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Journal of Sandwich Structures and Materials
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Application and Analysis of Sandwich Elements in the Primary Structure of Large Wind Turbine Blades

C. Berggreen

Department of Mechanical Engineering Technical University of Denmark DK-2800 Kgs. Lyngby, Denmark, cbe{at}mek.dtu.dk

K. Branner

Wind Energy Department, Risø National Laboratory DK-4000 Roskilde, Denmark

J.F. Jensen

Department of Mechanical Engineering Technical University of Denmark DK-2800 Kgs. Lyngby, Denmark

J.P. Schultz

Department of Mechanical Engineering Technical University of Denmark DK-2800 Kgs. Lyngby, Denmark

The present work studies the advantages of applying a sandwich construction as opposed to traditional single skin composites in the flanges of a load carrying spar in a future 180 m wind turbine rotor. A parametric finite element model is used to analyze two basic designs with single skin and sandwich flanges, respectively. Buckling is by far the governing criterion for the single skin design. Introducing a sandwich construction results in a globally more flexible structure making tower clearance the critical criterion. Significant weight reduction up to 22.3% and increased buckling capacity is obtained. Moreover, the study showed that proper choice of core material is important to prevent face wrinkling. Geometric nonlinear analysis showed sensitivity to imperfections. A consistent submodeling technique is presented for verifying the response from the global model in any section of interest.

Key Words: buckling • sandwich • FEA • sensitivity analysis • wind turbine blades.

Journal of Sandwich Structures and Materials, Vol. 9, No. 6, 525-552 (2007)
DOI: 10.1177/1099636207069071
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