STUDY, FABRICATION & TESTING OF HELICAL BLADE

VERTICAL AXIS WIND TURBINE (HBVAWT)

Group Members:

JAZIB SOHAIL (16-ME-136)

ALI USMAN (16-ME-152)

HASSAN ARSHAD PANNU (16-ME-180)

ALI RAZA (16-ME-195)

Project Supervisor

Rizwan Ullah

Lecturer

DEPARTMENT OF MECHANICAL ENGINEERING

HITEC UNIVERSITY, TAXILA

 STUDY, FABRICATION & TESTING OF HELICAL BLADE
VERTICAL AXIS WIND TURBINE (HBVAWT)
FINAL YEAR PROJECT REPORT

(2016-2020)

THESIS IS SUBMITTED TO THE FACULTY OF THE DEPARTMENT OF

MECHANICAL ENGINEERING, HITEC UNIVERSITY, TAXILA IN PARTIAL
FULFILLMENT OF THE REQUIREMENTS FOR THE DEGREE OF BACHELOR’S
OF SCIENCE IN MECHANICAL ENGINEERING

DEPARTMENT OF MECHANICAL ENGINEERING

STUDY, FABRICATION & TESTING OF HELICAL BLADE
VERTICAL AXIS WIND TURBINE (HBVAWT)

Submitted by:

JAZIB SOHAIL (16-ME-136)

ALI USMAN (16-ME-152)

HASSAN ARSHAD PANNU (16-ME-180)

ALI RAZA (16-ME-195)

Project Supervisor

Rizwan ullah

Lecturer

DEPARTMENT OF MECHANICAL ENGINEERING

HITEC UNIVERSITY, TAXILA

Head of Department

Dr. Liaquat Ali

Professor
 Acknowledgment

We would like to thank the Major Advisor for this project, Lecturer Rizwan Ullah for
trusting us and allowing us to work on this exclusive and important project, the Study, Fabrication,
and Testing of a VAWT, and the committee members of the department who help us throughout
the project to upgrade and rectify the knowledge of the field.

We are grateful to all people who have provided us with immense support whenever the situation
was critical and was about to give up on this research. This project is not only a product of back-
breaking but also the support of friends and family with unsought resources too.

Last but not least, we want to take a moment and acknowledge all the persons who devoted in
numerous ways and means to give us this priceless opportunity to expand as well as gain fresh
knowledge and experience vital for the successful performance as an engineer in the industry, and
who helped us in many ways throughout the project to make it a success.
 Declaration

It is announced that this is an authentic quantity of effort, besides where contrarily affirmation in-
content and reference. It has not been proposed in any form for an extra degree or diploma for any
institution for post-graduate education and shall not be given by us hereafter acquiring any degree
from this or any other university.

Jazib Sohail

16-ME-136

Ali Usman

16-ME-152

Hassan Arshad Pannu

16-ME-180

Ali Raza

16-ME-195

HITEC UNIVERSITY

TAXILA CANTT.
 Abstract

With the growth in the cost of verve separated from fossil fuels and deficiency of fuel sources, the
world now is converting to renewable energy resources. VAWT is a perfect choice for
microscopic-power. The savonius is one of the comprehensively matured, utilized, and appropriate
for a roof, self-supporting lights. We learn that there is adequate breeze with-out exception to fulfill
a lot, of human power necessities. This would be accumulated effectively on a horizontal axis
system, it might be essential, less difficult, and altogether less expensive to fabricate keep up than
horizontal axis system (HAWT).

A significant concern was forming the structure to empower the VAWT to work with the most
extreme productivity. A few parameters were investigated concerning wind speed to decide an
incentive for every framework which would give the most noteworthy proficiency, in this way
guaranteeing the greatest extreme exhibition of the VAWT. We have done mathematical modeling,
Solid Works modeling, illustrate graphs to different behavior and analyze the whole turbine in
ANSYS/Fluent for finding the velocity streamlines, pressure, and mesh of the design. We are using
two blades, strut, shaft, and the turbine rotor shaft, and also did an airflow analysis of blade through
CFD. The calculations were investigated using ANSYS/Fluent software package and the eventual
design was formed by following the acquired results. Then finally the power output was measured
and graphs were drawn. All the related theories, graphs, and figures are provided.
List of Figures

Figure 1. 1 Installed data (2013-2017) .......................................................................................... 16

Figure 1. 2 Horizontal axis wind turbine ...................................................................................... 18
Figure 1. 3 Horizontal axis wind turbine ...................................................................................... 18
Figure 1. 4 VAWT vs HAWT....................................................................................................... 20
Figure 1. 5 types of VAWT .......................................................................................................... 21

Figure 2. 1 Power Coefficient different rotors .............................................................................. 24

Figure 2. 2 Conversion of Mechanical to Electrical energy ......................................................... 25
Figure 2. 3 Power curve (Windpower program) ........................................................................... 27
Figure 2. 4 Betz Law ..................................................................................................................... 28
Figure 2. 5 Betz law- Fluid flow through the rotor ....................................................................... 29
Figure 2. 6 P/Po as a behavior of V2/V1 ...................................................................................... 31
Figure 2. 7 Swept area .................................................................................................................. 32

Figure 3. 1 Collection of wind data .............................................................................................. 35

Figure 3. 2 Average wind speed ................................................................................................... 36
Figure 3. 4 Power vs Velocity....................................................................................................... 66

Figure 4. 1 Turbine blade and shaft .............................................................................................. 43

