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<p>Enhancing aerodynamic efficiency and structural reliability remains a critical challenge in the design of horizontal axis wind turbine (HAWT) blades. This study presents a comprehensive aerodynamic–structural optimization framework incorporating five distinct design methodologies to improve lift generation, torque output, and material performance. Aerodynamic characteristics were evaluated using computational fluid dynamics (CFD), while structural behavior was examined through fluid–structure interaction (FSI) simulations. Among the investigated configurations, a profile-modified three-blade model demonstrated the highest aerodynamic performance, achieving a 38.05% increase in static torque compared to the baseline blade under identical operating conditions, confirming its effectiveness across varying wind speeds. Structural optimization was conducted using twenty-one advanced composite and hybrid material systems. Results indicate that E-Glass-based laminates exhibited up to 68% lower deformation and approximately 2% improved stress resistance relative to the base material while maintaining equivalent density. Hybrid configurations, particularly Epoxy E-Glass combined with Carbon unidirectional prepreg (230&#xa0;GPa), further enhanced structural efficiency by delivering a 3% improvement in stress performance alongside a 27% reduction in material density. Sandwich architectures such as Epoxy E-CFRP woven with steel foam yielded the lowest stress concentrations, achieving a 5.7% reduction compared to all other evaluated materials. Customized composite properties generated using Material Designer were integrated into FSI simulations to assess real-time blade response under aerodynamic loading. The combined aerodynamic and material-level optimization approach presented in this work provides a robust and scalable design pathway for developing high-performance, lightweight, and structurally resilient HAWT blades, supporting future experimental validation and commercial-scale deployment.</p> Graphical Abstract <p></p>

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Innovative design and optimization of lift-enhanced profiles for horizontal axis wind turbines

  • 期刊论文

  • 发表日期：

    2026年4月25日

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  • Durga Devi Gunasekaran,
  • Haridharan Kannan,
  • Srivathshan Manoharan,
  • Madhan Sasikumar,
  • Gopinath Vinayagam,
  • Raj Kumar Gnanasekaran,
  • Senthil Kumar Madasamy,
  • Beena Stanislaus Arputharaj,
  • Subhav Singh,
  • Deekshant Varshney,
  • Vijayanandh Raja

摘要

Enhancing aerodynamic efficiency and structural reliability remains a critical challenge in the design of horizontal axis wind turbine (HAWT) blades. This study presents a comprehensive aerodynamic–structural optimization framework incorporating five distinct design methodologies to improve lift generation, torque output, and material performance. Aerodynamic characteristics were evaluated using computational fluid dynamics (CFD), while structural behavior was examined through fluid–structure interaction (FSI) simulations. Among the investigated configurations, a profile-modified three-blade model demonstrated the highest aerodynamic performance, achieving a 38.05% increase in static torque compared to the baseline blade under identical operating conditions, confirming its effectiveness across varying wind speeds. Structural optimization was conducted using twenty-one advanced composite and hybrid material systems. Results indicate that E-Glass-based laminates exhibited up to 68% lower deformation and approximately 2% improved stress resistance relative to the base material while maintaining equivalent density. Hybrid configurations, particularly Epoxy E-Glass combined with Carbon unidirectional prepreg (230 GPa), further enhanced structural efficiency by delivering a 3% improvement in stress performance alongside a 27% reduction in material density. Sandwich architectures such as Epoxy E-CFRP woven with steel foam yielded the lowest stress concentrations, achieving a 5.7% reduction compared to all other evaluated materials. Customized composite properties generated using Material Designer were integrated into FSI simulations to assess real-time blade response under aerodynamic loading. The combined aerodynamic and material-level optimization approach presented in this work provides a robust and scalable design pathway for developing high-performance, lightweight, and structurally resilient HAWT blades, supporting future experimental validation and commercial-scale deployment.

Graphical Abstract