Analysis of Airfoils Modifications on Horizontal Axis Wind Turbine Blades Carlos M. Guzmán Claudio Master of Engineering in Mechanical Engineering Dr. Moisés Angeles Department of Mechanical Engineering Polytechnic University of Puerto Rico One modification consists in to use dimples on Abstract ⎯ This project investigates the the airfoil surface. In a golf ball, dimples act as combination of upper surface dimples and trailing vortex generators. These vortices force the air edge serrations of a 3D thin airfoil and their effect around the ball to transition from laminar to on aerodynamic performance. Dimples are known to turbulent at an earlier phase relative to a smooth ball. reduce a golf ball’s drag while a serrated trailing The turbulence mixes higher velocity air into the edge is known to reduce noise. A flatback design is surface of the ball, delaying the boundary layer also studied to see if its properties apply to a thin separation, as visualized in Figure 1. This delay then airfoil. The airfoil in the present study is NREL S825, reduces the wake drag of the ball, thus allowing the to be 3D-printed with six combinations of the ball to go farther and higher than a smooth proposed modifications and tested in a wind tunnel. counterpart [1]. This study has found that the combination of dimples, flatback, and serrations has increased the maximum lift coefficient by 9.85%; however the maximum lift-to-drag ratio has been reduced by 14.4%. Key Terms ⎯ Dimples, Flatback, NREL S825, Serrated Trailing Edge. INTRODUCTION The objective of this work is to study the behavior of a wind turbine blade when it is modified with upper surface dimples, flatback trailing edge, and trailing edge serrations. These modifications should help improve the performance of a blade by Figure 1 reducing the drag wake. The dimples should act as Flow Separation on A Sphere and a Golf Ball vortex generators, delaying boundary layer There is an effect on airfoil performance when separation; the flatback shape may reduce the introducing a variety of dimples to the upper surface pressure gradient along the surface of the blade; and of the wing, such as circular and squared shaped the serrations could break up vortices behind the dimples [2]. Notably, having either inwards or blade by forcing the wake to dissipate energy. outwards dimple on the upper surface delays flow The combination of these modifications would separation from the aircraft wing, resulting in give a better understanding of how to approach increased coefficient of lift and decreased coefficient designing future wind turbine blades for higher of drag [3]. Reference [4] observed that a more efficiency. continuous drop in pressure is produced by the dimpled surface, allowing the airfoil to stall at higher angles than the smooth counterpart. A symmetrical airfoil at an angle of attack of 20° with its upper One way to generate a flatback airfoil is to cut surface mostly covered in dimples decreased the off, truncating, a segment of the trailing edge of the drag coefficient by 20.5% (Figure 2) and increased airfoil. Another way to create a flatback airfoil is to its lift coefficient by 34.19% increase the thickness of the trailing edge while ( maintaining the mean camber line of the airfoil (Figure 6). Thickness must be added along the camber line to prevent adverse boundary layer effects. In reference [6], the author studied the effects of modifying a 35% thickness-to-chord (t/c) airfoil in the various forms. A comparison of these airfoils can be seen in Figure 4: Figure 3) [5]. • The base TR-35 sharp-trailing edge airfoil • TR-35.80 truncated at x/c = 80%, resulting t/c = 44% and tTE/c = 10% • TR-44 a sharp-trailing edge TR-35 airfoil thickened to t/c = 44% • TR-35-10 is a blunt trailing edge airfoil with a t/c = 35% and tTE/c = 10% Figure 2 (a) Drag Coefficient versus Angle of Attack and (b) Drag Coefficient Decrement of Model 2 with Respect to Model 1 versus Angle of Attack [5] Figure 4 TR Series Airfoils [6] Figure 3 This truncation method proved to hinder the (a) Lift Coefficient versus Angle of Attack and (b) Lift Coefficient Increment of Model 2 with Respect to Model 1 performance of the airfoil due to the loss of versus Angle of Attack [5] maximum camber, as seen