Figure 4. 2 Base and Strut ............................................................................................................. 44
Figure 4. 3 Exploded and Assembled view .................................................................................. 44
Figure 4. 4 Blade in the starting phase .......................................................................................... 46
Figure 4. 5 Meshing ...................................................................................................................... 47
Figure 4. 6 Using the Boolean command...................................................................................... 47
Figure 4. 7 Preprocessing.............................................................................................................. 48
Figure 4. 8 Defining Velocity ....................................................................................................... 48
Figure 4. 9 Graph .......................................................................................................................... 49
Figure 4. 10 Static pressure on the blade ...................................................................................... 49
Figure 4. 11 Effect of pressure contour blade ............................................................................... 50
Figure 4. 12 Velocity contour ....................................................................................................... 50
Figure 4. 13 Velocity contour ....................................................................................................... 51
Figure 4. 14 Velocity streamline ................................................................................................... 51
Figure 4. 15 Turbine ..................................................................................................................... 52
Figure 4. 16 Meshing .................................................................................................................... 53
Figure 4. 17 Graph ........................................................................................................................ 53
Figure 4. 18 Force vs Iteration ...................................................................................................... 54
Figure 4. 19 Drag vs Iteration ....................................................................................................... 54
Figure 4. 20 Pressure contour ....................................................................................................... 55
Figure 4. 21 Velocity surface turbine ........................................................................................... 55
Figure 4. 22 Side view of turbine.................................................................................................. 55
Figure 4. 23 Streamline velocity ................................................................................................... 56
Figure 4. 24 Another aspect of streamline .................................................................................... 56
Figure 4. 25 Different loads at wind speed ................................................................................... 57

Figure 5. 1 Different dimensions for selection of bearing sizes ................................................... 63

Figure 5. 2 Selection of Reynolds number.................................................................................... 65
Figure 5. 3 Power vs Velocity....................................................................................................... 66
 Nomenclature

A Swept Area

B Number of Blades

CL Lift Coefficient

CD Drag Coefficient

CP Power Coefficient

Cn Thrust Coefficient

Ct Torque Coefficient

P Power

P0 Free Stream Wind Power

R Blade Tip Radius

Re Reynolds Number

∆ Change in Time

V Absolute Air velocity

V0 Free Stream Velocity

α Angle of Attack

Ω Angular Speed

ϴ Twist Angle

Φ Relative Flow Angle

λ Tip Speed Ratio

λr Local Tip Speed Ratio

σ Solidity

Ƞ Mechanical Efficiency
Table of Content
Chapter 1 Introduction .................................................................................................................. 14

1.1 Renewable energy ............................................................................................................... 14

1.2 Wind Energy ....................................................................................................................... 15

1.2.1 What is Wind? .............................................................................................................. 15

1.2.2 Wind Turbine ................................................................................................................ 15

1.2.3 Background of a Wind Energy Windmills ................................................................... 15

1.2.4 Status of Wind Energy .................................................................................................. 16

1.2.5 Wind Measurement Instruments ................................................................................... 16

1.2.6 The Energy in the Wind................................................................................................ 16

1.2.7 Wind Speed................................................................................................................... 17

1.3 Wind Turbines ..................................................................................................................... 17

1.3.1 Wind Turbine Classification......................................................................................... 18

1.3.2 HAWT Advantages ...................................................................................................... 18

1.3.3 HAWT Disadvantages .................................................................................................. 19

1.3.4 Vertical Axis Wind Turbines ........................................................................................ 19

1.3.5 VAWT Advantages ...................................................................................................... 19

1.3.6 VAWT Disadvantages .................................................................................................. 20

1.4 Darrieus Wind Turbine ....................................................................................................... 20

1.5 Savonius Wind Turbine....................................................................................................... 21

1.5.1 Applications of Savonius .............................................................................................. 22

Chapter 2 Literature Review ......................................................................................................... 23

2.1 History of Energy ................................................................................................................ 23

2.2 Background ......................................................................................................................... 23

2.3 POWER ............................................................................................................................... 25

 2.4 Power Curve of Wind Turbines .......................................................................................... 26

2.5 Betz Law ............................................................................................................................. 27

2.5.1 Assumptions of Betz Law............................................................................................. 28

2.5.2 Proof ............................................................................................................................. 29

2.6 Swept Area .......................................................................................................................... 31

2.7 Coefficient.of Performance (Cp) ......................................................................................... 32

2.8 Tip Speed Ratio ................................................................................................................... 32

2.9 Square-Cube Law ................................................................................................................ 33

Chapter 3 Mathematical Modeling and Market Study .................................................................. 34

3.1 Weather Information about Taxila ...................................................................................... 34

3.1.1 First Approach .............................................................................................................. 34

3.1.2 Second Approach .......................................................................................................... 35

3.2 Market Study ....................................................................................................................... 36

3.3 Mathematical Modeling ...................................................................................................... 37

3.3.1 Air Density ................................................................................................................... 37

3.3.2 Power Output ................................................................................................................ 37

3.3.3 Swept Area ................................................................................................................... 38

3.3.4 Blade Radius ................................................................................................................. 38

3.3.5 Power of Wind .............................................................................................................. 38

3.3.6 Power of Turbine .......................................................................................................... 39

3.3.1 Tip Speed Ratio ............................................................................................................ 39

3.3.2 Rotor Blade Height ....................................................................................................... 40

3.3.3 Torque ........................................................................................................................... 40

3.3.4 Aspect Ratio ................................................................................................................. 41

3.3.5 Rated Velocity .............................................................................................................. 41

 3.3.6 Solidity.......................................................................................................................... 41

3.3.7 Chord Length ................................................................................................................ 41

Chapter 4 Modeling ...................................................................................................................... 43

4.1 Turbine Design .................................................................................................................... 43

4.2 CFD Analysis ...................................................................................................................... 45

4.2.1 What is Ansys? ............................................................................................................. 45

4.2.2 What do CFD Means? .................................................................................................. 45

4.2.3 Fluent ............................................................................................................................ 45

