Damage evolution simulation and lifetime prediction for composite blades under continuous droplet impacts

Offshore wind power generation is a promising technology in renewable energy applications due to its high reserves of wind energy in sea areas. To improve the energy transformation efficiency, the blade length of the offshore wind turbines has become larger and larger, and it has made rain erosion be one of the most frequent failures during the turbine operation. As the natural rainfall is stochastic in spatial and time domains, it is difficult to depict the damage evolution process caused by rain impact exactly. Therefore, regular and continuous droplet impact simulation and experiments present an alternative methodology for this issue. With the composite structure of the blade and deformability of the liquid droplet in consideration, a fluid solid interaction model will be established to investigate the impact response and subsequent damage evolution. In which, the Smooth Particle Hydrodynamics (SPH) model is utilized to depict the constitutive relationship within the droplet, and Finite Element Method (FEM) is used to construct the Representative Volume Element (RVE) model of the blade leading edge. The impact process is simulated first to obtain the impact pressure distribution at the contact center and velocity field in the droplet. Furthermore, the stress wave propagation in the blade multilayer structure can be analyzed. Owing to the multiaxial fatigue feature of the continuous droplet impact, the continuum damage mechanics is integrated with the fatigue criterion and the Jump-in-Cycle procedure is used to simulate the high-cycle fatigue process. The damage factor distribution on the blade coating surface and its influence on mechanical properties are analyzed. Thereafter, the droplet impact fatigue life can be accumulated based on Miner’s linear rules. The theoretical achievements are validated by experimental data provided by Rain Erosion Testing (RET), which shows a good agreement between each other. As a result, V-N curves and D-N curves, i.e. quantitative relationship between droplet falling conditions and impact fatigue life, are established. The achievements in this study can provide an effective tool for rain erosion mechanism analysis and life prediction in industrial applications.