Design Project: Wind
Turbine Shaft Design
Nicholas Rampersaud
Design
Project: wind
turbine
Turbine FBD:
-
I
↑
Turbine
bearing
↑
main
shaft
-
L
main shaft
Gearbox
......
....
Generator
Calculations:
diameter (d) calculation:
inedshaft
torsional shear
stress
(t)
d (16.5)
(64),
=
generated
where t=
=
- -
(5)
I
=
H
thrust=S=
25,133.7mie
I
T43,
=
100 Nm
d (10(43,100)) / (4(25, 133.7) (2.5)7"
=
d 0.291m
=
291mm
- -
Required
for
diameter
shaft
solid shaft
=
291mm
torque=43.1kN.M
(d; and do) calculation;
shaft
where T
=
rated
Turque
generator
Torsional shear stress:
T
4:
diameter ratio -0.8
(i)
=
do 291mm/(2.p)
=
do = 364mm
32
di=[[do"-(10(i)(n) (e)(d0)) ( / (i))
(32) "y
thrust *di)=
I
25, 133.7 N/m2 43, low in
-
I
di
=
4
(0.82304) 2S1mm
43,100)(t)
(
(
=
=
(*(25,7)(2.5))
Inside diameter 251mm
=
Outside
314mm,
diameter:
for hallow
shafts
two types metals:
am
of
SAE-ASI
1020
steel:
ultimate
strength (82)
440
=
yield strength (5y)
Mpa
370mpa
=
4140 steel:
SAE-AISE
ultimate
Yield
strength (in) 760Mpa
=
strength (8y) 640 Mpa
=
Factor ofsatety=
2.5
Allowable
stress
a0
=
2.5
(0a):
bympa_148Mpa
=s
Ja
=
When
(1020 steel
=
compared
Ja (allowable
means it
256
=
SAE-AlsI
stress]
will
costly, and
expensive.
(4140 steel
4140 steel has
than
handle
Mpa
SAE-AISI
a
higher
1020 steel.
greater loads. However
Which
it is
more
stress calculations:
Maximum shear stress:
FOS:
Imax
Fa
I
i
maximum
may:
on
acting
material
Ta:
allowable
(Tal
(2.5) (25133.7N/M2)
shearstress
shear stress
Tmax Fos
=
=
62,834.25
max
Design:
solid shaftdiameter:
Hallow
291mm
im
------
251mm
Axial thrust
-
shaft
niameter:
=SOK
I
Saw (eg
95,080kg
↳simm
↑
main
shaft
-
L
43.1
Gearbox
......
..
.
kn m
tor
Genera
Summary
To start off, A wind turbine is a machine that uses wind to make electricity. It has a tall
tower that holds up a part called a rotor, which has two or three blades that spin when
the wind blows. The spinning blades turn a generator, which makes electricity. Wind
turbines can be small or very big, and they make clean energy that doesn't pollute the
air. They are an important way to make electricity without using fossil fuels like coal or
oil.
In regards to this class, Strength of materials is an important area of study in
engineering that deals with how materials respond to forces and stresses. When
designing a wind turbine, engineers use strength of materials principles to calculate the
size and strength of the main shaft that connects the rotor blades to the generator. The
main shaft must be strong enough to withstand the forces generated by the rotating
blades and the weight of the rotor, while also being lightweight to reduce energy losses
due to friction. Using mathematical models and computer simulations, engineers can
predict how different materials and designs will perform under various loading
conditions, and choose the optimal materials and dimensions for the main shaft to
ensure the safe and reliable operation of the wind turbine.
When calculating and comparing the different materials. It is most notable that the SAEAISE 4140 steel is more stronger than the SAE-AISI 1020 steel. This is proven by
calculating the allowable stress when using the ultimate stress of each material as well
as the given factor of safety of 2.5. I chose this design because I believe it was the most
optimal and cost effective . Although the SAE-AISI 4140 Steel is more expensive it’s
strength was crucial to the design process, as well as the size of the gears.