4.2.4 Use of CFD in Project .................................................................................................. 45

4.3 Loads & stresses .................................................................................................................. 57

4.3.1 Static Loading & Wind Pressure of Turbine ................................................................ 57

4.3.2 Graph ............................................................................................................................ 57

4.3.3 Sizing of shaft ............................................................................................................... 58

4.3.4 Stresses on the Shaft are by given Equation ................................................................. 58

4.3.5 Torsion on the shaft ...................................................................................................... 59

4.3.6 Principal Stresses .......................................................................................................... 60

4.3.7 Factor of Safety ............................................................................................................ 60

4.3.8 The torque of the Shaft ................................................................................................. 61

4.3.9 Factor of Safety ............................................................................................................ 61

Chapter 5 Discussion and Results ................................................................................................. 62

5.1 Selection of Bearing ............................................................................................................ 62

5.1.1 Shaft Output of the Turbine .......................................................................................... 63

5.1.2 Wind Power in Blade .................................................................................................... 63

5.1.3 Wind Turbine Efficiency .............................................................................................. 64

5.1.4 Reynolds Number ......................................................................................................... 64

 5.1.5 Drag Force .................................................................................................................... 65

5.2 Estimation of Power and Sizing of Turbine ........................................................................ 65

Graph ..................................................................................................................................... 66

Chapter 6 Conclusion and Summary ............................................................................................ 67

6.1 References ........................................................................................................................... 68

Chapter 1 Introduction
1.1 Renewable energy

Unlike inadequate fossil fuels, renewable resources are continuously refreshed, recreate, and
eternal. These are also known as ‘non-conventional energy resources’. The five sustainable power
source assets utilized regularly are; biomass (counting wood pellets and wood squander sewage
and agricultural waste), Hydropower (counting tidal, water moving, and sea wave energy),
geothermal energy, tidal energy, and wind energy.

The adoption of these energies is not recent. In old occasions, wood is used for the consumption
of human heat during winter. Now, we are looking again at renewable energy resources to meet
our energy needs.

Properties:

 Greenhouse effect
 Air pollution
 It can be non-renewable if it used greater than the capacity

Sustainable power source creates no CO2 during operation. Then again, fossil fuels are great
emitters of carbon dioxide, which leads to global warming which leads to dirtier air, high death
rates, and higher sea levels. Coal-burning power stations also cause cancer, asthma, lung ailments,
and acidic rain.

Sustainable power source additionally positively affects the nature of the earth. The ignition of
fossil fuels produces SO2and NO2 both ultimate sources of pollution.
1.2 Wind Energy

1.2.1 What is Wind?

The Wind is moving air across the earth’s surface. This weight distinction results from the
differential heating of the earth’s surface which is caused by the sun bang the surface of the earth
because of air pressure. It heats the one area of the surface to another, the difference in pressure
creates wind. Cool and warm airframes a rotational cyclic motion. As the solar radiation falls on
the surface and the surface begins to ascend in temperature. The air starts to ascend on the hot
surfaces due to its lighter weight and less thickness. Air on the cooler surface starts to sink.

1.2.2 Wind Turbine

Turbines which use wind as its input is known as a wind turbine. Wind power fundamentally relies
upon the communication between the rotor and the wind. The wind energy changes Propeller-like
blades around a rotor which is associated with the shaft. This main shaft twists an electric generator
to create electricity. As the wind is flowing with velocity so it has some kinetic energy. The wind
turbines convert the kinetic energy into power. The power is changed by mechanical force from a
generator.

1.2.3 Background of a Wind Energy Windmills

 Crumbling corns
 The Mashing of sugar cane
 Threshing
 Water pumping for flooding and soaking
 Sailing of gigantic ships
 1.2.4 Status of Wind Energy

The latest disclosure of wind capacity discharged on 12 February 2018 by the World Wind Energy
Association (WWEA, 2018) states that the global quantity of all wind turbines equipped
worldwide reached at the end of approximately 539’291 Megawatt. According to the WWEA,
52’552 Megawatt were added in the year 2017 that is more compared in previous which is 51’402
Megawatt is added. Wind turbines installed in the year of 2017 can cover more than 5% of the
overall demand.

Figure 1. 1 Installed data (2013-2017)

1.2.5 Wind Measurement Instruments

 Anemometers to calculate wind velocity

 Wind vanes to calculate wind direction
 Thermometers to calculate the ambient air temperature
 Barometers to calculate the air pressure

1.2.6 The Energy in the Wind

The energy that can be obtained from the wind is directly proportional to the cube of the wind
speed. The wind is highly varying in its nature. Broadly more is endorsed on the tops of hills and
mountains compared in low areas. Narrowly, velocity is transformed into the wind turbine.

1.2.7 Wind Speed

 Cut-in Wind Speed

The wind speed at which the turbine will deliver power (usually 3 to 5 m/s).

 Cut out Wind Speed

The high wind speed at which the turbine is generally programmed stops to avoid damage
to the turbine or its surroundings.

1.3 Wind Turbines

The wind turbines harness the kinetic energy of wind incorporate in the air. These wind turbines
are supplied with a rotor to excerpt the capacity and generally consist of one or many rotor blades.
The derived energy generates rotation and is converted into mechanical power at the rotor shaft.
This mechanical power is then transmitted to a machine to produce electricity.
 1.3.1 Wind Turbine Classification

Horizontal Axis Wind Turbine

Figure
Figure 1.
1. 3
2 Horizontal
Horizontal axis
axis wind
wind turbine
turbine

Horizontal-axis wind turbines (HAWT) realize their name from the look that the axis of rotation
is horizontal. They have the main rotor shaft and electrical generator at the top and directed to the
wind. A gear system is included in the system which also helps the turbine rotate the strike by slow
into fast rotation of the blades and more suitable for electrical instruments.