in Figure 5. The TR-44 airfoil is too thick for practical use. The truncated The next modification involves a flatback TR-35.80 resulted with a higher maximum lift, but trailing edge. The idea behind blunting the trailing with a significantly reduced lift slope. The TR-35-10 edge is to improve structural integrity of the root possesses superior lift performance along the entire region of the blade by increasing the cross-sectional angle-of-attack range. area, resulting in greater buckling resistance. Blunting the trailing introduces an increased base drag at higher Reynolds Number, so it is best used for the root region of the blade. It also comes with the benefit of increased lift performance and greater resistance to leading edge soiling [6]. Figure 7 Figure 5 Base Pressure of a Slotted and an M-shaped Serrated Effect of Trailing Edge Modification on Lift, Re = 4.5e6 [6] Trailing Edge [9] Figure 6 Blunt Trailing-edge Airfoil with T/c=35%, Tte/c=10% [6] The subsequent modification proposed is the serrating the trailing edge which comes from a need to reduce the aerodynamic noise profile of the blade, Figure 8 mainly from the tip, as its periodic nature can Base Pressure of A 60o and 120o Sawtooth Serrated Trailing become an annoyance to nearby residences [7]. A Edge [9] variety of serrations can be generated, such as In reference [8] two airfoils, namely a NACA rectangular, sawtooth, and M-shaped. The most 0012 and a NACA 65(12)-10, were studied in a wind common of these is the sawtooth shape. They serve tunnel with a variety of trailing edge forms. These to induce a span-wise pressure gradient, forcing forms include a sawtooth, sinusoidal, and slotted vortices to collide and breakup. Figure 7 and Figure sawtooth serrations of various frequencies. The 8 show a few example comparisons of different study shows that, for the NACA 65(12)-10, kinds of possible serrations and their effects on base serrations don’t significantly change the drag drag reduction. Figure 7 shows how an M-Shaped coefficient and the lift coefficient reduces up to 15% serration has lower base pressure loses over a between angles of -5° to 10°, however at higher rectangular serration. Figure 8 shows how the angles the drag increases with larger wavelength differences in angle on a sawtooth serration impact serrations. Figure 9 shows these results for various the overall base drag on a flatback blade. sawtooth serrations. The sinusoidal serration has similar performance to the sawtooth serration. The slotted-sawtooth resulted in up to 30% reduction in lift coefficient over the entire range on angles studied. Figure 9 Lift and Drag Coefficients for A NACA 65(12)-10 Airfoil Figure 11 Fitted with Different Sawtooth Serrations [8] Upper Surface Dimple Dimensions, Side View A follow up study [9] investigated the wake development of the previously mentioned airfoil serrations. It found that for the NACA 65(12)-10, the overall wake development for both the sawtooth and slotted sawtooth serrations is less turbulent due to the interactions of the tip-flow and the root-flow. Figure 12 Upper Surface Dimple Dimensions, Top View For the purposes of this project, the dimple characteristics will be fixed to: 𝜀 = 30% of the chord h = .1114in r = .1856in Figure 10 d = 1.5in Wake Turbulent Kinetic Energy for NACA 65(12)-10 Airfoil a = .75in at a=10°. [8] METHODOLOGY Flatback Conversion Dimple Geometry For this project, the flatback airfoils will be To determine the position and dimension of the created by thickening the rear segment of the airfoil, upper surface dimples, the following characteristics past the maximum thickness point. This method are required. The term 𝜀 refers to the x-coordinate of provides a reduced pressure gradient along the airfoil the dimple’s center relative to the chord line of the compared to the original and maintains the camber airfoil. To generate the dimple the terms r and h are line shape and thickness ratio, which is not the case used to define the radius and the depth of on a truncated airfoil. indentation, respectively. As the dimples will be To transform the airfoil, the flatback profile applied along the entire span of the blade the term d equation will be used. This equation takes the will denote the center-to-center distance between original set of coordinates that define the selected each dimple (seen in Figure 11 and Figure 12). profile and adds thickness pass a desired point in a symmetrical manner [10]: With these conditions, it is now possible to calculate 𝑇𝐸/100 ?