Fatigue and fracture mechanical behaviour of a wind turbine rotor shaft made of cast iron and forged steel

Herrmann, Jenni; Rauert, Thes; Dalhoff, Peter; Sander, Manuela

doi:10.1016/j.prostr.2016.06.369

Cited by 8 publications

(6 citation statements)

References 1 publication

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“…The high number of load cycles and operating ranges during the life cycle of the wind turbine makes the fatigue conditions be the most important issue. One of the components of the wind turbine that is subject to bending and torsion loads is the shaft [5].…”

Section: Introductionmentioning

confidence: 99%

Fatigue Failure Analysis of Shaft in As-developed Wind Turbine with Reinforced-welding Elbow

Daging

Basino

Sukismo

et al. 2022

J. Phys.: Conf. Ser.

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This paper reports the fatigue analysis for a failure of a shaft in a wind turbine in which reinforced-welding elbow to support the shaft load. The shaft was broken near the reinforcing elbow. When designing mechanical and structural components, the diameter and the characteristics of materials have been considered not to exceed the permissible limit. However, after 40 days of the cycle operation, the shaft was broken at the accepted loading conditions within reasonable limits at a wind speed of 6-10 m/s. The crack initiate fatigue in the shaft is influenced by many variables that may due to uniaxial, bending, torsion, the shape of loading curve, part size, part finish, operating temperature, and atmosphere. For these reasons, it is important to investigate the fatigue behavior on the failure of the shaft. The main goal is to investigate and analyze the fatigue behavior on a broken shaft of the wind turbine gearbox to determine the features that cause the failure. A microscopic investigation of the fatigue-fracture surface was done. The microscopic analysis was carried out in terms of the chemical composition using ARL Spark Spectrometer, energy dispersive spectroscopy (EDS), the morphology of the fatigue by using scanning electron microscopy (SEM) and hardness test. Moreover, a theoretical analysis was made to illustrate the results and comparison between these results and the corresponding stress distribution data from a finite element method (FEM) simulation to know how the fatigue fracture began and propagated along the shaft. The result of the analysis shows that the fatigue occurred due to the unbalanced of the bending and torsion stress in the junction of the reinforced-welding elbow with hardness testing at the extreme cracking area is 435 HV. It is emphasized that the microstructure of fatigue surface structure shows sensitization to facilitate intergranular cracking and fatigue corrosion.

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Section: Introductionmentioning

confidence: 99%

Fatigue Failure Analysis of Shaft in As-developed Wind Turbine with Reinforced-welding Elbow

Daging

Basino

Sukismo

et al. 2022

J. Phys.: Conf. Ser.

View full text Add to dashboard Cite

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“…Moreover, reduced CO2 Emissions and energy consumption for cast components are reached due to its lower smelting temperature [4]. Despite all the advantages of cast iron, mostly forged main shafts are used in wind turbines [5,6], because the mechanical properties of forged steel materials are higher than those of nodular cast iron [7].…”

Section: Introductionmentioning

confidence: 99%

Optimized cast components in the drive train of wind turbines and inner ring creep in the main bearing seat

Kirsch

Kyling

2021

Forsch Ingenieurwes

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Using large components made of nodular cast iron (GJS) in wind turbines enables the application of lightweight construction through the high degree of design freedom. Besides the sand-casting process, casting into a permanent metal mould, i.e. chill casting, leads to a finer microstructure and higher quasi-static mechanical properties as well as higher fatigue strength. Unfortunately, in present design methodologies specific fatigue data is only available for sand cast and not for chilled cast GJS. Thus, lightweight design strategies for large, chilled cast components are not achievable, which led to the publicly funded project “Gusswelle”. Based on material investigations of EN-GJS-400-18-LT chill cast, an optimized hollow rotor shaft is developed. The design process and the resulting shaft design are presented. The optimized hollow rotor shaft prototype will be tested on a full-scale test bench to validate the design methodology. The intended validation plan as well as the test bench setup is shown in this paper. Furthermore, the decreasing wall thickness influences the interference fit between main bearing and hollow rotor shaft. Thus, through the applied bending moment, inner ring creep is more probable to occur in the main bearing seat. The creeping behaviour is investigated with finite element simulations and a measuring method is presented.

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“…The rapidly changing speed induces the fatigue load and in turn causes failure of components. 1–4 The said fluctuations can be reduced by installing energy-storing devices like flywheels or hydraulic accumulators. Due to high cycle life, high power density, low cost, and simple design of the flywheel, it is widely used in industrial drives.…”

Section: Introductionmentioning

confidence: 99%

Dynamic analysis of a hydraulic motor drive with variable inertia flywheel

Kushwaha

Ghoshal

Dasgupta

2019

Proceedings of the Institution of Mechanical Engineers, Part I:

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A flywheel is presented in this article, which can adaptively generate variable inertia in response to the application requirements in a hydraulic drive. The said flywheel consists of four sliders in the guide track of a host flywheel frame which change its position as the rotational speed of the flywheel varies. The varying distance between the slider and the center of rotation leads to a variable inertial mass. This passive inertial mass has a potential to reduce the speed fluctuations of the drive. A comparative study has been made on the effects of the variable inertia flywheel on the hydraulic motor speed fluctuations with that of the fixed inertia flywheel. In this respect, a bond graph model of the hydraulic motor drive with the variable inertia flywheel and the fixed inertia flywheel is developed to analyze their performances. The variable inertia generated by the variable inertia flywheel reduces the hydraulic motor speed fluctuations in response to the changes in the excitation inputs. The tests were conducted to validate the model for step change in speed of the hydraulic motor. The test results of the hydraulic motor speed response are found in good agreement with the predicted response. The proposed design of the flywheel reduces the peak speed of the hydraulic motor that enhances the reliability and performance of the drive.

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Fatigue and fracture mechanical behaviour of a wind turbine rotor shaft made of cast iron and forged steel

Cited by 8 publications

References 1 publication

Fatigue Failure Analysis of Shaft in As-developed Wind Turbine with Reinforced-welding Elbow

Fatigue Failure Analysis of Shaft in As-developed Wind Turbine with Reinforced-welding Elbow

Optimized cast components in the drive train of wind turbines and inner ring creep in the main bearing seat

Dynamic analysis of a hydraulic motor drive with variable inertia flywheel

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