1.3.2 HAWT Advantages

 Better performance
 Higher efficiency than the vertical axis wind turbine
 Because of design structure, full convenience of gaining higher wind speeds
 Self-start mechanism
 1.3.3 HAWT Disadvantages

 Construction cost is high

 Its operation often leads to noise
 HAWT’s require collapsing during high winds
 Noisy structure
 Need a lot of land for installation
 High preservation cost

1.3.4 Vertical Axis Wind Turbines

In Vertical Axis Wind Turbine (VAWT), the blades are seated on the top of the main shaft structure
instead of the front like an aircraft rotor. Vertical Axis Wind Turbine is a type of turbine in which
the axis of rotation is perpendicular to the wind tide. It doesn’t require a structure like HAWT and
can be placed adjoining to a ground permissive approach to electrical components.

1.3.5 VAWT Advantages

 Don’t require yaw mechanism

 Install in low wind speed areas
 Environment friendly and do not damage the wildlife
 Capacity to operate in extreme weather conditions
 Safety for workers because of their components
 They do not disturb in residential areas
 More economical than the horizontal axis wind turbine
 1.3.6 VAWT Disadvantages

 The structure needs low height because it won’t work higher altitude
 Their stress is on a bearing, it holds the structure
 Their efficiency is less
 Turbulence and vibration issues in the structure
 The rotors faced more drag and aerodynamics on the blades

Figure 1. 4 VAWT vs HAWT

1.4 Darrieus Wind Turbine

This wind turbine is used to generate electrical power. It is made in different ways, oil drums,
paddles, and buckets. It generally requires a human push from a foreign source to initiate and also
reducing negative torque in the opposite direction. This is working on the H rotor turbines.
1.5 Savonius Wind Turbine

It is one of the types of VAWT which subsist of two or three scoops working the same as a cup
anemometer. It was created by a finish engineer S.J Savonius. Savonius has an S-shaped cross-
section, and due to this curvature. The wind is against the structure, it has less drag experience.
Savonius turbines achieve much less power compared to similar-sized type turbines. This might
not be well for the production of electricity but with an appropriate gear system help us in
production. Their output to weight ratio is also less.

Figure 1. 5 types of VAWT

Advantages

 Low construction cost

 Simple design geometry
 Starts working at lower wind speeds
 Very less noise during operation
 1.5.1 Applications of Savonius

It is used where cost and trustworthiness are much more imported than efficiency.

 Anemometers
It is used for finding direction and wind speed for the vertical axis wind turbines.

 Flettner Ventilators
It is also being used as a Flettner ventilator on the roof of some vans as a cooling device.
It was created by German aircraft engineer Anton Flettner. It uses as savonius to drive the
extractor fan. The Vents are still being constructed in the UK.

 Deep Water Buoys

It has already been for electricity generation on deep water buoys, which require a small
volume of power.

 Other Applications
For small scale electricity production, for example, rooftops.
Chapter 2 Literature Review
2.1 History of Energy

If we review the history and wanted to know how human survive before the revolution. The basic
fundamental need of humans is to survive instinct in their nature and never die of hunger. These
needs help humans to seek for new notions to create a sustainable environment. Still, there was
always a need for a cause that can integrate and fulfill their needs. With the exploration of
electricity and other causes of energy, people relied only on natural resources. They used simple
and universal tools to complete some fundamental tasks for their survival. For occurrence, they
used fire for heating purposes, candles for lightening, and weapons made from stone for shooting.
Over time, many scientists disclosed different types of energy in different periods.

2.2 Background
Wind Turbine is a piece of inexhaustible energy-based equipment, which generates electricity. It
consist may consist of one, two, three, or six blades attached to the hub. Although based on higher
efficiency, three-blade wind turbines are most common. The primary components of a wind turbine
are the rotor, generator, and a rotating shaft. A small-scale wind turbine (SSWT) has a rotor
diameter between 10 cm to 100 cm.

The power coefficient of the wind turbines increases as the quantity of blades increase. However,
the (Cp) starts to decrease if more than three blades are installed, the drag factor along with the
blades and the air locking between the blades start to occur, resulting in a power coefficient
decreases.
Figure 2. 1 Power Coefficient different rotors

Reviewing the literature, there are is very finite research on (SSWT) due to
their lower efficiency. The difference in the efficiency of any component results in
a big effect on the power output.

Kishore designed and fabricated the small wind turbines (Kishore, 2013) that could engage on the
wind speed of less than 5 m/s. The power coefficient initially was taken as 45% to 50%. After the
careful iterative method, the design was tested in the wind tunnel and had a maximum (COP) of
about 14%. The operating wind speed required was 5 m/s. Another portable small a scaled wind
turbine was designed about a diameter of 40cm. It was quite efficient having 34% of efficiency.

Aravind S, given an idea to find the stress distribution and displacement of the model at the
different thicknesses. The calculations in the model analysis by using graphs that the helical
VAWT rotor with thickness 2.5mm has an effective range of frequency. In other words, the
damping effect is lesser than the model without the damping effect with thickness 2.5mm of the
model. However, the assumptions of the paper concluded that this could also be used for the
incentive of urban applications.

2.3 POWER

Wind kinetic energy is an essential source of power. It obtains the power from wind and turns it to
mechanical energy, which is then more after converted to electrical energy. The kinetic energy that
can be recovered from the wind depends on the following factors:

 Inlet wind velocity. (Meter per second).

 The swept area. (Square meter).
 The efficiency of the installed components.

The inlet velocity of the wind is high and as it comes in contact with wind
turbine, the energy is obtained in the form of resistance. So, the outlet velocity of the wind is
reduced.

