Fatigue life on a full scale test rig: Forged versus cast wind turbine rotor shafts

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

doi:10.1088/1742-6596/753/7/072021

Cited by 2 publications

(2 citation statements)

References 2 publications

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“…Through the 8% lower density of cast iron compared to the density of steel [3], lightweight design can also be considered through the choice of material if the same material strength is assumed. 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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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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“…Along with the growing rotor diameters and hub heights, the loads on the main shaft and the main bearing are continuously increasing. Nowadays, more compact drive chain designs have been developed, with short and hollow rotor shafts [4]. Accordingly, relative movements between the rotor shaft and the inner ring of the main bearing will occur.…”

Section: Introductionmentioning

confidence: 99%

Method for evaluation of surface crack size of wind turbine main shaft by using ultrasonic diffracted waves

Cheng¹,

He²,

Lyu³

et al. 2020

Smart Mater. Struct.

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The structural damage in the main shaft threatens the service safety of the wind turbine directly. The mechanical properties of the in-service main shaft tend to degrade severely due to the transverse cracks extending from the outer circumference. In the health monitoring of the shaft, it is of great importance not only to identify the cracks, but also to accurately evaluate the crack size. In this research, a novel quantitative method is proposed for the transverse crack characterization. The diffracted waves from the crack tip received in the central hole of the shaft are used to construct elliptic trajectories of beam path. The crack position and its depth can be determined by the intersection of the trajectories. Furthermore, a crack size quantification model is established, and the numerical demonstration is given for evaluation of crack position and depth. Meanwhile, an acoustic finite element model is developed, in which the path of the acoustic waves radiated from the end face of the shaft is analyzed in detail. The quantitative method is well confirmed by the simulation of cracks at different locations with different depths. Considering the accuracy of crack evaluation from a large size zone, the time of diffracted echo is calibrated by measuring the time shift of the transducers. A shaft sample with a transverse crack was used to implement the experimental verification. Totally, the sizing error is less than 5 mm, which indicates that this proposed method is effective for the evaluation of surface cracks in the main shaft.

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Fatigue life on a full scale test rig: Forged versus cast wind turbine rotor shafts

Cited by 2 publications

References 2 publications

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

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

Method for evaluation of surface crack size of wind turbine main shaft by using ultrasonic diffracted waves

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