This study presents an aerostructural optimization process for wind turbine blades aimed at enhancing the turbine’s performance. The optimization framework integrates DAFoam as the computational fluid dynamics (CFD) solver, TACS as the finite element method (FEM) solver, Mphys for fluid–structure coupling, and SNOPT as the optimizer within the OpenMDAO framework. The objective is to simultaneously increase the torque generated by the wind turbine while decreasing the mass of the blade, thereby improving its efficiency. The design variables in this optimization process are the blade shape and panel thickness. The aerodynamic objective function is torque, a key performance indicator for wind turbine efficiency. The structural objective function is the blade mass, as reducing mass is essential to minimize material and manufacturing costs. The optimization process utilizes the integrated capabilities of DAFoam, TACS, Mphys, and SNOPT to iteratively evaluate and modify the blade shape and panel thickness. The OpenMDAO framework facilitates seamless communication between the solvers and the optimizer, ensuring a well-coordinated, efficient optimization process. The results of the optimization show a 6.78% increase in torque, which indicates a significant improvement in the wind turbine’s energy production capacity. Additionally, a 4.22% decrease in blade mass demonstrates a successful reduction in material usage without compromising structural integrity. These findings highlight the potential of the proposed aerostructural optimization process to enhance the performance and cost-effectiveness of wind turbine blades, contributing to the advancement of sustainable energy solutions. This work represents the first attempt to implement DAFoam for wind turbine aerostructural design optimization.

This work presents a high-fidelity two-way coupled Fluid-Structure Interaction (FSI) simulation framework for wind turbine blades, developed using the Arbitrary Hybrid Turbulence Modelling (AHTM) implemented through Very Large Eddy Simulation (VLES) in the DAFoam solver. By integrating VLES with the Toolkit for the Analysis of Composite Structures (TACS) structural solver via the OpenMDAO/MPhys framework, this work aims to accurately model the complex aeroelastic characteristics of wind turbines, specifically focusing on the NREL Phase VI wind turbine. The numerical model accounts for the effects of transient, turbulent, and unsteady aerodynamic loading, incorporating the impact of structural deflections. A comparison of the calculated results with experimental data demonstrates strong agreement in key performance metrics, including blade tip displacements, power output, and pressure distribution. This alignment confirms that the proposed model is effective at predicting wind turbine performance. One of the significant advantages of this study is the integration of advanced turbulence modeling with shell element structural analysis, enhancing the design and performance predictions of modern wind turbines. Although computationally intensive, this approach marks a significant advancement in accurately simulating the aeroelastic response of turbines, paving the way for optimized and more efficient wind energy systems.

During this research, aerodynamic shape optimization is conducted on the Ahmed body with the drag coefficient as the objective function and the ramp shape as the design variable, while aero-structural optimization is conducted on NACA 0012 to reduce the drag coefficient for the aerodynamic performance with the shape as the design variable while reducing structural mass with the thickness of the panels as the design variables. This is accomplished through a gradient-based optimization process and coupled finite element and computational fluid dynamics (CFD) solvers under fluid–structure interaction (FSI). In this study, DAFoam (Discrete Adjoint with OpenFOAM for High-fidelity Multidisciplinary Design Optimization) and TACS (Toolkit for the Analysis of Composite Structures) are integrated to optimize the aero-structural design of an airfoil concurrently under the FSI condition, with TACS and DAFoam as coupled structural and CFD solvers integrated with a gradient-based adjoint optimization solver. One-way coupling between the fluid and structural solvers for the aero-structural interaction is adopted by using Mphys, a package that standardizes high-fidelity multiphysics problems in OpenMDAO. At the end of the paper, we compare and discuss our findings in the context of existing research, specifically highlighting previous results on the aerodynamic and aero-structural optimization of wind turbine blades.