Figure 2. 2 Conversion of Mechanical to Electrical energy

 (2.1)

the power extracted depends on wind velocity. The following equation is proportional to the area
and cubed wind speed. The density of air depends on power. Due to this, it increases the altitude.
But it has a very low effect.

2.4 Power Curve of Wind Turbines

The power curve of any turbine illustrates the electrical output at different wind speeds. The power
output of a wind turbine is usually characterized by the power curve, the relationship
between uninterrupted wind speed at the nerve Centre height, and the power output. The power
curve is the primary means of symbolizing the act of a turbine.

A typical power curve is shown in Fig 2.3. The cut-in speed at which the turbine start working is
the minimum speed. The cut-out speed is the maximum wind speed at which the turbine can
produce energy. Generally, the output power of a wind turbine is calculated by:

= ƞ
(2.2)

Where P is output power, ρ is density, A is swept area, U is wind speed,  is the efficiency and CP
is the turbine power coefficient of the rotor. It is a common framework used to assess the
performance of a wind turbine.
Figure 2. 3 Power curve (Windpower program)

2.5 Betz Law

The Wind is a renewable source of energy. It possesses the kinetic energy in it. It is one of the
types of equipment used to obtain and convert it into electrical energy. The theory of Betz law tells
us about the maximum amount of energy that can be extracted from wind regardless of the type
and the design. So, we performed many experiments and proved that a maximum of 59% of energy
can be extorted from wind in an open stream and this finding of his still holds.

= / ( ) (2.3)
 2.5.1 Assumptions of Betz Law

1. There is no hub on the rotor and it is supposed ideal.

2. The rotor has immeasurable blades and has no drag on them.

3. The fluid flow is taken incompressible with constant temperature and density.

4. Consider that the flow into and out of the rotor is axial and the upstream and downstream volume
is constant.

Figure 2. 4 Betz Law

 2.5.2 Proof

Figure 2. 5 Betz law- Fluid flow through the rotor

Turbines work done = Difference in kinetic energy.

W = ∆K

Consider that the average speed throughout the average wind speed is constant and equal
at point 1 and Point 2, V1, and V2 respectively.

i.e. (V1+V2)/2.

The total air mass of the rotor is:

= ( + )/ (2.4)

Where;

ρ = Density of air.

m = Air mass.

A = Swept area of the rotor.

V = Velocity.
ρ = Density of air.

According to Newton’s law, the wind power losses are;

= / ( - ) (2.5)

Putting the value of mass in Eq.2,

=( / )( - )( + ) (2.6)

After analyzing the results relative to the obtained power, when the wind is
passed through the rotor undisturbed, having no blades, consider the power P0.

=( ) (2.7)

Observe the Power ratio between the powers that were obtained from wind to
the power from uninterrupted wind:
 Figure 2. 6 P/Po as a behavior of V2/V1

From the above graph, it is concluded that the power ratio is the maximum point at V2/V1= 1/3,
and the obtained maximum wind power is 16/27 = 0.59 of the wind energy.

2.6 Swept Area

The area swept by the blades of the turbine spin is called the swept area. The calculations of the
area are very important as the power achieved by the turbine directly depends on the area of the
turbine. Larger area means larger the blades that result in large power generation.

The swept area simply not includes the rotor and the hub, it is the whole area through which the
air passes and energy is obtained, leaving the low energy wind behind. The equation for the swept
area is:

= (2.8)

Where ‘R’ is the tip radius.

 Figure 2. 7 Swept area

2.7 Coefficient.of Performance (Cp)

The proportion of power in the wind that the rotor cause obtain is known as the Coefficient of
performance (Power coefficient). It is not a constant value, it alters with the wind speed, rotational
speed, and turbine parameters like angle of attack and pitch angle.

2.8 Tip Speed Ratio

It is an important framework associated with turbines. It regulates how fast the wind turbines will
turn. If the motor is moving too slow, the wind will pass through the between rotor blades. On the
flip side, it is moving fast, the blades will come out like a solid wall to the wind. So, wind turbines
are designed with an optional ratio to obtain as plenty of power as possible.
2.9 Square-Cube Law

It limits the eventual size that the wind turbine can attain. Assuming material and mathematical
similarity, the dimension will increase if the turbine size gets larger.

 The power output progress by the square of dimension

 The weight progress by the cube of dimension
Chapter 3 Mathematical Modeling and Market Study
3.1 Weather Information about Taxila
The collection of wind data through the first approach is using an anemometer. Anemometer is a
device that is used to calculate wind speed and its direction. We measure wind speed at three
different locations using an anemometer.

1. Cafe top

2. Jinnah Hostel top

3. Mechanical department top

The wind speed found at the cafe top was the highest which was a little more than 2 m/s while at
Jinnah Hostel top it was 2m/s and on department top, it was 1.6 m/s.

3.1.1 First Approach

The collection of wind data through the first approach is using Transys software. This is used in
energy simulation software especially in the fields of renewable energy engineering. The data
collected from the Transys simulation software consists of wind speed, direction, humidity, and
temperature.

