A computational framework for the lifetime prediction of vertical-axis wind turbines: CFD simulations and high-cycle fatigue modeling

A novel computational framework is presented for the lifetime prediction of vertical-axis wind turbines (VAWTs). The framework uses high-fidelity computational fluid dynamics (CFD) simulations for the accurate determination of the aerodynamic loading on the wind turbine, and includes these loading characteristics in a detailed 3D finite element method (FEM) model to predict fatigue cracking in the structure with a fatigue interface damage model. The fatigue interface damage model allows to simulate high-cycle fatigue cracking processes in the wind turbine in an accurate and robust fashion at manageable computational cost. The FEM analyses show that the blade-strut connection is the most critical structural part for the fatigue life of the VAWT, particularly when it is carried out as an adhesive connection (instead of a welded connection). The sensitivity of the fatigue response of the VAWT to specific static and fatigue modeling parameters and to the presence of a structural flaw is analyzed. Depending on the flaw size and flaw location, the fatigue life of the VAWT can decrease by 25%. Additionally, the decrease of the fatigue resistance of the VAWT appears to be mainly characterized by the monotonic reduction of the tensile strength of the adhesive blade-strut connection, rather than by the reduction of its mode I toughness, such that fatigue cracking develops in a brittle fashion under a relatively small crack opening. It is emphasized that the present computational framework is generic; it can also be applied for analyzing the fatigue performance of other rotating machinery subjected to fluid–structure interaction, such as horizontal-axis wind turbines, steam turbine generators and multistage pumps and compressors.