̅?𝑓𝑏 = ?̅?𝑜𝑟 (1) ± 𝑎(?̅?) 2 the constants for a(?̅?): where: 1𝐴 = (1 − 𝐵)𝑛 − 𝑛(𝜀 − 𝐵)𝑛−1 𝑓𝑏 (6) ?̅? : y-coordinate of flatback profile (non- dimensional) ?̅?𝑜𝑟: y-coordinate of original profile (non- 𝐵 = 𝜀(1 − 𝑛) (7) dimensional) 𝐶 = 1 − 𝐴(1 − 𝐵)𝑛 (8) TE: Desired trailing edge thickness with respect to the chord (%) For the present research, a script developed in ?̅?: x-coordinate of profile (non-dimensional) MATLAB was used to generate the conversion. The input variables for the Flatback conversion are as 𝑎(?̅?): Distribution factor (non-dimensional) follows: The distribution factor 𝑎(?̅?) is a function that TE =4.2% t/c distributes the additional thickness along the chord length. The distribution factor is defined as: ε = 29.9% x/c n = 0.5 𝑎(?̅?) = 𝐴(?̅? − 𝐵)𝑛 + 𝐶?̅? (2) Serration Geometry The constants A, B, and C are computed by The serration to be used in this project will be applying boundary conditions on the profile, which an M-Shaped trailing edge [12]. As the airfoil will are the point where the thickness addition begins and possess a flatback shape, the trailing edge will have the trailing edge. The parameter n is used to adjust a thickness, h, which is the basis of the equations the transition smoothness. It was tested to be used to define the serration dimensions. The term b1 smoothest when n = 0.5 [11]. The term ε is used to is the width of the separation between each M-shape denote the starting point along the x-axis from the and b2 is the width of the M-shape itself. The term a leading edge where the thickness is added to the is the depth of the serration while γ is angle of the airfoil. serration. Figure 13 illustrates the parameters for this To set up the boundary conditions, a few geometry: conditions need to be met. It is desired that the distribution factor begins just after the point ε and finishes at the trailing edge. It is also desired that at point ε the distribution factor is parallel to the x-axis to ensure the thickness is added smoothly after the starting point. The boundary conditions are as follows: ?̅? = 𝜀 → 𝑎 = 0 (3) Figure 13 ?̅? = 0 → 𝑎 = 1 (4) Dimensions of M-shaped Serrated Trailing Edge [9] The design is characterized by the optimizations 𝑑𝑎 = 𝐴𝑛(?̅? − 𝐵)𝑛−1 + 𝐶 = 0 (5) that reduce the drag generated by the flatback shape 𝑑?̅? by 46%. [12] The optimized parameters are related A linear behavior can be seen from -5° up to 8° with as follows: the maximum lift coefficient at 12°. The angle for zero lift occurs at -4.62°. A sudden lift coefficient 𝑎 = 1.9 (9) drop is seen between 17° and 18°. For drag, a linear ℎ behavior is also seen from -2° up to 17°, when the 𝑏 = 𝑏 = 3.66ℎ (10) drag coefficient increase occurs. Afterwards, the 1 2 linear behavior continues with a slightly steeper 𝛾 = 40° (11) slope. The effect of the sudden coefficient spike on drag is more pronounced compared to lift. 0.5 The serrations will be part of a splitter plate 0.4 integrated into a flatback blade and will be aligned with camber of the blade. Effectively, it will be a 0.3 3mm plate protruding at an angle of 16.44° 0.2 downwards. 0.1 Wind Tunnel Testing 0 The wind tunnel used is a Flotek 1440, an open Angle of Attack (deg) circuit system with a 12” x 12” x 36” test section Control Lift Control Drag with an airspeed of approximately 93 fps. The models are placed vertically inside the test section. Figure 14 A force balance is used to measure the lift and drag Lift and Drag Curve for the Control Blade, Re = 2.95E5 on the blade over a time interval of 15 seconds, When introducing the dimples to the control taking the last 5 seconds for evaluation. Wind tunnel model, no significant differences can be observed. speed, lift and drag measurements of the 5 second The linear region is near identical for both lift and interval are then averaged and tabulated. Each blade drag. The angle where lift coefficient drop occurs is is tested three times from an angle of attack ranging increased to 19° and the maximum lift coefficient is from -15° to 