EXPERIMENTAL ANALYSIS OF TURBULENCE

EFFECT BETWEEN DOUBLE ROTOR WIND TURBINE

A PROJECT REPORT

Submitted by

ISHWARYA.V (311016101020)

JAGANBABU.C (311016101021)

JENIFER.C (311016101022)

KARTHICK RAJA.K (311016101302)

In partial fulfilment for the award of the degree

Of

BACHELOR OF ENGINEERING

IN

AERONAUTICAL ENGINEERING

KCG COLLEGE OF TECHNOLOGY, KARAPAKKAM

ANNA UNIVERSITY, CHENNAI 600025

 SEPTEMPER 2020

BONAFIDE CERTIFICATE

This is to certify that the project report titled “EXPERIMENT ANAYSIS OF

TURBULENCE EFFECT BETWEEN DOUBLE ROTOR WIND TURBINE”

being submitted by “ISHWARYA.V (311016101020), JAGANBABU.C

(311016101021), JENIFER.C (311016101022), and KARTHICK RAJA.K

(311016101302)” to the Department of Aeronautical engineering, KCG

VOLLEGE OF TECHNOLOGY, Chennai, as for the partial fulfillment of the

requirements for the award of degree of bachelor of engineering. This is a

bonafide record of the work out this group under my supervision and guidance in

the even semester of the academic year 2019-2020.

SUPERVISOR HEAD OF THE DEPARTMENT

Gp Capt T. Kumadresan Dr.K.Vijayaraja
Professor, Professor,
Department of Aeronautical Engineering, Department of Aeronautical Engineering,
KCG College of Technology, KCG College of Technology,
Karapakkam. Karapakkam.

INTERNAL EXAMINER EXTERNAL EXAMINER

 ACKNOWLEDGEMENT

We would like to thank Dr.G.Prabakaran, Principal, KCG COLLEGE OF TECHNOLOGY and

Dr. K.VijayaRaja, Head of Department, Aeronautical Engineering, KCG COLLEGE OF
TECHNOLOGY for providing such a wonderful opportunity to carry out our Project in a very
successful manner. We are very grateful to our Internal Guide Gp Capt T. Kumaresan, Dept. Of
Aeronautical Engineering, KCG COLLEGE OF TECHNOLOGY for his consistent guidance and
encouragement throughout the whole phase of our Design Project.
 ABSTRACT

This paper presents an analysis on the phenomenon of turbulence effect in a double

rotor wind turbine and attempts to minimise turbulence. We all are aware that the
existing fossil fuel energy will not last long due to its rampant usage and depleting
availability. On the contrary, wind energy is freely available and environmental
friendly. Normally, wind turbines does not utilise full energy obtained from wind
due the phenomenon called interference. In a typical double rotor wind turbine,
two types of turbulence occur, one is called the atmospheric turbulence and the
other one is the turbulence created within the blades. Atmospheric turbulence is
due to the continuously changing air motions. This impacts wind energy in several
ways such as power performance effects, turbine loads, fatigue and wake effects.
Similarly, the turbulence between the blades may affect the blade rotation and
leads to blade failure. So, it is necessary to reduce the turbulence by adjusting the
angular positions of turbine hub or blade orientations and by varying the distances
from primary to secondary rotor. The analysis starts with design of scaled model of
double rotor wind turbine using CATIA V5 R20 software followed by fabrication
of scaled model. The analysis is done in two phases. The first one is the monitor
phase in which the design is analysed by ANSYS 13.0 software. Next one is the
wind tunnel testing for flow visualisation, pressure and force measurement by
varying the angular positions of turbine hub or blade orientations and by varying
the distances from primary to secondary rotor analysis for different types of
terrains. From the analysis, the turbulence over various regions can be determined
and the optimum angular positions of turbine hub or blade orientations and the
distance from primary to secondary rotor blades can be arrived at to obtain least
turbulence.
Keywords- Wind energy, Double rotor, turbulence, Computer Aided Three-
dimensional Interactive Application (CATIA), Analysis of Systems (ANSYS)
 TABLE OF CONTENTS

Acknowledgement

Abstract

1. Introduction 1

1.1 Wind Turbine 1

1.2 Wind Farms 2

1.3 Wind turbine – Types 3

1.4 Working procedure of HAWT 3

1.5 Wind turbine blade design IKW micro wind turbines 4

1.6 Micro wind turbines 4

1.7 Micro wind system advantages 5

2 Literature survey 6

3 Scope and problem identification 10

3.1 scope of the project 10

3.2 site selection 10

3.3 problem identification 10

4 Determination of blade design 11

4.1 Basic assumption and requirements 11

4.2 Blade design procedure 11

 4.3 Blade design calculation 12

4.3.1 To find blade radius 12

4.3.2 To find RPM of rotor blade 12

4.3.3 To find blade angle 13

4.3.4 To find chord or width of blade 13

4.3.5 Selection of Aerofoil 14

5 Blade designing - CATIA V5 R20 15

5.1 Importing from NOTEPAD 15

6 Power calculation 20

6.1 Pressure contour results of single rotor 20

6.2 Velocity contour results of single rotor 21

6.3 Pressure contour results of double rotor 22

6.4 Velocity contour results of double rotor 23

6.5 Power calculations 24

7 Finite element methods 27

7.1 Introduction of FEA 27

7.1.1 Pre-processing 28

7.1.2 Solver 29

7.1.3 Post-processing 29

7.2 Assumptions 29
8 Material testing 36

8.1 Impact test (IZOD) 36

8.1.1 Impact energy 36

8.2 Compression test 38

8.3 Tensile test 40

8.3.1 Tensile specimen 40

9 Conclusion 43
 CHAPTER I

INTRODUCTION

1.1 WIND TURBINE

A turbine is a machine that spins around in a moving fluid (liquid or gas) and
catches some of the energy passing by. All sorts of machines use turbines, from jet
engines to hydroelectric power plants and from diesel railroad locomotives to windmills.
Even a child's toy windmill is a simple form of turbine.

