Three dimensional analysis and aerodynamic modelling of different wind turbine blade profiles accounting materials’ Roughness impact

• Different airfoil profiles of a small-scale wind turbine have been modelled and numerically analysed. • The NREL S826 profile recorded the least drag force, while the DU86 exhibited the highest drag force. • A significant relationship exists between airfoil profile shape and attack angle that optimizes performance. • The effect of wind speed alongside the turbine model material has been studied. • The material roughness influence indicated that E-glass was superior, whereas Kevlar achieved the highest values in roughness and wind speed. Wind turbine energy is a promising candidate source to achieve near-zero carbon energy. However, the inaccurate design of airfoil profile as well as the blade material is considered the main limit for achieving the best performance for wind turbines. This research examines five different types of airfoil profiles for horizontal axis wind turbines under a range of boundary conditions, including various angles of attack from 0° to 20° and at low wind velocities (5, 7, and 9 m/s), employing Ansys Fluent 2023 R1 for analysis. Consequently, the 3D model of the best airfoil has been further analysed to elucidate the impact of material surface roughness, which exerts a considerable influence on the aerodynamic efficacy of wind turbines. This investigation was conducted utilizing the most prevalent composite materials employed in wind turbine fabrication, namely E-glass, Kevlar fiber, and carbon nanotubes. Upon evaluating models, the NREL S826 emerged as the superior profile among five primary airfoils considered: NACA 4418, Sd 7080-il, DU86-08418-il, and NACA 0012. Also, for all investigated airfoil profiles, it has been shown that the best registered attack angle ranges from 8° to 15°. Following a comparative analysis of various roughness values (5, 10, 15, 20, and 25 μm), it is proposed that carbon nanotubes serve as the most advantageous reinforcement material for the fabrication of wind turbine blades, attributed to their superior torque characteristics. Furthermore, this methodology has resulted in enhancements of 55% and 36% in the drag force and the lift force, respectively. This study connected the 2D analysis, by nominating the best airfoil shape among five different types, with the 3D analysis and examined the implications of varying roughness values, wind speed parameters, and diverse airfoil blade configurations. It provides a valuable analysis procedure for enhancing the wind turbine performance.