journal article·2015-07Open access

Pultrusion of a vertical axis wind turbine blade part-I: 3D thermo-chemical process simulation

Ismet Baran, Cem C. Tutum, Jesper H. Hattel, Remko Akkerman

Abstract

A novel three dimensional thermo-chemical simulation of the pultrusion process is presented. A simulation is performed for the pultrusion of a NACA0018 blade profile having a curved geometry, as a part of the DeepWind project. The finite element/nodal control volume (FE/NCV) technique is used. First, a pultrusion simulation of a U-shaped composite profile is performed to validate the model and it is found that the obtained cure degree profiles match with those given in the literature. Subsequently, the pultrusion process simulation of the NACA0018 profile is performed. The evolutions of the temperature and cure degree distributions are predicted inside the heating die and in the post-die region where convective cooling prevails. The effects of varying process conditions on the part quality are investigated for two different heater configurations and with three different pulling speeds. Larger through-thickness gradients are obtained for the temperature and degree of cure as the pulling speed increases. This will affect the process induced residual stresses and distortions during manufacturing.
Source: openaire · Quality: candidate unverified · Source record ↗

Research context

OpenAlex topics: Fiber-reinforced polymer composites · Epoxy Resin Curing Processes · Mechanical Behavior of Composites

SciVX discovery tags are terminology-based. OpenAlex topics are source-provided classifications.

References (28)

Show source-provided references
1. Schmidt PU, Vita L, Aagaard MH, Hattel J H, Ritchie E, Leban KM, et al. (2012) 1st DeepWind 5 MW baseline design. Energy Procedia 24:27–3510.1016/j.egypro.2012.06.083 ↗
2. Paulsen U S, Madsen H A, Hattel J H, Baran I, Nielsen P H (2013) Design optimization of a 5 MW floating offshore vertical-axis wind turbine. Energy Procedia 35:22–3210.1016/j.egypro.2013.07.155 ↗
3. Sutherland HJ, Berg DE, Ashwill TD (2012) A retrospective of VAWT technology. Sandia report, SAND2012-0304
4. Palikhel DR, Roux JA, Jeswani AL (2012) Die-attached versus die-detached resin injection chamber for pultrusion. App Compos Mat. doi: 10.1007/s10443-012-9251-110.1007/s10443-012-9251-1 ↗
5. Baran I, Tutum C C, Hattel J H (2013) The effect of thermal contact resistance on the thermosetting pultrusion process. Compos Part B- Eng 45:995–100010.1016/j.compositesb.2012.09.049 ↗
6. Ahmed F, Joshi S C, Lam Y C (2004) Three-dimensional FE-NCV modeling of thermoplastic composites pultrusion. J Thermoplast Compos 17:447–46210.1177/0892705704038222 ↗
7. Joshi S C, Lam Y C, Win Tun U (2003) Improved cure optimization in pultrusion with pre-heating and die-cooler temperature. Compos Part A-Appl S 34:1151–115910.1016/j.compositesa.2003.08.003 ↗
8. Carlone P, Palazzo G S, Pasquino R. (2006) Pultrusion manufacturing process development by computational modelling and methods. Math Comput Model 44:701–70910.1016/j.mcm.2006.02.006 ↗
9. Baran I, Tutum C C, Hattel J H (2013) The internal stress evaluation of the pultruded blades for a Darrieus wind turbine. Key Eng Mater 554–557:2127–213710.4028/www.scientific.net/KEM.554-557.2127 ↗
10. Tutum C C, Baran I, Hattel J H (2013) Utilizing multiple objectives for the optimization of the pultrusion process. Key Eng Mater 554–557:2165–217410.4028/www.scientific.net/KEM.554-557.2165 ↗
11. Joshi S C, Chen X. (2010) Time-variant simulation of multi-material thermal pultrusion. Appl Compos Mater 18:283–29610.1007/s10443-010-9156-9 ↗
12. Joshi S C, Lam Y C (2001) Three-dimensional finite-element/nodal-control-volume simulation of the pultrusion process with temperature-dependent material properties including resin shrinkage. Compos Sci Technol 61:1539–154710.1016/S0266-3538(01)00056-2 ↗
13. Carlone P, Palazzo G S (2007) Pultrusion manufacturing process development: cure optimization by hybrid computational methods. Comput Math Appl 53:1464–147110.1016/j.camwa.2006.02.031 ↗
14. Baran I, Tutum C C, Hattel J H (2012) Reliability estimation of the pultrusion process using the first-order reliability method (FORM). App Compos Mat 20:639–65310.1007/s10443-012-9293-4 ↗
15. Liu X L, Crouch I G, Lam Y C (2000) Simulation of heat transfer and cure in pultrusion with a general-purpose finite element package. Compos Sci Technol 60:857–86410.1016/S0266-3538(99)00189-X ↗
16. Baran I, Tutum C C, Nielsen M W, Hattel J H (2013) Process induced residual stresses and distortions in pultrusion. Compos Part B: Eng 51:148–16110.1016/j.compositesb.2013.03.031 ↗
17. Baran I, Hattel J H, Tutum C C (2013) Thermo-chemical modelling strategies for the pultrusion process. App Compos Mat 20(6):1247–126310.1007/s10443-013-9331-x ↗
18. Carlone P, Baran I, Hattel J H, Palazzo G S (2013) Computational approaches for modeling the multiphysics in pultrusion process. Adv Mech Eng 2013(301875):14. doi: 10.1155/2013/301875.
19. Baran I, Tutum C C, Hattel J H (2012) Optimization of the thermosetting pultrusion process by using hybrid and mixed integer genetic algorithms. App Compos Mat 20:449–46310.1007/s10443-012-9278-3 ↗
20. Chachad Y R, Roux J A, Vaughan J G, Arafat E (1995) Three-dimensional characterization of pultruded fiberglass-epoxy composite materials. J Reinf Plast Comput 14:495–51210.1177/073168449501400506 ↗
21. Liang G, Garg A, Chandrashekhara K (2005) Cure characterization of pultruded soy-based composites. J Reinf Plast Comp 24(14):1509–152010.1177/0731684405050387 ↗
22. Liu X L (2001) Numerical modeling on pultrusion of composite I beam. Compos Part A-Appl S 32:663–68110.1016/S1359-835X(00)00164-0 ↗
23. Liu X L, Hillier W (1999) Heat transfer and cure analysis for the pultrusion of a fiberglass-vinyl ester I beam. Compos Struct 47:581–58810.1016/S0263-8223(00)00029-5 ↗
24. Roux J A, Vaughan J G, Shanku R, Arafat E S, Bruce J L, Johnson V R (1998) Comparison of measurements and modeling for pultrusion of a fiberglass/epoxy I-beam. J Reinf Plast Comp 17:1557–157810.1177/073168449801701705 ↗
25. Sarrionandia M, Mondragn I, Moschiar S M, Reboredo M M, Vzquez A. (2002) Heat transfer for pultrusion of a modified acrylic/glass reinforced composite. Polym Composite 23:21–2710.1002/pc.10408 ↗
26. Valliappan M, Roux J A, Vaughan J G, Arafat E S (1996) Die and post-die temperature and cure in graphite-epoxy composites. Compos Part B-Eng 27:1–910.1016/1359-8368(95)00001-1 ↗
27. ABAQUS 6.11 Reference Guide (2011)
28. Bogetti T A, Gillespie J W (1992) Process-induced stress and deformation in thick-section thermoset composite laminates. J Compos Mater 26(5):626–66010.1177/002199839202600502 ↗