The huge rotor blades (propellers) on the front of a wind turbine are the "turbine"
part. As wind passes by, the kinetic energy (energy of movement) it contains makes the
blades spin around (usually quite slowly). The blades have a special curved shape so they
capture as much energy from the wind as possible.

Although we talk about "wind turbines," the turbine is only one of the three main
parts inside these giant machines. The second part is a gearbox whose gears convert the
slow speed of the spinning blades into higher-speed rotary motion—turning the drive
shaft quickly enough to power the electricity generator.

The generator is the third main part of a turbine and it's exactly like an enormous,
scaled-up version of the dynamo on a bicycle. When you ride a bicycle, the dynamo
touching the back wheel spins around and generates enough electricity to make a lamp
light up. The same thing happens in a wind turbine, only the "dynamo" generator is
driven by the turbine's rotor blades instead of by a bicycle wheel, and the "lamp" is a light
in someone's home dozens of miles away.

1
1.2 WIND FARMS:

Arrays of large turbines, known as wind farms, are becoming an increasingly

important source of renewable energy and are used by many countries as part of a
strategy to reduce their reliance on fossil fuels. Collective forms of large wind turbines
are collected in a single place where the velocity and other featured conditions are in a
perfect range for wind turbines. On most horizontal wind turbine farms, a spacing of
about 6-10 times the rotor diameter is often upheld. However, for large wind farms
distances of about 15 rotor diameters should be more economically optimal, taking into
account typical wind turbine and land costs. Wind farms will collectively give more
power compare to other renewable sources. Outside of living areas are mostly selected
for wind farms.

FIG NO 1.1 WIND TURBINE

1.3 WIND TURBINE - TYPES:

Wind turbines can rotate about either a horizontal or a vertical axis. Depends upon
this basic rotational axis wind turbine can be classified in to two basic types as Horizontal
Axis Wind Turbine (HAWT) and Vertical Axis Wind Turbine (VAWT).

Horizontal-axis wind turbines have the main rotor shaft and electrical generator at
the top of a tower, and must be pointed into the wind. Small turbines are pointed by a
simple wind vane, while large turbines generally use a wind sensor coupled with a servo
motor. Most have a gearbox, which turns the slow rotation of the blades into a quicker
rotation that is more suitable to drive an electrical generator.

Vertical-axis wind turbines have the main rotor shaft arranged vertically. One
advantage of this arrangement is that the turbine does not need to be pointed into the
wind to be effective, which is an advantage on a site where the wind direction is highly
variable. It is also an advantage when the turbine is integrated into a building because it is
inherently less steerable. Also, the generator and gearbox can be placed near the ground,
using a direct drive from the rotor assembly to the ground-based gearbox, improving
accessibility for maintenance.

Apart from these two types other wind turbines are also useful in some other areas.
They are: Darrieus wind turbine, Giromill, Savonius wind turbine, Savonius wind
turbine. They aren’t commonly utilized but the implement researches about this design
are going on in various applications.

1.4 WORKING PROCEDURE OF HAWT:

 In order to generate power via a HAWT system, the wind must first blow on the
giant blades of the turbine. As the wind blows the blades, they begin to rotate in a given
direction, based on the angle of deflection of the blades. The rotating blades are
connected to a gearbox located at the top of the turbine's tower. In the gearbox, the slow
movement of the blades is transformed into a quicker rotation of gears which is much
better suited to generating electrical power.

1.5 WIND TURBINE BLADE DESIGN 1KW MICRO WIND TURBINES:

Wind turbine is small in size in, and simple in design. It fully uses lift and drags
force, easily produce rated power at low wind speed. 3 phase permanent magnet AC
generator ,direct driven, no gear box, and no need tail. Less maintenance is due to simple

construction.

FIG NO 1.2 1KW MICRO WIND TURBINE

1.6 MICRO WIND TURBINES:

A small wind turbine is a wind turbine used for micro generation, as opposed to
large commercial wind turbines, such as those found in wind farms, with greater
individual power output.
 Micro wind turbine is an umbrella term for small scale wind turbine that are
typically deployed on or near buildings and used to generate electricity that is transmitted
direct to the property

Micro wind turbines have in the past been critized for being visually intrusive and
generating less energy than expected.

However, supplies maintain that models can generate up to 100kw of energy and
represent an efficient source of on – site renewable energy as long as they are situated.

1.7 MICRO WIND SYSTEM ADVANTAGES:

Usually micro wind turbines characterized by a rated power range from 5 to 20

KW, a tower height range from 12 to 20 meters and a rotor diameter range from 6 to 10
meters, represent the best solution for the realization of either stand-alone power systems
for small activities (just like farms or isolated houses) or wind parks for the energy
supply of small municipalities, communities and industrial areas.

The main reasons and advantages favoring the installation of micro wind turbines are:

1. In spite of the large wind systems, micro wind turbines show an almost no-
environmental Impact. As a matter of fact, if we consider the small size of tower height
(< 20 m), the low tip speed of rotor blades (up to 90 m/s in spite of 200 m/s of large wind
turbines) and the Resulting noiseless of micro wind rotors, we can define the micro wind
turbines as very high Environmentally friendly power systems.

2. For the mentioned reasons, any kind of authorization is not requested to the
authorities in order to proceed with the installation of micro wind turbines.

