Performance Optimization of Conventional Savonius Rotor for Different Construction Materials through CFD Study

The study concludes the potential for conducting a computational analysis on the conventional design of the Savonius rotor made with Poly-Lactic Acid (PLA), which is a 3-D printer material. This material can be molded into any shape with the 3D printer capabilities. The output from the simulation results thus provides an effective design solution for the purpose of constructing the Sovonius Rotor to be produced by a 3D printing technology. A computer design model thus aids in conducting simulation studies to find the torque and Coefficient of Performance (COP) as the primary performance indicators, followed by structural analysis on the rotor blades as the secondary performance indicator. It is a dual simulation study for the evaluation of torque based on the best design of the rotor, for the production of these designs based on the material selection after structural analysis simulation test, both conducted by ANSYS. The material selection was based on easily available metallic and composite material choices, such as aluminum, steel, and PLA. These materials were tested for their structural deformity under wind velocities of 6 m/s, 8 m/s, and 10 m/s. The COP was found to be maximum at 10 m/s for the configuration of the turbine used. The use of PLA is an affordable 3D printing material for building a small Vertical-Axis Wind Turbine (VAWT). PLA is a light material having low density and thermal conductivity as compared to steel and aluminum (88%), tested for producing stress values of 14 mPa, 156 mPa, and 10638 MPa, respectively, at 10 m/s. Deformation over rotor blades was found to be highest for aluminum (88%) at 1 m, and lowest for steel at 0.015 m. Though steel shows more reliable deformation results, PLA is a more preferred material for complex designs of 3-D printing turbine construction due to the lower material cost than steel.