Department of Energy
Robust Design of Wind Turbine Blades
AlphaSTAR demonstrated Certification-by-Analysis (CBA) capability for wind turbine blades made
from advanced lightweight composite materials. The approach integrated durability and damage
tolerance analysis with robust design and virtual testing capabilities to deliver superior,
durable, low weight, low cost, long life, and reliable wind turbine blade design. AlphaSTAR
implemented cost effective design methods with special focus on service life and durability
and damage tolerance (D&DT). It accounted for the considerable scatter in manufacturing anomalies
and defects (i.e. voids, fiber waviness, and fiber and matrix damage during manufacturing).
AlphaSTAR implemented well established modeling and design techniques that reduced weight
by as much as 15% without loss in reliability or durability and with no increase in cost.
Progressive failure analysis and test validation of Sandia's BSDS blade under static loading
|Damage at peak load of a demo turbine blade|
|Damage from test at peak load for the same blade|
|Galib Abumeri, Joshua Paquette, Frank Abdi, "Durability and Reliability of Wind Turbine Composite Blades Using Robust Design Approach,", AIAA-SDM 2011 conference, Denver Colorado, AIAA_SDM_945357 reliability.|
High-Performance Computing Development of a Real-Time Dynamic Super-Element Forced Partitioning
The ever-increasing size of computational structural mechanics (CSM) simulations imposes a pressing
need for commensurate increases in computational speed to keep costs and computation times in
check. Conventional FEM development tools do not have the flexibility, where major components
(e.g. wing/fuselage, wing/engine, etc.) can be changed while keeping the other components unchanged.
During the aircraft preliminary and detail design phases, modification and/or redesign of particular
substructures are often required. Each time a substructure is modified, the entire airframe
structural response must be re-calculated. Such calculations are extremely time consuming and
expensive due to the large scale of the entire airframe's structural model.
A flexible-forced and/or automatic partitioning technique, based on super-elements, was developed
by AlphaSTAR to isolate designated portions of a structure for evaluation. The technique allows
the engineer a broad range of partitioning choices for a large structure. This approach reduces
the cost and time of airframe structural configuration trade studies because trade studies generally
concentrate on a single substructure. Consequently computer processing can be concentrated on
target areas. It is anticipated with the developed technology to reduce running time for progressive
failure analysis by two orders of magnitude.
|Partitioning an Airframe Finite Element Model into Super-elements|