3. Since micro wind systems don’t need great electric transformation cabins but
just simple tri phase connections working at low tension, it’s not necessary to carry out
great Infrastructural works to execute the installation of micro wind turbines;
 4. Micro wind systems are well suited for different energy demands just like those
of small Centre's and municipalities up to 4-5000 citizens, which are willing to cut their
electricity Charges for public utilities

CHAPTER 2

LITERATURE

SURVEY

[1] “Buyung Kosasih*, Andrea Tondelli” EXPERIMENTAL STUDY OF

SHROUDED MICRO-WIND TURBINE,30TH JULY 2012, Shrouding (diffuser
augmented) horizontal axis micro-wind turbine has been shown to be an effective way to
potentially improve the performance of micro wind turbine for applications in built
environments. It is well understood that the degree of the performance enhancement
depends on several factors including the diffuser shape and geometries, blade airfoils, and
the wind condition at the mounting site. The effect of diffuser shape and geometries is
reported in this paper. Performance of diffuser with three different geometrical features
namely: straight diffuser, nozzle-diffuser combination, and diffuser-brim (brimmed
diffuser) combination have been investigated.

[2] “ Md.Abu Abrar,A M Ishtiaque mahbub,Mohammad Mamun”, DESIGN

OPTIMIZATION OF A HORIZONTAL AXIS MICRO WIND TURBINE
THROUGH DEVELOPMENT OF CFD MODEL AN EXPERIMENTATION
2013,This paper comprises of investigating the viability of using an available indigenous
blade as horizontal axis micro wind turbine blade and further improvement of this
particular blade performance through design modification and CFD simulation. Though it
requires a minimum wind speed of around 4.2 m/s to start self rotation of this available
blade without the help of external aid ,the optimize design would demand a less airspeed
as the tourqe would be increasedand this might be successfully used in road side or
housetop application.
[3] “Gianluca De Majo, Maurizio De Santis, Sandro Corradi Ph.D.” A MICRO
WIND TURBINE DEVELOPED FOR LOW ENVIRONMENTAL IMPACT,2011,
micro wind turbines characterized by a rated power range from 5 to 20 KW, a tower
height range from 12 to 20 meters and a rotor diameter range from 6 to 10 meters,
represent the best solution for the realisation of either stand-alone power systems for
small activities (just like farms or isolated houses) or wind parks for the energy supply of
small municipalities, communities and industrial areas.

[4] Hayati MAMUR, DESIGN, APPLICATION, AND POWER PERFORMANCE

ANALYSES OF A MICRO WIND TURBINE,2015, In this study, design,
implementation, and power performance analyses of a micro wind turbine (MWT) system
are presented. An original permanent magnet synchronous generator (PMSG) that
reduced cogging torque was employed as a generator in the MWT. A novel blade form
better performance at low wind speeds was also utilized for the MWT blades. Power
performance analyses of the MWT were carried out for different wind regimes by truck
testing. Performance coefficient, cut-in, and cut-out of the MWT were determined as
27.7%, 2.7 m/s, and 20 m/s at the end of the truck testing, respectively. Moreover, a new
supervisory control and data acquisition (SCADA)program based on a programmable
logic controller was written to measure the electrical power of the MWT, and hence the
analyses of the MWT were easily full filled through the SCADA.

[5], Donny R. Cagle, Anthony D. May, Brian D. Vick and Adam J. Holman,
EVALUATION OF AIRFOILS FOR SMALL WIND TURBINES, A new set of
blades have been designed, fabricated, and tested at the United States Department of
Agriculture-Agricultural Research Service-Conservation and Production Research
Laboratory in Bushland, Texas in an attempt to improve the overall performance of small
(1-10 kilowatt) wind turbines. The new turbine blades feature more advanced NREL
S822 and S823 airfoils, a linear chord distribution, and a near Glauert twist distribution.
The blades were fabricated using a hand lay-up method in a single mold. The rotor blades
were adapted to a 1.5kW wind turbine for performance and reliability testing.
[6], D. Corbus and M. Meadors, SMALL WIND RESEARCH ,October 2005,Many
small wind turbines use furling, whereby the rotor either tilts and/or yaws out of the wind
to protect itself from over speed during very high winds. In the past, most small wind
turbine designers used trial and error approaches that often used variable geometry test
platforms to vary furling offsets. Although recent advances in understanding furling have
resulted in furling being incorporated into wind turbine aero elastic simulation models, to
date there has been a limited amount of test data available for validation of small furling
wind turbine models .

[7], J. M. M. Monteiro1, J. C. Páscoa1 and F. M R. P. Brójo2, SIMULATION OF

THE AERODYNAMIC BEHAVIOUR OF A MICRO WIND TURBINE,2009, In
this paper the Computational Fluid Dynamics (CFD) simulation of a wind turbine with a
rotor diameter of 2.2 meters is performed using the Fluent commercial code. Renewable
energies are only effective if implemented in a large scale basis. Given this fact, this CFD
study is part of the effort that is currently being made at the University of Beira Interior,
Portugal, in order to develop a family of complete micro wind systems suitable for partial
production by the final users. The target objectives of the project are to provide a quality,
open source, small wind turbine project for the masses, with emphasis on low cost,
reliability and ease construction.

[8], Ramadoni Syahputra1,2, Imam Robandi1, and Mochamad Ashari1,

PERFORMANCE ANALYSIS OF WIND TURBINE AS A DISTRIBUTED
GENERATION UNIT IN DISTRIBUTION SYSTEM,2014, the performance analysis
of wind turbine as a distributed generation unit is presented. In this study a model of wind
power is driven by an induction machine. Wind power that is distributed generation is
capable of supplying power to ac power distribution network. Wind power generation
system is modeled and simulated using Matlab Simulink software such that it can be
suitable for modeling some kind of induction generator configurations. To analyze more
deeply the performance of the wind turbine system, both normal and fault conditions
scenarios have been applied. Simulation results prove the excellent performance of the
wind power unit under normal and fault conditions in the power distribution system.

