Nonlinear Finite Element Analysis of Tubular Steel Wind Turbine Towers near Man Door and Ventilation Openings to Optimize Design against Buckling

Abstract

The safe and cost-effective design of wind turbine towers is a critical and challenging aspect of the future development of the wind energy sector. This process should consider the continuous growth of towers in height and blades in length. Among potential failure modes of tubular steel towers, shell local buckling due to static axial compressive stresses from the rotor, blades, and tower weight, as well as dynamic flexural compressive stresses from wind actions on the rotating blades and the tower itself, are dominant as thickness is optimized to reduce weight. As man door and ventilation openings are necessary for the towers’ operation, the local weakening of the tower shell in those areas leads to increased buckling danger. This is compensated for by tower manufacturers by the provision of stiffening frames around the openings. However, the cold-forming and welding of these frames are among the most time-consuming aspects of tower fabrication. Working towards the optimization of this design aspect, the buckling response of tubular steel towers near such openings is investigated by means of nonlinear finite element analysis, accounting for geometrical and material nonlinearity and imperfections (GMNIA), and also considering several wind directions with respect to the openings. The alternatives of stiffened and unstiffened openings are investigated, revealing that a thicker shell section around the opening may be sufficient to restore lost stiffness and strength, while the stiffener frame may also be eliminated, offering substantial benefits in terms of manufacturing effort, time and cost.