It was collected for the whole year with the time step of 15 minutes. The average wind speed found
out to be near 2.7m/s for the whole year for the Taxila region which is a bit more than average
wind speeds.
 Figure 3. 1 Collection of wind data

3.1.2 Second Approach

The data collected from the last approach is using world weather online weather forecast sites. The
data was collected for one month with a time difference of one hour. It consists of temperature,
wind speed, humidity, and wind direction. So, the average wind speed of one month found out to
be is 2.42 m/s.
 Figure 3. 2 Average wind speed

3.2 Market Study

Blades

• Using 26 gauge stainless steel (SS) (for prototype)

• Weighing 4.5 - 5 kgs. (per blade)

• Costing 1300- 1500 Rs (per blade)

Rotor Shaft

• Using 6063 –T3 Aluminum pipe

• 20 gauge (0.81mm) thickness pipe (prototype)

• Weight= 4-5 kgs surface area=3.67 m

Base

Using simple iron casting

Struts

Using 22/24 gauge stainless sheet

3.3 Mathematical Modeling
3.3.1 Air Density

The average wind speed in Taxila is 2 m/s. The average temperature is 35

ρ= (3.1)
×

Where:

: Air density

p=101.325pa

: Gas constant which is 287 Kj/k

R=287.05 KJ/k

: Temperature of air in Kelvin

T=35

ρ = 1.20 kg/m

The size we chose for the turbine is 2.37 ℎ ×1.5 , as they may be for a small-
scale wind turbine.

3.3.2 Power Output

Considering the following power coefficient factors:

P= × × ×ƞ× (3.2)

v= velocity of wind (m/s)

A=swept area

ρ =density of air

c = coefficient of power

Ƞ= Generator efficiency
r= Blade radius (m)

Ƞ= 0.9 . ρ=1.20

3.3.3 Swept Area

×
= (3.3)
× ×ƞ ×

A=1.78

3.3.4 Blade Radius

The blade radius find by using equation (3.3), the swept area is 1.78 .

A=Swept area

π = 3.1416

r=Blade radius

= × r= = 0.75m

3.3.5 Power of Wind

× × ×
(3.4)

v= velocity of wind (m/s)

A=swept area

ρ =density of air ( )

A=1.78 ρ=1.20 V=2m/s

=8.5watt
 3.3.6 Power of Turbine

The power of turbine using by the previous equation (3.4) to put the value of Power of wind in
equation (3.5) as follows.

= × (3.5)

p = Power of wind (watt)

= coefficient of power

=8.5 watt .

= 2.97= 3 watt

At 3 m/s:

× × ×
(3.6)

P=1/2× 1.20× 1.78 × ( )

=28.83 watt

= × (3.7)

=28.83x 0.35

=10 watt

3.3.1 Tip Speed Ratio

×
‫=גּ‬ (3.8)

W= Angular velocity (rad/sec)

v= Wind velocity (m/s)

R= radius (m)

ρ = Density ( )
‫ =גּ‬Tip speed ratio
×
‫=גּ‬ =0.97 V=2m/s R=0.75m

W= =2.6 rad/s

3.3.2 Rotor Blade Height

A=R×H (3.9)

H=Blade height (m)

R=radius (m)

A=swept area (m )

A=R×H A=1.78 R=0.75m H= =2.37m

3.3.3 Torque

The torque is find by equation (3.10) with the data collected from equation (3.3) and density in the
first equation (3.1). After this, put all the values in equation in (3.10) to find the torque.

× × ×
T= (3.10)

v= Wind velocity (m/s)

A= Swept area (m )

ρ = Density of air ( )

= Coefficient of power

. W=2.6 rad/s A=1.78 ρ=1.20 V=2m/s

× × ×
T=

T=1.15Nm
 3.3.4 Aspect Ratio

In aspect ratio, the rotor blade height is 2.37m and it is from equation (3.9) to put into the following
equation.

AR= ×
(3.11)

H=Blade height (m)

R= Blade Radius
.
AR=
× .

AR=1.58

3.3.5 Rated Velocity

=1.5× = 2 m/s

= 3m/s

3.3.6 Solidity

σ= (3.12)

Where:

= Solidity

= Number of blades

= Chord length

= Diameter the solidity optimal value (0.09–0.36)

σ= 0.15

3.3.7 Chord Length

× ×
C= r= d=2r d=2(0.35) d=0.7m
 . × × .
C=

C=0.16m
Chapter 4 Modeling
This chapter is divided into the three parts. The first part is explaining the virtual design of the
Turbine, blades, strut and rotor in Solid Works. The second part is elaborating the airflow,
streamline velocity, effect of pressure on the whole turbine during rotation by using CFD/Fluent.
The last but not the least discussed about finding different stresses using mechanics of material.

4.1 Turbine Design

The whole process is divided into five phases. These phases are Design, and Modeling,
Fabrication, Testing. We designed our turbine model using Solid Works 2018 which include
following parts:

 Blade
 Rotor shaft
 Struts
 Base

(a)

Figure 4. 1 Turbine blade and shaft

 (b)

Figure 4. 2 Base and Strut

(c)

Figure 4. 3 Exploded and Assembled view

4.2 CFD Analysis
4.2.1 What is Ansys?
According to Google Ansys is engineering simulation and 3D design software delivers product
modeling solutions with unmatched scalability and a comprehensive Multiphysics.

4.2.2 What do CFD Means?

Its Abbreviation is termed as “Computational Fluid Dynamics” is a simulation software is a
comprehensive suite of products that allows you to predict, with confidence, the impact of fluid
flows on your product.

4.2.3 Fluent
Fluent software contains the broad, physical modeling capabilities needed to model flow,
turbulence, heat transfer, and reactions for industrial applications.

4.2.4 Use of CFD in Project

To find the functionality, working, and rigidness of our turbine we have to stimulate our project
In CFD using fluent. We had performed two studies on our model which are with their explanation:

 Design of blade
 Design of the turbine
 Effectiveness of whole design

 Design of Blade

The main problems in designing our blade were its size, helix shape, and the twist of the angle of
a helix. From the design to its solution involves the following steps:
  Geometry
 Meshing
 Setup
 Solution
 Results

 Geometry

For designing our turbine blade we used Solid works 2018 which include extrude, trim, and sweep
commands.