[9] Buyung Kosasih and Andrea Tondelli, “EXPERIMENTAL STUDY OF

SHROUDED MICRO-WIND TURBINE”, 30th July 2012,shrouding (diffuser
augmented) horizontal axis micro-wind turbine has been shown to be an effective way to
potentially improve the performance of micro wind turbine for applications in built
environments. It is well understood that the degree of the performance enhancement
depends on several factors including the diffuser shape and geometries, blade airfoils, and
the wind condition at the mounting site. The effect of diffuser shape and geometries is
reported in this paper. Performance of diffuser with three different geometrical features
namely: straight diffuser, nozzle-diffuser combination, and diffuser-brim (brimmed
diffuser) combination have been investigated. The coefficient of performance of the
micro wind turbine increased by approximately 60% with the addition of simple conical
diffuser, and 63% with the addition of nozzle conical diffuser shroud compared to the
performance of the bare turbine. The optimal tip speed ratio also increased by 33% for
the diffuser and nozzle-diffuser augmentations compared to the bare turbine results.

[10] D.Y.C. Leung, Y. Deng, M.K.H. Leung, DESIGN OPTIMIZATION OF A

COST-EFFECTIVE MICRO WIND TURBINE,2010, this paper is to investigate the
performance of a specially designed micro wind turbine for urban environment where the
wind speed is usually low. Differing from the traditional wind turbine that can be
connected directly to the grid, the micro wind turbine is linked to a small generator and
mainly used for local applications. The advantage of the micro wind turbine is that, apart
from its low cost, it can be propelled by a wind speed as low as 2 m/s.
 CHAPTER 3

SCOPE & PROBLEM IDENTIFICATION

3.1 SCOPE OF THE PROJECT :

 To run the double rotor wind turbine blade even in low speed wind velocity
condition.
 To increase the power of the wind turbine.
 To withstand the blade even at high turbulence.

3.2 SITE SELECTION:

The site selection of data are collected in Tirunelveli region, where the design of
wind turbine will be implemented and type of the application will mounted on the roof
top of the buildings like schools, collages, offices, homes etc..if the wind turbines are
already planted over in this area and also some new designs are going to be planted over
there. From the site survey, the approximate height of the hub of real wind turbine is
notified as 100 m and the power was generated as 800W per wind turbine.

3.3 PROBLEM IDENTIFICATION:

Even though some micro wind turbines are not working ,when the velocity of
below <6m/s. So for that we doing this optimization we can achieve the maximum power
in the minimum velocity. The contribution of the part will be in the roof top-micro wind
turbine in all rural/village.

CHAPTER 4

DETERMINATION OF BLADE DESIGN

4.1 BASIC ASSUMPTIONS & REQUIREMENTS:

The following data are assumed for the initial process of calculation:

1. Amount of Power produced by the wind turbine = 600w

2. Wind speed at selected site = 10 m/s
3. Number of rotor blades = 3
4. Angle of Attack = 00
5. Hub height from the ground level = 2 m
6. Tip speed ratio of micro wind turbines = 10
7. From the introduction to flight data book the value of the altitude will be 100m
for the air density will be 1.20 kg/m^3.

The selection of these blade parameters are often based on the Blade Element Momentum
(BEM) theory. Blade element momentum theory is a theory that combines both blade
element theory and momentum theory. It is used to calculate the local forces on a
propeller or wind-turbine blade. Blade element theory is combined with momentum
theory to alleviate some of the difficulties in calculating the induced velocities at the
rotor. The blade design parameters include airfoil shape, design angle of attack, design tip
speed ratio, and rated wind speed, which are to be considered in the wind turbine blade
aerodynamic design stage.
4.2 BLADE DESIGN PROCEDURE:

1. By the assumption and required values find out the radius of the blade.
2. Assume the tip speed ratio for the appropriate value of blade radius
3. Find out the RPM of the blade for a particular tip speed ratio
4. Divide the blade in to multiple sections
5. Find the blade angle of the blade at every section
6. By using the blade angle find the chord length at different locations of the
blade
7. Choose an aerofoil appropriate to the blade design
8. By using the co-ordinates, pitch angle and chord length design the blade using
s software.

4.3 BLADE DESIGN CALCULATIONS:

4.3.1 To find Blade Radius:

1
P = × 𝜌 × 𝐴 × 𝑉3 × 𝐶 × 𝜂
2 𝑃

1
600= × 1.225 × 𝜋 × 𝑅2 × 103 × 0.5418 × 0.9
2

𝑅2 =0.6381

R = 0.8m

4.3.2 To find RPM of rotor blade:

Based on the observations RPM of the generator shaft is directly proportional to

the TSR. Higher the TSR there will be an increase in the power output. This can be
achieved by a better design of the wind turbine blade.

RPM selection based on TSR

𝑇𝑆𝑅 ∗ 𝑉 ∗ 60
𝑅𝑃𝑀 =
𝜋∗𝐷
4 ∗ 5 ∗ 60
=
𝜋 ∗ 1.6

𝑹𝑷𝑴 = 𝟐𝟑𝟖. 𝟖𝟓𝟑

4.3.3 To find blade Angle:

Initially divide the blade section in to 10 different section to find chord length and
pitch angle at each section. Whole radius notified as ‘R’, and the radius at each section
notified as ‘r’.

𝐵𝑒𝑡𝑎 𝑎𝑛𝑔𝑙𝑒 ᵦ = 𝑎𝑟𝑐 𝑡𝑎𝑛 ( 2𝑅

)− 𝛼
3𝑟𝜆

4.3.4 To find chord or width of blade:

By using the value of pitch angle, tip speed ratio and radius at each section the
chord of the blade at each section is found as follows.

