Catastrophic Failure Analysis of a Wind Turbine Gearbox by the Finite Element Method and Fracture Analysis (2025)
- Authors:
- Autor USP: ROMÃO, ESTANER CLARO - EEL
- Unidade: EEL
- DOI: 10.3390/designs9010004
- Assunto: FADIGA DOS MATERIAIS
- Keywords: Energia renovável; renewable energy; wind turbine; gearbox; catastrophic failure; fatigue; Falha catastrófica
- Language: Inglês
- Abstract: The wind turbine gearbox, used as a multiplier, is one of the main components directly related to a wind turbine’s efficiency and lifespan. Therefore, strict control of the gearbox and its manufacturing processes and even minor improvements in this component strongly and positively impact energy production/generation over time. Since only some papers in the literature analyze the mechanical aspect of wind turbines, focusing on some parts in depth, this paper fills the gap by offering an analysis of the gearbox component under the highest amount of stress, namely relating to the sun shaft, as well as a more holistic analysis of the main gear drives, its components, and the lubrification system. Thus, this work diagnoses the fracture mechanics of a 1600 kW gearbox to identify the main reason for the fracture and how the chain of events took place, leading to catastrophic failure. The diagnoses involved numerical simulation (finite element analysis—FEA) and further analysis of the lubrication system, bearings, planetary stage gears, helical stage gears, and the high-speed shaft. In conclusion, although the numerical simulation showed high contact stresses on the sun shaft teeth, the region with the unexpectedly nucleated crack was the tip of the tooth. The most likely factors that led to premature failure were the missed lubrication for the planetary bearings, a lack of cleanliness in regard to the raw materials of the gears (voids found), and problems with the sun shaft heat treatment. With the sun gear’s shaft, planet bearings, and planet gears broken into pieces, those small and large pieces dropped into the oil, between the gears, and into the tooth ring, causing the premature and catastrophic gearbox failure.
- Imprenta:
- Source:
- Este periódico é de acesso aberto
- Este artigo NÃO é de acesso aberto
-
ABNT
MARTINS, Jairo Aparecido e ROMAO, Estaner Claro. Catastrophic Failure Analysis of a Wind Turbine Gearbox by the Finite Element Method and Fracture Analysis. Designs, v. 9, n. 1, p. 1-15, 2025Tradução . . Disponível em: https://doi.org/10.3390/designs9010004. Acesso em: 18 fev. 2026. -
APA
Martins, J. A., & Romao, E. C. (2025). Catastrophic Failure Analysis of a Wind Turbine Gearbox by the Finite Element Method and Fracture Analysis. Designs, 9( 1), 1-15. doi:10.3390/designs9010004 -
NLM
Martins JA, Romao EC. Catastrophic Failure Analysis of a Wind Turbine Gearbox by the Finite Element Method and Fracture Analysis [Internet]. Designs. 2025 ;9( 1): 1-15.[citado 2026 fev. 18 ] Available from: https://doi.org/10.3390/designs9010004 -
Vancouver
Martins JA, Romao EC. Catastrophic Failure Analysis of a Wind Turbine Gearbox by the Finite Element Method and Fracture Analysis [Internet]. Designs. 2025 ;9( 1): 1-15.[citado 2026 fev. 18 ] Available from: https://doi.org/10.3390/designs9010004 - The Importance of Accurate Boundary Condition in Obtaining Reliable Shearing Stresses on a Torsional Finite Element Simulation
- Assessing the Impact of Changes on Design and Material of Howe Bridgesby Finite Element Analysis
- Managing individuals, collectiveness and environment in Decision Making Process for Businesses (an unpretentious approach)
- A importância do uso da tecnologia no ensino de geometria: planejamento e plano de aula
- Numerical Simulation of a One-Dimentional Non-Linear Wave Equation
- Aprendizagem baseada em projetos na aplicação de gráficos de funções
- Fracture Analysis of a Cycloidal Gearbox as a Yaw Drive on a Wind Turbine
- Studying Resonant Frequencies of a Helical Spring with and Without Axial Loads
- Numerical Simulation by Galerkin Method of 2D Nonlinear Convection-Diffusion
- An Important and Simple Roadmap to Analyze Failures and Avoid Poor Conclusions When Evaluating Failures of Metallic Products
Informações sobre o DOI: 10.3390/designs9010004 (Fonte: oaDOI API)
How to cite
A citação é gerada automaticamente e pode não estar totalmente de acordo com as normas