Figure 4. 4 Blade in the starting phase

 Meshing

This is an important difficult part of Ansys which involves dividing the whole body into small
segments called cells. We have performed our meshing on Mesh Editor in Ansys 2019 R3.In our
case, we used the Quadratic element order with the size of the element of 0.01mm.
 Figure 4. 5 Meshing

After having meshing done, we use Enclosure and Boolean command to create a surrounding
boundary to perform our calculation and flow of air around it.

Figure 4. 6 Using the Boolean command

  Setup

This is an important step in calculating and defining the initial boundaries for the solution this is
also known as Preprocessing i.e. defining the inlet and outlet velocity, density and type of fluid,
etc.

Figure 4. 7 Preprocessing

Figure 4. 8 Defining Velocity

  Solution

After setup, the solution is to proceed by choosing the number of iterations and plotting the graphs.
We iterated our setup 300 times.

Figure 4. 9 Graph

Static pressure effecting on the blade is the following:

Figure 4. 10 Static pressure on the blade

  Results

This is the last step also known as post-processing which involves finalizing the results in form of
streamline bodies, animations, and contours.

Figure 4. 11 Effect of pressure contour blade

Figure 4. 12 Velocity contour

 Figure 4. 13 Velocity contour

Figure 4. 14 Velocity streamline

From our these results we have found that our design for the blade is ok because it produces more
thrust and less resistance in the way of air and gives more output as it is perfectly balanced
streamline body as it can be shown on velocity contours and streamlines.

 Design of the Turbine

The main problems in designing our blade were its size, helix shape, and the twist of the angle of
a helix. From the design to its solution involves the following steps:

 Geometry
 Meshing
 Solution
 Results

 Geometry

For designing our turbine blade we used Solid works 2018 which include extrude, trim, and sweep
commands.

Figure 4. 15 Turbine
 Meshing

This is an important difficult part of Ansys which involves dividing the whole body into small
segments called cells. We have performed our meshing on Mesh Editor in Ansys 2019 R3.In our
case, we used the Quadratic element order with the size of the element of 0.01mm.
 Figure 4. 16 Meshing

 Solution

After setup, the solution is to proceed by choosing the number of iterations and plotting the graphs.
We iterated our setup 300 times.

(a)

Figure 4. 17 Graph
 (b)

Figure 4. 18 Force vs Iteration

(c)

Figure 4. 19 Drag vs Iteration

 Results

This is the last step also known as post-processing which involves finalizing the results in form
of streamline bodies, animations, and contours.
 Figure 4. 20 Pressure contour

Figure 4. 21 Velocity surface turbine

Figure 4. 22 Side view of turbine

 (a)

Figure 4. 23 Streamline velocity

(b)

Figure 4. 24 Another aspect of streamline

4.3 Loads & stresses

4.3.1 Static Loading & Wind Pressure of Turbine

By using a wind velocity of 2m/s and the density is 1.20 blade surface area of 1.78

calculated using Solid Works, the load on a blade is determined to near 2.4 , consequently, the

wind load is located using the equation.

Dynamic pressure P = ×ρ× v

=2.4 pa ρ=1.20 v= 2m/s A=1.78

Wind load = Dynamic pressure× Blade Area

Wind load =2.4×1.78

Wind load =4.272N

4.3.2 Graph

Wind Velocity VS Wind Load

1200

1000
Wind Load N/m2

800

600

400 Wind Velocity VS Wind Load

200

0
0 1 2 3 4 5 6 7
Velocity m/s

Figure 4. 25 Different loads at wind speed

 4.3.3 Sizing of shaft
The shaft is exposed to 2 forces and torque, the consequence of the rotating blades because of wind
orthogonal to the shaft; the torque is formerly determined and changed into located to be identical
to 1.15 . , the wind load calculated that’s identical to 4.32 , and the turbine weight which is
obtained via Solid Works, turned into determined to be 167 .

Weight of turbine =17 kg

W=m×g (3.13)

W=17(9.81)

W=166.77N=167N

4.3.4 Stresses on the Shaft are by given Equation

= A= × (3.14)

d= diameter of shaft=0.12m

A= ×( . )

A =0.0113

P = Wind load

A= Cross section area

= (3.15)

.
=
.

= 380pa

=0.38kpa

Where:
 .
σ = = Turbine weight
.
= Cross-section area of the shaft

σ = 14.77kpa

4.3.5 Torsion on the shaft

×
= (3.16)

Where:

T= Torque

R= Radius of the shaft

J= Polar moment of inertia

J. = × (3.17)

d = Diameter of shaft

d=0.12m

J= ×( . )

.
J = 2.03× r= = =0.006m

×
=

. × .
=
. ×

= 3399.014778pa

=0.003399Mpa

=3.399kpa
 4.3.6 Principal Stresses
.
, = ± ( ) + (3.18)

So

. = + ( ) + .

. . . .
. = + ( ) +( . )

= 15.52kpa

.
= - ( ) +

. . .. .
= - ( ) +( . )

. = - 0.3786kpa

4.3.7 Factor of Safety

By using Von Misses Stresses Theory

( ) ( ) ( )
. = (3.19)

= 15.52kpa

= 0kpa

= - 0.3786kpa

( . ) ( ( . ) ) ( . . )
. =

( . ) ( . × ) .
. =

= 15.7Mpa
 4.3.8 The torque of the Shaft

T= × × (3.20)

T = 0.003999× ×( . )

T = 1.15Nm

4.3.9 Factor of Safety

N= =35Mpa = 15.7Mpa

= yield strength

n=
.

n = 2.2

The factor of safety is 2.2 and the diameter of shaft is 0.12m which is eligible for the design
process. The design is completely safe regarding it load and stresses analyze theoretically.
Chapter 5 Discussion and Results
5.1 Selection of Bearing

Based on the varieties of forces on the shaft, which might be radial and axial forces calculated
4.272N and 167 accordingly. We have selected a ball bearing to be installed on the top because
of the radial pressure caused by the shaft rotation. Since we have a distributed load of 4.272 acting
at the blade, each bearing is subjected to an equal reaction force of 2.136 N, that's the radial force.