5.6 ∗ 𝑅 ∗ 𝑅
𝐶1 =
𝑖 ∗ 𝑐𝑙 ∗ 𝑡𝑠𝑟 ∗ 𝑡𝑠𝑟 ∗ 𝑟

Therefore maximum chord will be placed in root portion and the minimum chord
will be placed at the tip portion for producing maximum lift force. The radius, blade
angle and chord length are listed below.
 Blade station Radius (m) Chord Length (m) Blade Twist (𝜷)
1 0.16 0.135 23.1
2 0.224 0.112 17.62
3 0.288 0.091 14.35
4 0.352 0.076 12.05
5 0.416 0.0655 10.31
6 0.48 0.057 9.32
7 0.544 0.051 8.23
8 0.608 0.046 7.44
9 0.672 0.0415 6.79
10 0.736 0.038 6.14
11 0.8 0.035 5.66

TABLE NO 4.1 BLADE DESIGN PARAMETERS

4.3.5 Selection of Aerofoil:

According to the aerofoil selection is based on the series which represented either
by NACA/NASA or NREL. These will gives the series of both symmetric and un
symmetric aerofoil. For my project let us select the cambered aerofoil which is otherwise
called as un symmetric aerofoil. It will generates lift at 0º angle of attack. Here the
detailed investigation of the aerofoil S822, NACA series 4412, 4415, 4418 and
Gottingen398.
 CHAPTER 5

BLADE DESIGNING – CATIA V5 R20

CATIA (Computer Aided Three-dimensional Interactive Application) is a multi-

platform CAD/CAM/CAE commercial software suite developed by the French company
Dassault Systems. CATIA enables the creation of 3D parts, from 3D sketches, sheet
metal, composites, molded, forged or tooling parts up to the definition of mechanical
assemblies. The software provides advanced technologies for mechanical surfacing &
other features. It provides tools to complete product definition, including functional
tolerances as well as kinematics definition. CATIA provides a wide range of applications
for tooling design, for both generic tooling and mold & die.

CATIA offers a solution to shape design, styling, surfacing workflow and

visualization to create, modify, and validate complex innovative shapes from industrial
design to Class-A surfacing. CATIA supports multiple stages of product design whether
started from scratch or from 2D sketches. CATIA is able to read and produce STEP
format files for reverse engineering and surface reuse

Apart from the manual design of an aerofoil, the computerized model will give
applicable shape to blade. Two methods are commonly used for importing aerofoil co-
ordinates from excel or notepad to CATIA. The method of importing the co-ordinates
explained here. In these two methods we will use any method to get appropriate blade
design. Two methods are finally align the aerofoil's in such a way of root to tip via mean
blade span.

5.1 IMPORTING FROM NOTEPAD:

1. By using NREL site the co-ordinates for the required aerofoil's such as NACA
4412 Copy & Paste the co- ordinates in a excel document and additionally add one
more column to the right or left side of co-ordinates in order to get three axes
values.
2. Now copy and paste these three columns in a separate notepad and save it in the
format of .txt format
3.

S.NO X- AXIS Y - AXIS

1 1 0.0013
2 0.95 0.0147
3 0.9 0.0271
4 0.8 0.0489
5 0.7 0.0669
6 0.6 0.0814
7 0.5 0.0919
8 0.4 0.098
9 0.3 0.0976
10 0.25 0.0941
11 0.2 0.088
12 0.15 0.0789
13 0.1 0.0659
14 0.075 0.0576
15 0.05 0.0473
16 0.025 0.0339
17 0.0125 0.0244
18 0 0

TABLE NO 5.1 UPPER SIDE CO-ORDINATES

 S.NO X- AXIS Y - AXIS
19 0.0125 -0.0143
20 0.025 -0.0195
21 0.05 -0.0249
22 0.075 -0.0274
23 0.1 -0.0286
24 0.15 -0.0288
25 0.2 -0.0274
26 0.25 -0.025
27 0.3 -0.0226
28 0.4 -0.018
29 0.5 -0.014
30 0.6 -0.01
31 0.7 -0.0065
32 0.8 -0.0039
33 0.9 -0.0022
34 0.95 -0.0016
35 1 0.0013

TABLE NO 5.2 LOWER SIDE CO-ORDINATES

4. Now the co-ordinates with different points will be plotted as points. By clicking
points and clouds, you can change the points into visible points.
5. Connect those points by using a spline, now we will get the aerofoil for root
like below.
 FIG NO 5.2 FINISHED AEROFOIL DESIGN

6. Similarly follow up the procedure for other aerofoil's root to tip.

7. Finally produce the blades in a single product file with the specified distance of
1.8 m each. This will be obtained by creating a blade with appropriate blade and
distance between the sections.
8. Connect all the aerofoil's by multi section pad. Final blade will be obtained look
like this (This model was created in excel but for example this was shown here)
9. All the aerofoil's are aligned in way from root to tip and connected by multi
section pad. The final blade will be look like this,
.
FIG NO 5.3 SINGLE ROTOR

FIG NO 5.4 DOUBLE ROTOR

 CHAPTER 6

POWER CALCULATIONS

6.1 PRESSURE CONTOUR RESULTS OF SINGLE ROTOR

 FIG NO 6.1 PRESSURE CONTOURS OF SINGLE ROTOR

From the static pressure contour values the values of max pressure is occur in the hub
portions

6.2 VELOCITY CONTOUR RESULTS OF SINGLE ROTOR

 FIG NO 6.2 VELOCITY CONTOURS OF SINGLE ROTOR

From the results of the velocity contour results get the results up on the surface of
the value can be taken at the rotation portions give more velocity

