflection graph was generated by the computer. The same failure load was used to determine the induced flexural stress in the specimens by numerical simulation using QFEM.

t/c=17% Results & discussions: The results of the flexural test

NO Thickness /chord ratio Airfoil section at root Specimen 1

remaining length Maximum load in UTM test KN Numerical

3 t/c=17% Results & discussions: The results of the flexural test conducted on UTM and QFEM numerical simulation are as below. S.NO Thickness /chord ratio Airfoil section at root Specimen 1 17% FX84- W175 Specimen 2 20% FX84- W175 Airfoil section for remaining length Maximum load in UTM test KN Numerical simulation using QFEM Flexural stress MPa NACA NACA

4 load KN Load KN Flexural testing setup in UTM t/c=17% deflection mm t/c=17% Deflection mm

5 Scope for future work Full scale 3D printed blades can be manufactured and used for small scale wind turbine production unit. Such units can be installed on roof-tops for house hold power generation.

STRUCTURAL DESIGN AND ANALYSIS OF ELLIPTIC CYCLOCOPTER ROTOR BLADES

16 TH INTERNATIONAL CONFERENCE ON COMPOSITE MATERIALS STRUCTURAL DESIGN AND ANALYSIS OF ELLIPTIC CYCLOCOPTER ROTOR BLADES In Seong Hwang 1, Seung Yong Min 1, Choong Hee Lee 1, Yun Han Lee 1 and Seung Jo