= { } (5.1)

C = Catalog rating, lbf or KN

F = Desired radial load

L = Desired life, hours

n = Desired speed, rev/min

L = Rating life in hours

n = Rating speed, rev/min

= revolutions = 5000 hrs

×
W= (5.2)

×
=

. ×
=

= 24.82=25 rpm

= { }

× ×
= . { }
 = 4.18

From the table, we can choose to bear with bore more than or equal to 10mm and also calculate the
value of C andC .

Figure 5. 1 Different dimensions for selection of bearing sizes

5.1.1 Shaft Output of the Turbine

P =T×w (5.3)

T = Torque of shaft

W = Angular velocity (rad/s)

W= =2.6 rad/s V=2m/s R=0.75m T =1.15Nm

= 1.15 × 2.6

= 2.99=3watt

5.1.2 Wind Power in Blade

Before finding the blade power and cover every aspects of the formula, the area is already been
calculated and discussed in chapter 3 and equation (3.9).
 × × ×
(5.4)

v= Wind velocity (m/s)

A= Swept area (m )

ρ = Density of air ( )

A=1.78 ρ=1.20 V=2m/s

=8.5watt

5.1.3 Wind Turbine Efficiency

The efficiency of the turbine is found by shaft out in equation (3.5) and the wind power blade in
equation (5.4). The helical blade vertical axis wind turbine efficiency is lower than Horizontal axis
wind turbine but it is cost efficient.

ƞ = ×100% (5.5)

ƞ = ×100%
.

ƞ = 35%

5.1.4 Reynolds Number

= (5.6)

ρ =Density ( )

v= Wind velocity (m/s)

D = Diameter of turbine

U = Kinematic viscosity= 1.8× 10

A=1.78 R = 0.75m ρ=1.20 V=2m/s

r= d=2×r d= 2× . = 1.5m = 0.8 from graph

. × × .
=
. ×
 = 200000

= ×

Figure 5. 2 Selection of Reynolds number

5.1.5 Drag Force

= × ×ρ× × (5.7)

= 0.8 × ×1.20×1.78× ( )

= 3.4 N

5.2 Estimation of Power and Sizing of Turbine

In widespread, the environmental parameters, or the parameters governed through the flow field
in which the turbine is to be placed are constant and the fashion designer has little choice to
exchange any of them in a try and increase efficiency. The framework falls mostly into two
categories, particularly those ruled by using the geometry of the turbine. These frameworks include
a vital role inclusive of unfastened move velocity, and the density of the air. The output of the
shaft is estimated about 3W and average velocity of 2.77m/s. The blade height is 2.37m, diameter
of turbine 1.5m, shaft diameter 0.12m, blade radius 0.75m.
Graph

Power vs Velocity
90
80
70
Power (W)

60
50
40
30 Series1
20
10
0
0 1 2 3 4 5 6 7
Velocity (m/s)

Figure 5. 3 Power vs Velocity

Chapter 6 Conclusion and Summary
The above consequences of the project show the effort of colleagues, who put his best in the last
reproduction of helical blade vertical axis wind turbines. The tremendous knowledge has been
gathered and examine the CFD analysis on blades and turbines. On average speed of 2.77 m/s, it
gives power up to 3W. The fluctuation in voltage is due to variation in wind velocity. The blades
first design on Solid Works and afterward, the simulation has been done approximately 300 times.
The time has gone through 1-2 hours for each simulation. Before making the model, we have found
different stresses and forces on the blade and cover every aspect of the turbine. In CFD analysis,
the simulation results of wings during airflow are good because the airflow not blocked and the
turbine rotates freely. For those simulations, more than 50 meshes have been drawn. In the case of
simulations, most of the Laptops available easily were hardly fulfilled the requirement of the
software. Those problems were unique problems for user to user. Then the new areas had to be
explored with great courage. So it is all about learning new and challenging things.
6.1 References
[1]. Ragheb, M., 2011. Vertical axis wind turbines. University of Illinois at Urbana-Champaign, 1.

[2]. Naskali, P.H., MacLean, A., Gray, N.C., Lewis, J.H. and Newall, A.P., Arrowind Corp,
2008. Helical wind turbine. U.S. Patent 7,344,353.

[3]. Jeon, K.S., Jeong, J.I., Pan, J.K. and Ryu, K.W., 2015. Effects of end plates with various
shapes and sizes on helical Savonius wind turbines. Renewable energy, 79, pp.167-176.

[4]. Sullivan, J.T., Sullivan John T, 2011. Helical airfoil wind turbines. U.S. Patent Application
12/587,168.

[5]. Kamoji, M.A., Kedare, S.B. and Prabhu, S.V., 2009. Performance tests on helical Savonius
rotors. Renewable Energy, 34(3), pp.521-529.

[6]. Jaakkola, R., Shield Oy, 2002. Helical wind rotor and a method for manufacturing the same.
U.S. Patent 6,428,275.

[7]. Byrne, B.W. and Houlsby, G.T., 2015. Helical piles: an innovative foundation design option
for offshore wind turbines. Philosophical Transactions of the Royal Society A: Mathematical,
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[8]. Akwa, J.V., Vielmo, H.A. and Petry, A.P., 2012. A review on the performance of Savonius
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[9]. Lee, J.H., Lee, Y.T. and Lim, H.C., 2016. Effect of twist angle on the performance of Savonius
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[10]. Zhao, Z., Zheng, Y., Xu, X., Liu, W. and Zhou, D., 2010, July. Optimum design configuration
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