6.3 PRESSURE CONTOUR RESULTS OF DOUBLE ROTOR

 FIG NO 6.3 PRESSURE CONTOUR RESULTS OF DOUBLE ROTOR

Behind the turbine blade portion give the more turbulence on the blade surfaces

6.4 VELOCITY CONTOUR RESULTS OF DOUBLE ROTOR

 FIG NO 6.4 VELOCITY CONTOUR RESULTS OF DOUBLE ROTOR

6.5 POWER CALCULATIONS

 1
𝑃 = ρ(U2 − U2 )U
∞ W R
2
𝑈𝑅 = 𝑈∞(1 − 𝑎)
𝑈𝑊 = 𝑈∞(1 − 2𝑎)
𝑈∞ − 𝑈𝑅
𝐴=
𝑈∞
where,
P = Power
ρ = Density
UW = Wind Velocity
U∞ = Free stream velocity
A = Axial Induction Factor

a
WIND (Axial UW UR Power
U∞ VELOCITY Induction (m/s) (m/s) (Watts)
(m/s) Factor)

6.227 5 0.197045 3.773 5 75.15375

12.46 10 0.197432 7.54 10 602.7
18.69 15 0.197432 11.31 15 2034.113
24.92 20 0.197432 15.08 20 4821.6

TABLE NO 6.1 POWER CALCULATION IN PRIMARY ROTOR

 POWER IN PRIMARY ROTOR
POWER IN WATTS 6000
5000
4000
3000
2000POWER IN
PRIMARY ROTOR
1000
0
0102030
WIND VELOCITY (m/s)

GRAPH NO 6.1 COMPARISON OF POWER IN PRIMARY ROTOR

WIND a
(Axial Induction UW UR Power
U∞ VELOCITY
Factor) (m/s) (m/s) (Watts)
(m/s)
6.02 4 0.168053 3.99 4 78.792
12.14 8.1 0.176277 7.86 8.1 649.4078

19.86 12.3 0.244713 10.14 12.3 2368.521

24.29 16.16 0.174917 15.76 16.16 5169.638

TABLE NO 6.2 POWER CALCULATION IN SECONDARY ROTOR

 POWER INSECONDARY ROTOR
6000
POWER IN WATTS
5000

4000

3000
POWER INSECONDARY
2000ROTOR

1000

0
0510152025
WIND VELOCITY (m/s)

GRAPH NO 6.2 COMPARISON OF POWER IN SECONDARY ROTOR

POWER IN WATTS

POWER COMPARISION
12000
10000 POWER IN
8000 PRIMARY ROTOR
6000
4000 POWER IN
2000 SECONDARY ROTOR
0 CUMILATIVE POWER

05101520 25
WIND VELOCITY (m/s)

GRAPH NO 6.3 COMPARISON OF POWER

CHAPTER 7
 FINITE ELEMENT METHODS

The finite element method is numerical analysis technique for obtaining approximate
solutions to a wide variety of engineering problems. Because of its diversity and
flexibility as an analysis tool, it is receiving much attention in engineering schools and
industries. In more and more engineering situations today, we find that it is necessary to
obtain approximate solutions to problems rather than exact closed form solution.

It is not possible to obtain analytical mathematical solutions for many engineering

problems. An analytical solutions is a mathematical expression that gives the values of
the desired unknown quantity at any location in the body, as consequence it is valid for
infinite number of location in the body. For problems involving complex material
properties and boundary conditions, the engineer resorts to numerical methods that
provides approximate, but acceptable solutions. The finite element method has become a
powerful tool for the numerical solutions of a wide range of engineering problems. It has
developed simultaneously with the increasing use of the high-speed electronic digital
computers and with the growing emphasis on numerical methods for engineering
analysis. This method started as a generalization of the structural idea to some problems
of elastic continuum problem, started in terms of different equations or as an extranet
problem.

7.1 INTRODUCTION OF FEA

ANSYSIS is a finite element analysis (FEA) software package. It uses a pre

processor software engine to create geometry. Then it uses a solution routine to apply
loads to the meshed geometry. Finally it outputs desired results in post-processing. FEA
is used throughout almost all engineering design including mechanical systems and civil
engineering structures. In most structural analysis applications it is necessary to compute
displacements and stresses at various points of interest. The finite element method is a
very valuable tool for studying the behaviour of structures. In the finite element method,
the finite element model is created by dividing the structure in to a number of finite
elements. Each element is interconnected by nodes. The selection of elements for
modelling the structure depends upon the behaviour and geometry of the structure being
analyzed. The modelling pattern, which is generally called mesh for the finite element
method, is a very important part of the modelling process. The results obtained from the
analysis depend upon the selection of the finite elements and the mesh size. Although the
finite element model does not behave exactly like the actual structure, it is possible to
obtain sufficiently accurate results for most practical applications.

The goal of meshing in ANSYS Workbench is to provide robust, easy to use

meshing tools that will simplify the mesh generation process. These tools have the benefit
of being highly automated along with having a moderate to high degree of user control.

Advantages of FEA:

 Visualization increases
 Design cycle time reduces
 No. of prototypes reduces
 Testing reduces
 Optimum design
The process of performing ANSYS can be broken down into three main steps.

