Structural Analysis, Modal Characterisation, and Fatigue Life Assessment of a 5 kW Small Wind Turbine Blade Using GFRP, CFRP, and Hybrid Composite Materials Under Combined Aerodynamic and Centrifugal Loading

Abstract

Small wind turbines in the 1–10 kW range serve the critical role of distributed power generation for rural households, telecom towers, and off-grid industrial facilities, particularly relevant to regions of Maharashtra with consistent wind resources above 5 m/s mean annual wind speed. The structural design of wind turbine blades for this power class must balance aerodynamic performance, structural integrity across the full wind speed operating range, dynamic resonance avoidance, and fatigue life over the 20-year design service life — all within material cost and manufacturing constraints appropriate for decentralised rural deployment. This paper presents a comprehensive finite element structural analysis of a 5 kW, 4.8 m diameter (2.4 m blade length) horizontal axis wind turbine blade using three composite laminate configurations: glass fibre reinforced polymer (GFRP, E-glass/epoxy), carbon fibre reinforced polymer (CFRP, T300/epoxy), and a hybrid configuration with a CFRP D-spar load-carrying element and GFRP aerodynamic skin panels.

Cite as:

S. J. Mulani. (2026). Structural Analysis, Modal Characterisation, and Fatigue Life Assessment of a 5 kW Small Wind Turbine Blade Using GFRP, CFRP, and Hybrid Composite Materials under Combined Aerodynamic and Centrifugal Loading. Research and Reviews: Journal of Mechanical Engineering, 2(2), 21–30. https://doi.org/10.5281/zenodo.21870530