Catastrophic Failure Analysis of a Wind Turbine Gearbox by the Finite Element Method and Fracture Analysis
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 pro...
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MDPI AG
2025-01-01
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| author | Jairo Aparecido Martins Estaner Claro Romão |
| author_facet | Jairo Aparecido Martins Estaner Claro Romão |
| author_sort | Jairo Aparecido Martins |
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| description | 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. |
| format | Article |
| id | doaj-art-c71bf10014e24fefb6345097a526a9f3 |
| institution | DOAJ |
| issn | 2411-9660 |
| language | English |
| publishDate | 2025-01-01 |
| publisher | MDPI AG |
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| spelling | doaj-art-c71bf10014e24fefb6345097a526a9f32025-08-20T02:44:32ZengMDPI AGDesigns2411-96602025-01-0191410.3390/designs9010004Catastrophic Failure Analysis of a Wind Turbine Gearbox by the Finite Element Method and Fracture AnalysisJairo Aparecido Martins0Estaner Claro Romão1Department of Research & Development—Desch North America, Cambridge, ON N1T 1J6, CanadaDepartment of Basic Sciences and Environmental, Engineering College of Lorena, University of São Paulo—USP, São Paulo 12602-810, BrazilThe 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.https://www.mdpi.com/2411-9660/9/1/4renewable energywind turbinegearboxcatastrophic failurefatigue |
| spellingShingle | Jairo Aparecido Martins Estaner Claro Romão Catastrophic Failure Analysis of a Wind Turbine Gearbox by the Finite Element Method and Fracture Analysis Designs renewable energy wind turbine gearbox catastrophic failure fatigue |
| title | Catastrophic Failure Analysis of a Wind Turbine Gearbox by the Finite Element Method and Fracture Analysis |
| title_full | Catastrophic Failure Analysis of a Wind Turbine Gearbox by the Finite Element Method and Fracture Analysis |
| title_fullStr | Catastrophic Failure Analysis of a Wind Turbine Gearbox by the Finite Element Method and Fracture Analysis |
| title_full_unstemmed | Catastrophic Failure Analysis of a Wind Turbine Gearbox by the Finite Element Method and Fracture Analysis |
| title_short | Catastrophic Failure Analysis of a Wind Turbine Gearbox by the Finite Element Method and Fracture Analysis |
| title_sort | catastrophic failure analysis of a wind turbine gearbox by the finite element method and fracture analysis |
| topic | renewable energy wind turbine gearbox catastrophic failure fatigue |
| url | https://www.mdpi.com/2411-9660/9/1/4 |
| work_keys_str_mv | AT jairoaparecidomartins catastrophicfailureanalysisofawindturbinegearboxbythefiniteelementmethodandfractureanalysis AT estanerclaroromao catastrophicfailureanalysisofawindturbinegearboxbythefiniteelementmethodandfractureanalysis |