30°. As we are assuming a standard reduced by 5.88%. atmospheric condition, the Reynolds Number will be around 296,000. All models were 3D printed with 0.5 PLA, then progressively sanded down with 80, 150, 0.4 320, and 500 grit sandpaper. An aluminum insert 0.3 was manufactured to fit inside the blades and threaded to hold the blade onto the force balance 0.2 beam. 0.1 0 RESULTS Angle of Attack (deg) Wind tunnel experimentation results are Dimpled Lift Control Lift Dimpled Drag Control Drag presented. Observing the control model was the first step; then compared the variations against the Figure 15 control. The dimpled variations with their smooth Lift and Drag Comparison Between the Dimple Control counterpart were compared too. Blade and the Control Blade, Re = 2.95E5 The S825 control blade’s aerodynamic The Flatback modification to the S825 airfoil is characteristics are shown in Figure 14 and Figure 15. effectively identical to the control model for both lift Lift Coefficient Lift Coefficient Drag Coefficient Drag Coefficient and drag, main difference being in the lift coefficient 0.5 drop occurring at higher angles between 19° and 20°. 0.4 0.3 0.5 0.2 0.4 0.1 0 0.3 0.2 Angle of Attack (deg) Flatback Dimple Lift Control Lift Flatback Dimple Drag Control Drag 0.1 0 Figure 17 Angle of Attack (deg) Lift and Drag Comparison Between the Flatback Dimple Flatback Lift Control Lift Flatback Drag Control Drag Blade and the Control Blade, Re = 2.95E5 Figure 16 Lift and Drag Comparison Between the Flatback Blade and 0.5 the Control Blade, Re = 2.95E5 0.4 Introducing the dimples to the flatback design 0.3 has increased the lift coefficient on positive angles 0.2 of attack by a noticeable, yet not significant, average of 3.71%. However, the drag coefficient increases by 0.1 an average of 10.28% over the control blade. 0 At near stall angles between 9° and 13°, the Angle of Attack (deg) blade seems to be suffering from some form of Flatback Dimple Lift Flatback Lift Flatback Dimple Drag Flatback Drag instability, based on the fact that the data collected is not as consistent compared to the rest of the domain. Figure 18 The Flatback Dimple model also shares the Lift and Drag Comparison Between the Flatback Dimple characteristic with its smooth counter that the Blade and the Flatback Blade, Re = 2.95E5 pressure drop occurs between angles of 19° and 20°. The M-shape serrations have markedly When comparing the two flatback designs with each introduced an improvement in lift performance for other, the increase in lift reduces to 1.93% and drag an average of 7.43%, with the maximum lift coefficient increases to 5.94%. Both the Flatback increasing by 9.94% over the control. However, the blade and the Flatback Dimpled blade have similar drag coefficient has increased for an average of aerodynamic behavior. 22.62%. Interestingly, the pressure drop occurring at 17° does not have as pronounced an effect on the lift as it did on the previous blades. This drop can still be seen on the drag curve. The zero-lift angle serrated blade occurs at -5.56°, 16.14% further behind what was observed in the control blade. Lift Coefficient Drag Coefficient Lift Coefficient Lift Coefficient Drag Coefficient Drag Coefficient 0.5 0.5 0.4 0.4 0.3 0.3 0.2 0.2 0.1 0.1 0 0 Angle of Attack (deg) Angle of Attack (deg) Serrated Lift Control Lift Serrated Drag Control Drag Serrated Dimple Lift Serrated Lift Serrated Dimple Drag Serrated Drag Figure 19 Figure 21 Lift and Drag Comparison Between the Serrated Blade and Lift and Drag Comparison Between the Serrated Dimple the Control Blade, Re = 2.95E5 Blade and the Serrated Blade, Re = 2.95E5 Adding the dimples to the serrated blade does The following Table 1 organizes the main not significantly alter the aerodynamic performance aerodynamic characteristics for each blade model, to the blade. In comparison with the smooth serrated namely the Maximum lift coefficient and its angle, blade the average lift only increases by 0.77% while the zero-lift angle, and the maximum lift-to-drag the drag increases by 4.79%. When compared to the ratio with its angle. In general, both Serrated blades control blade, lift and drag are increased by 12.6% and the Flatback dimple blade have improved and 31.55%, respectively, for