Structural Analysis of Wind Turbine Blade Using Composite Materials

Abstract

This research investigates the comparative structural behaviour of wind turbine blades manufactured using Carbon Fiber Reinforced Polymer (CFRP) and Glass Fiber Reinforced Polymer (GFRP) through finite element analysis (FEA). A three-bladed propeller, with 37 cm blade span and 210 mm hub-to-tip radius, was modelled in CATIA and imported into ANSYS Workbench. Static structural simulations were carried out under a uniform external surface pressure of 0.00012 MPa and a rotational velocity of 2 rad/s, with fixed hub boundary conditions. The analysis considered total deformation, von Mises stress, and equivalent strain. Mesh independence tests were performed to ensure reliability, and high-quality tetrahedral meshing was applied with refinements at the hub-blade junction. Results revealed that CFRP exhibited superior mechanical performance compared to GFRP: maximum deformation of 0.011 mm, peak von Mises stress of 0.125 MPa, and strain of 0.00020 mm/mm. In contrast, GFRP recorded higher deformation (0.014 mm), stress (0.132 MPa), and strain (0.00035 mm/mm), reflecting lower stiffness and greater fatigue risk. The hub-blade junction consistently emerged as the critical stress concentration region. While CFRP’s higher stiffness and lower density contribute to improved structural integrity and fatigue life, its higher cost may limit large-scale adoption. GFRP remains a cost-effective option for small or moderate load applications. The study concludes with recommendations for material selection based on performance requirements and suggests future research directions including hybrid laminates, dynamic load modeling, thermal coupling, and experimental validation.

Introduction

Context & Importance:
Wind energy is rapidly expanding as a key renewable resource. Turbine blades are crucial for efficient energy capture, with their structural and aerodynamic performance impacting power output, safety, and lifecycle costs.

Materials:
Composite materials, mainly Carbon Fiber Reinforced Polymer (CFRP) and Glass Fiber Reinforced Polymer (GFRP), dominate blade construction.

• GFRP: Cost-effective, easier to manufacture, but heavier, less stiff, and more fatigue-prone.

• CFRP: Higher stiffness, lighter weight, longer fatigue life, but costlier and more complex to produce.

Research Objective:
This study uses finite element analysis (FEA) to compare the structural responses of CFRP and GFRP blades under identical static loading conditions.

Methodology:

• A 3-bladed propeller model with detailed geometry was designed in CATIA.

• Simulations were performed in ANSYS Workbench applying uniform pressure and rotational speed, with fixed hub constraints.

• Key outputs: total deformation, von Mises stress, and strain distributions.

• Mesh refinement and independence checks ensured result accuracy, especially near the critical hub-blade junction where stress concentrations occur.

Key Findings:

• CFRP blades show lower deformation and stress, indicating superior stiffness and durability.

• GFRP blades exhibit higher deflections and stress concentrations, implying greater fatigue risk and maintenance needs.

• Centrifugal stiffening effects are more pronounced in CFRP blades due to their lower density and higher stiffness.

• Strain distributions indicate CFRP better resists fatigue-related damage.

Implications:

• CFRP is ideal for large, high-performance turbines (e.g., offshore farms) where cost is justified by improved reliability and efficiency.

• GFRP suits smaller or cost-sensitive turbines with moderate performance demands.

Sustainability Considerations:

• Both materials face recycling challenges—GFRP due to thermoset matrices and CFRP due to energy-intensive production.

• Emerging research explores hybrid composites and thermoplastics to enhance recyclability and performance.

Literature Context:

• Prior studies confirm CFRP’s mechanical advantages but highlight cost limits.

• Hybrid layups combining carbon and glass fibers show promise in balancing cost and performance.

• Thermoplastic composites and predictive maintenance techniques are advancing sustainable blade design.

Conclusion

The present study successfully demonstrated the comparative structural analysis of a three-bladed wind turbine propeller designed in CATIA and analyzed in ANSYS Workbench using CFRP and GFRP composite materials. The simulation results confirmed that material selection plays a critical role in determining the overall performance, durability, and efficiency of wind turbine blades. CFRP showed superior mechanical characteristics, including lower total deformation, reduced equivalent von Mises stress, and more uniformly distributed strain contours, as compared to GFRP under identical loading conditions. These results suggest that CFRP can withstand operational stresses more effectively, ensuring minimal deflection, enhanced load-bearing capacity, and improved fatigue life, which are essential for long-term, maintenance-free wind turbine operation.Furthermore, the finite element analysis proved to be a reliable predictive tool, enabling accurate assessment of structural behaviour before actual manufacturing. The study validates the application of FEM-based simulations for optimizing blade designs, reducing prototype costs, and improving design safety margins. While GFRP remains a cost-effective material, its higher deformation and stress concentration near the root region indicate potential limitations for high-capacity wind turbines, especially in offshore or high-wind environments where structural integrity is crucial.CFRP is recommended as the more suitable material for modern wind turbine blades, especially in applications where high efficiency, longevity, and structural stability are paramount. This research contributes to the growing body of literature advocating the use of advanced composites in renewable energy infrastructure. Future studies should focus on incorporating hybrid composites, dynamic loading scenarios, and environmental effects such as moisture absorption and temperature variation to further enhance the reliability of simulation-based design for wind energy systems.

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Copyright

Copyright © 2025 Tanmay Singh, Mr. K B Patel. This is an open access article distributed under the Creative Commons Attribution License, which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.