Design, fabrication, and evaluation of a small turbine blade manufactured by rotational molding

Abstract

The notion of renewable energy has become deeply ingrained in the world, captivating an increasing number of researchers and industry professionals who invest substantial resources to advance the development of more efficient systems. While large-scale wind turbine blades currently reach lengths exceeding 50 m and are typically manufactured as single entities, this study focuses on the design and evaluation of a blade profile tailored specifically for small turbines. The blades were manufactured using rotational molding, employing various groups of polymers including thermosets and thermoplastics. To enhance their mechanical performance, foams were incorporated into the polyurethane and polyethylene blades. The suitable blade by evaluating various formulations and foams was identified by mechanical analysis. Aerodynamic analysis was conducted across different ranges of wind speeds and pitch angles. The results indicate that the power coefficient (Cp) closely approaches 0.5.