positive angles. The maximum lift coefficient. Only the Serrated dimple maximum lift coefficient is 10% higher compared to blade has a noticeable reduction in the angle of the control blade, occurring at 10.31°. maximum lift coefficient and the zero-lift angle. Due to the large increases in drag for all blade variations, 0.5 the Cl/Cdmax of the control blade is the highest of the 0.4 group. It does not appear that the dimples assist in 0.3 the aerodynamic performance of the blades in this study; they only managed to increase drag. It also 0.2 seems that the serrations used only increases drag by 0.1 an average of 0.20% while reducing total lift by an 0 average of 0.072% compared to the flatback design. Angle of Attack (deg) Table 1 Serrated Dimple Lift Control Lift Serrated Dimple Drag Control Drag Aerodynamic Characteristics of Experimented Blades Figure 20 Model Characteristic Clmax αClmax αCL=0 CL/CDmax αCL/CDmax Lift and Drag Comparison Between the Serrated Dimple Blade and The Control Blade, Re = 2.95E5 Control 1.32 12.00 -4.45 10.42 2.00 Control Dimple 1.24 13.00 -4.63 9.65 3.00 Flatback 1.33 13.00 -4.57 9.65 5.00 Flatback Dimple 1.39 13.00 -5.15 9.15 5.00 Serrated 1.44 12.00 -5.17 9.35 1.00 Lift Coefficient Lift Coefficient Drag Coefficient Drag Coefficient Lift Coefficient Drag Coefficient Serrated Dimple 1.45 10.31 -6.15 8.92 4.16 Comparing all these blades, side by side, we get the following charts for lift and drag coefficients, Figure 22 and Figure 23 respectively. These charts are polynomial trendlines based on the data acquired during the experiments. As previously stated, we can see how similar the two Flatback models and the Control Dimple model are to the Control Blade and how much more lift is generated by the two Serrated models. We can also see that all increase in lift is accompanied by a larger increase in drag for each of the blades compared to the control. Lift Coefficient, Re = 295,000 Control Airfoil Flatback Airfoil Dimpled Flatback Airfoil Dimpled Control Airfoil Serrated Airfoil Dimpled Serrated Airfoil Angle of Attack (deg) Figure 22 Trendlines for Lift Coefficient of All Experimented Blades Drag Coefficient, Re = 295,000 Control Airfoil Flatback Airfoil Dimpled Flatback Airfoil Dimpled Control Airfoil Serrated Airfoil Serrated Dimple Airfoil Angle of Attack (deg) Figure 23 Trendlines of Drag Coefficient for All Experimented Blades DISCUSSION the maximum thickness of the airfoil occurs. Flow separation does not occur near this area when The researcher speculates that the position of reaching the maximum lift angle; therefore, the the upper surface dimples is one of the major recirculation provided by the dimples does not causes of unexpected results. These dimples were impact the boundary layer. The thickness of the placed far forward on the chord line, right where Drag Coeffifient Lift Coefficient serrations might also have negatively affected the [7] J. Mathew, A. Singh, J. Madsen and C. A. León, "Serration Design Methodology for Wind Turbine results of the experiments. Both of these features Noise Reduction," Journal of Physics: Conference should demand further investigation. Series, September 2016. [8] X. Liu, M. Azarpeyvand and R. Theunissen, "On The The original objective of this experiment was Aerodynamic Performance of Serrated Airfoils," in The 22nd International Congress on Sound and to improve the aerodynamic characteristics of a Vibration, Florence, Italy, 2015. wind turbine blade by introducing modifications [9] X. Liu, H. K. Jawahar and M. Azarpeyvand, "Wake to the upper surface and to the trailing edge of the Development of Airfoils with Serrated Trailing Edges," 2016. blade. During the course of the study, the [10] O. C. Seix, "Aerodynamic study on the design and investigator found that these modifications did not optimization of flatback airfoils for wind turbine applications," Barcelona, 2015. improve the lift performance of the blade enough [11] E. S. Ferry, "Estudio aerodinámico y optimización de to justify the increase of drag that has been perfiles flatback aplicado a aerogeneradores.," Universitat Politècnica de Catalunya, 2014. observed. The serration geometry studied seems [12] C. v. Dam, D. 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