Accurate Modeling of Material Nonlinearities in a Wind Turbine Spar Cap

Abstract This study presents component-level testing of carbon fiber sandwich beams and the effect of carbon fiber material nonlinearity in its strain response in bending. A simple material model is presented and validated that accurately captures the carbon fiber longitudinal nonlinearity in both the tensile and compressive response. This material model is implemented in a finite element model of the BAR-DRC reference wind blade, a downwind 100-meter rotor blade, and the effects of the nonlinearity on ultimate limit states of the blade are analyzed. The material nonlinearity has negligible effect on the deflection, and material failure predictions. The buckling analysis revealed significant reductions in buckling load factor in the controlling flap direction caused by the material nonlinearity, revealing the importance of including this material model for buckling analyses of wind blade with carbon fiber reinforced spar caps.