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How can you accurately model wind turbine blade aerodynamics with CAD?

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Wind turbines are a key source of renewable energy, but designing their blades to maximize performance and efficiency is a complex challenge. How can you accurately model wind turbine blade aerodynamics with CAD? In this article, you will learn about the basics of blade aerodynamics, the steps involved in creating a CAD model, and the tools and methods for simulating and testing your design.

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Haris Hameed M.
Erencan Bulut

Robotics Research Assistant @Fraunhofer CML | M.Sc. @TU Hamburg

1 Blade aerodynamics basics

The aerodynamics of wind turbine blades depend on several factors, such as the shape, size, orientation, and pitch of the blades, the wind speed and direction, and the rotational speed and torque of the turbine. The blades generate lift and drag forces that affect the power output and the loads on the structure. The goal of blade design is to optimize the lift-to-drag ratio, the tip speed ratio, and the angle of attack for different wind conditions.

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Haris Hameed M.
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Well the aerodynamics does not depend on torque. It is generated by the turbine itself or simply it is the output. Other factors (inputs) influence the aerodynamics of the turbine.

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Erencan Bulut

Robotics Research Assistant @Fraunhofer CML | M.Sc. @TU Hamburg
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In real-world applications, the aerodynamics of wind turbine blades are influenced by additional factors such as atmospheric pressure, temperature, humidity, and turbulence. These factors can be incorporated into the design process using meteorological data and advanced simulation techniques.

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2 CAD model creation

To create a CAD model of a wind turbine blade, you need to define the geometry and the material properties of the blade. You can use different software tools, such as SolidWorks, CATIA, or ANSYS, to create a 3D model based on a parametric or non-parametric approach. A parametric approach allows you to control the shape of the blade by adjusting variables, such as the chord length, the twist angle, and the airfoil profile. A non-parametric approach allows you to import a predefined shape from a database or a file.

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Haris Hameed M.
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Well if you only create geometry for aerodynamics you don't need material information. For aerodynamics only the outer geometry is important. We need inner details and material information if we want to do structural analysis using finite element analysis.

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Erencan Bulut

Robotics Research Assistant @Fraunhofer CML | M.Sc. @TU Hamburg
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Other CAD tools like AutoCAD, Inventor, Siemens NX, or Fusion 360 can also be used for creating the 3D model of a wind turbine blade. These tools offer different features and capabilities that can be beneficial depending on the specific requirements of the project.

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3 Mesh generation

Once you have a CAD model of the blade, you need to generate a mesh that divides the blade and the surrounding air into small elements. The mesh is essential for applying the boundary conditions and solving the fluid dynamics equations. You can use different types of mesh, such as structured, unstructured, or hybrid, depending on the complexity and accuracy of your model. You can also use different meshing tools, such as ICEM CFD, Fluent Meshing, or Pointwise, to create and refine your mesh.

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Haris Hameed M.
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Yes this information is correct. For CFD analysis you need a water tight geometry. If the geometry is not closed or has complex features then meshing will be complex. Computational results are dependent on the mesh. So it is a key element for CFD or FEM analysis.

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Erencan Bulut

Robotics Research Assistant @Fraunhofer CML | M.Sc. @TU Hamburg
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In aerospace engineering, the creation of a computational mesh around an aircraft structure is critical for CFD simulations. Meshing tools are used to ensure that the mesh accurately represents complex geometries like air intakes or exhaust nozzles, crucial for analyzing aerodynamic performance and engine efficiency.

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4 Simulation setup

To simulate the aerodynamics of your blade, you need to set up the physical models, the boundary conditions, and the numerical methods for your simulation. You can use different software tools, such as Fluent, CFX, or OpenFOAM, to perform the simulation. You can choose different physical models, such as inviscid, laminar, or turbulent, depending on the flow regime and the Reynolds number of your blade. You can also choose different boundary conditions, such as inlet, outlet, wall, or periodic, depending on the domain and the problem.

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Erencan Bulut

Robotics Research Assistant @Fraunhofer CML | M.Sc. @TU Hamburg
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Other simulation tools like Star-CCM+, COMSOL Multiphysics, or SU2 can also be used for aerodynamic simulations. These tools offer different modeling capabilities and numerical methods that can be beneficial for specific types of flow regimes.

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5 Simulation run

To run the simulation, you need to initialize the solution and iterate until convergence. You can monitor different parameters, such as the residuals, the lift and drag coefficients, the power coefficient, and the pressure and velocity fields, to check the accuracy and stability of your solution. You can also use different numerical methods, such as implicit or explicit, steady or unsteady, or linear or nonlinear, depending on the complexity and speed of your simulation.

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Erencan Bulut

Robotics Research Assistant @Fraunhofer CML | M.Sc. @TU Hamburg
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For large-scale simulations, high-performance computing (HPC) resources can be used to reduce the computational time. This involves running the simulation on multiple processors or clusters, which requires additional setup and management.

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6 Simulation results

To analyze the results of your simulation, you need to visualize and compare the output data. You can use different software tools, such as CFD-Post, Paraview, or Tecplot, to display and manipulate the results. You can also use different methods, such as contour plots, streamlines, vectors, or iso-surfaces, to illustrate the flow patterns and the forces on the blade. You can also use different metrics, such as the performance curves, the blade element theory, or the blade element momentum theory, to evaluate and optimize your design.

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Haris Hameed M.
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The most important part is to make sure that the CFD analysis is mesh, domain size, time step size independent. These factors affect the CFD results. Another important aspect is the validation of the numerical model. If experimental results are available for turbine blades then the numerical results could be compared with them. Otherwise analytical or semi empirical methods could also be used to match and cross validate the CFD results.

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7 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?

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Haris Hameed M.
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Well the question must be rephrase, and it should be how well we can model the blade aerodynamics. No need to mention CAD. computer aided design (CAD) is used for model (geometry ) creation only. There are other tools and software that are used to model the aerodynamics.

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How can you accurately model wind turbine blade aerodynamics with CAD?

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3

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5

6

7

1 Blade aerodynamics basics

2 CAD model creation

3 Mesh generation

4 Simulation setup

5 Simulation run

6 Simulation results

7 Here’s what else to consider

Aerospace Engineering

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How can you accurately model wind turbine blade aerodynamics with CAD?

1

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3

4

5

6

7

1 Blade aerodynamics basics

2 CAD model creation

3 Mesh generation

4 Simulation setup

5 Simulation run

6 Simulation results

7 Here’s what else to consider

Aerospace Engineering

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