1) Pre-processing

2) Solver

3) Post-processing

7.1.1 PRE-PROCESSING

This step is most important in analysis of leaf spring. Any modelling software can
be used for modelling of geometry and can be shifted to other simulation software for
analysis purpose. After mesh generation (grid generation) is the process of subdividing a
region to be modelled into a set of small elements. Meshing is the method to define and
breaking up the model into small elements. In general a finite element model is defined
by a mesh network, which is made up of the geometric arrangement of elements and
nodes. Nodes represent points at which features such as displacements are calculated.
Elements are bounded by set of nodes, and define localized mass and stiffness properties
of the model. Elements are also defined by the number of mesh, which allowed reference
to be made to corresponding deflections, stresses at specific model location. The common
type of mesh element used in ANSYS solver is hexahedral, tetrahedral and brick.

7.1.2 SOLVER

During pre processing user has to work hard while solution step is the turn of computer
to do the job. User has to just click on solve icon & enjoy a cup of tea! Internally
software carries out matrix formations, inversion, multiplication & solution for unknown.
e.g. displacement & then find strain & stress for static analysis.

7.1.3 POST-PROCESSING

The final step in ANSYS is Post-processing, during which the ANSYS results are
analyzed. However, the real value of ANSYS simulation is frequently found in its ability
to provide accurate predictions of integrated quantities such as find displacement and
stresses. Post processing is viewing results, verifications, conclusions & thinking about
what steps could be taken to improve the design.

7.2 ASSUMPTIONS

 Software to be used for ANSYS 13.0

 Model simplification for FEA.
 Meshing size is limited to computer compatibilities.
 Static analysis is considered.
 Material used for steel leaf spring analysis is isotropic.
FIG 7.1 3D MODEL OF DOUBLE ROTOR WIND TURBINE BLADE

FIG 7.2 MESH IMAGE OF DOUBLE ROTOR WIND TURBINE

 FIG 7.3 IMPORTED PRESSURE FROM THE CFD ANALYSIS

FIG 7.4 BOUNDARY CONDITIONS FOR STRUCTURAL ANALYSIS

FIG 7.5 DEFORMATION RESULT OF DOUBLE ROTOR WIND TURBINE

FIG 7.6 STRAIN RESULT OF DOUBLE ROTOR WIND TURBINE

FIG 7.7 STRESS RESULT OF DOUBLE ROTOR WIND TURBINE

 DOUBLE ROTOR MATERIALS DEFORMATION

STEEL 4.133

ALUMINIUM 0.76302

GFRP 0.30206

TABLE 7.1 DEFORMATION RESULT WITH VARIOUS MATERIALS

DEFORMATION IN mm

DEFORMATION
3

2.5

1.5
DEFORMATION
1

0.5

0
STEEL ALUMINIUM GFRP

GRAPH 7.1 DEFORMATION RESULT WITH VARIOUS MATERIALS

DOUBLE ROTOR MATERIALS STRAIN
STEEL 0.00041322
ALUMINIUM 8.61E-05
GFRP 1.24E-05

TABLE 7.2 STRAIN RESULT WITH VARIOUS MATERIALS

STRAIN
0.00045
0.0004
0.00035
0.0003
0.00025
0.0002
0.00015
0.0001 STRAIN
0.00005
0

STEELALUMINIUMGFRP

GRAPH 7.2 STRESS RESULT WITH VARIOUS MATERIALS

DOUBLE ROTOR MATERIALS STRESS IN MPA

STEEL 6.1983
ALUMINIUM 4.2568
GFRP 2.4824

TABLE 7.3 STRESS RESULT WITH VARIOUS MATERIALS

 STRESS IN MPA
STRESS IN MPA 7

4
STRESS

3
2

0 STEEL ALUMINIUM GFRP

GRAPH 7.3 STRESS RESULT WITH VARIOUS MATERIALS

 CHAPTER 8

MATERIAL TESTING

8.1 IMPACT TEST (IZOD)

IZOD impact testing is an ASTM standard method of determining the impact

resistance of materials. A pivoting arm is raised to a specific height (constant potential
energy) and then released. The arm swings down hitting the sample, breaking the
specimen. The energy absorbed by the sample is calculated from the height the arm
swings to after hitting the sample. A notched sample is generally used to determine
impact energy and notch sensitivity.

The test is similar to the Charpy impact test but uses a different arrangement of the
specimen under test. The IZOD impact test differs from the Charpy impact test in that the
sample is held in a cantilevered beam configuration as opposed to a three-point bending
configuration.

The test is named after the English engineer Edwin Gilbert IZOD (1876–1946),
who described it in his 1903 address to the British Association, subsequently published
in Engineering.

8.1.1 Impact energy

Impact is a very important phenomenon in governing the life of a structure. For

example, in the case of an aircraft, impact can take place by a bird hitting a plane while it
is cruising, or during takeoff and landing the aircraft may be struck by debris that is
present on the runway, and as well as other causes. It must also be calculated for roads if
speed breakers are present, in bridge construction where vehicles punch an impact load,
etc.

Impact tests are used in studying the toughness of material. A material's toughness
is a factor of its ability to absorb energy during plastic deformation. Brittle materials have
low toughness as a result of the small amount of plastic deformation that they can endure.
The impact value of a material can also change with temperature. Generally, at lower
temperatures, the impact energy of a material is decreased. The size of the specimen may
also affect the value of the Izod impact test because it may allow a different number of
imperfections in the material, which can act as stress risers and lower the impact energy.

FIG NO 8.1 IMPACT TEST SPECIMEN (BEFORE TESTING)

FIG NO 8.2 IMPACT TEST SPECIMEN (AFTER TESTING)

8.2 COMPRESSION TEST

The three point bending flexural test provides values for the modulus of elasticity
in bending Ef, flexural stress sigma f, flexural strain epsilon f and the flexural stress-strain
response of the material. The main advantage of a three-point flexural test is the ease of
the specimen preparation and testing. However, this method has also some disadvantages:
the results of the testing method are sensitive to specimen and loading geometry and
strain rate.

The test method for conducting the test usually involves a specified test fixture on
a universal testing machine. Details of the test preparation, conditioning, and conduct
affect the test results. The sample is placed on two supporting pins a set distance apart
and a third loading pin is lowered from above at a constant rate until sample failure.

FIG NO 8.3 TEST FIXTURE ON UNIVERSAL TESTING MACHINE FOR

THREE POINT FLEX TEST
FIG NO 8.4 COMPRESSION TEST(BENDING TEST) SPECIMEN BEFORE
TESTING

FIG NO 8.5 COMPRESSION TEST(BENDING TEST) SPECIMEN AFTER

TESTING
8.3 TENSILE TEST

FIG NO 8.6 TENSILE TESTING MACHINE

Tensile testing, is also known as tension testing, is a fundamental materials

science test in which a sample is subjected to a controlled tension until failure. The
results from the test are commonly used to select a material for an application, for quality
control, and to predict how a material will react under other types of forces. Properties
that are directly measured via a tensile test are ultimate tensile strength,
maximum elongation and reduction in area. From these measurements the following
properties can also be determined: Young's modulus, Poisson's ratio, yield strength,
and strain-hardening characteristics. Uniaxial tensile testing is the most commonly used
for obtaining the mechanical characteristics of isotropic materials.
For anisotropic materials, such as composite materials and textiles, biaxial tensile
testing is required.

8.3.1 TENSILE SPECIMEN

A tensile specimen is a standardized sample cross-section. It has two shoulders

and a gage (section) in between. The shoulders are large so they can be readily gripped,
whereas the gauge section has a smaller cross-section so that the deformation and failure
can occur in this area.
 The shoulders of the test specimen can be manufactured in various ways to mate to
various grips in the testing machine (see the image below). Each system has advantages
and disadvantages; for example, shoulders designed for serrated grips are easy and cheap
to manufacture, but the alignment of the specimen is dependent on the skill of the
technician. On the other hand, a pinned grip assures good alignment. Threaded shoulders
and grips also assure good alignment, but the technician must know to thread each
shoulder into the grip at least one diameter's length, otherwise the threads can strip before
the specimen fractures.

In large castings and forgings it is common to add extra material, which is

designed to be removed from the casting so that test specimens can be made from it.
These specimens may not be exact representation of the whole work piece because the
grain structure may be different throughout. In smaller work pieces or when critical parts
of the casting must be tested, a work piece may be sacrificed to make the test
specimens. For work pieces that are machined from bar stock, the test specimen can be
made from the same piece as the bar stock.

FIG NO 8.7 TENSILE TEST SPECIMEN (BEFORE TESTING)

FIG NO 8.8 TENSILE TEST SPECIMEN (AFTER TESTING)
 CHAPTER 9
CONCLUSION

The overall comparison of the power double rotor produce 100% more than single
rotor wind turbine Due to the reason of secondary rotor produce more power to primary
rotor Turbulence effect is the main factor in the double rotor wind turbines Optimized
angular position of the secondary rotor for reduce the turbulence effect
FEA analysis is taken for the double rotor wind blade material selection process in
this place steel, aluminum and GFRP materials are choose for the structural analysis
pressure load condition is taken from the CFD analysis results from the analysis GFRP
material produce the very low stress value in the wind pressure condition so GFRP
material is taken for experimental analysis
GFRP material specimen is prepared by using hand layup method and getting the
results of tensile strength 93MPa, impact strength 64 Joules, Vickers Hardness value is
48Hv and bending strength of 69MPa obtained in this domestic purpose wind turbine
blade will not create much stress and need a weightless material so GFRP material is
choose for double rotor wind turbine blade application
 REFERENCE

[1] Spreadsheet assisted overall Design of a Wind Turbine Blade

[2] U. Aguirre Llona1, J. J. Pérez Rambla2 and G. Aguirre Zamalloa

[3] INTERNATIONAL JOURNAL of RENEWABLE ENERGY RESEARCH,

Izelu, Christopher Okechukwu Wind Energy Conversion System for Electrical
Power Generation in UNIPORT and UPTH, Port Harcourt, Rivers State, Nigeria
[4] INTERNATIONAL JOURNAL of RENEWABLE ENERGY RESEARCH Sandip. A.
Kale ,Aerodynamic Design of a Horizontal Axis Micro Wind Turbine Blade Using
NACA 4412 Profile
[5] EVALUATION OF PERFORMANCE OF HORIZONTAL AXIS,WIND TURBINE
BLADES BASED ON OPTIMAL ROTOR THEORY,Nitin Tenguria1, N. D. Mittal1 and
Siraj Ahmed
[6] Wind Turbines Theory - The Betz Equation and Optimal Rotor Tip Speed Ratio,Magdi
Ragheb1 and Adam M. Ragheb

[7] BLADE PERFORMANCE ANALYSIS AND DESIGN IMPROVEMENT OF

A SMALL WIND TURBINE FOR RURAL AREAS,Verónica Cabanillas
Sánchez

[8] Wind Turbine Blade Design,Peter J. Schubel and Richard J. Crossley

[9] Wind Turbine Blade Analysis using the Blade Element Momentum Method. Grant
Ingram,October 18, 2011.
[10] International journal of Energy – Science direct

[11] Wikipedia,googlescholar – For basic knowledge and thoughts

[12] AIAA journal papers (American Institute of Aeronautics and Astronautics)

and US Patent papers.
[13] http://www.altitude.nu/index.jsp?id=3809
http://wind.nrel.gov/airfoils/Coefficients/
http://wind.nrel.gov/airfoils/AirfoilList.html
http://wind.nrel.gov/airfoils/Documents/AirfoilDocuments.html
[14] http://airfoiltools.com
[15] Wind Turbine Power Calculations