Technical and functional analysis of Spanish windmills: 3D modeling, computational-fluid-dynamics simulation and finite-element analysis

Highlights: • Technical and functional analysis of the two typologies of windmills in Spain. • Spatial distribution of velocities and pressures by computational-fluid dynamics (CFD). • Finite-element analysis (FEA) of the rotors of these two types of windmills. • Validation of the operative functionality of these windmills. - Abstract: A detailed study has been made of the two typologies of windmills in Spain, specifically the rectangular-bladed type, represented by the windmill 'Sardinero', located near the town of Campo de Criptana (Ciudad Real province, Spain) and the type with triangular sails (lateens), represented by the windmill 'San Francisco', in the town of Vejer de la Frontera (Cádiz province, Spain). For this, an ad hoc research methodology has been applied on the basis of three aspects: three-dimensional geometric modeling, analysis by computational-fluid dynamics (CFD), and finite-element analysis (FEA). The results found with the CFD technique show the correct functioning of the two windmills in relation to the spatial distribution of the wind velocities and pressures to which each is normally exposed (4–7 m/s in the case of 'Sardinero', and 5–11 for 'San Francisco'), thereby validating the operative functionality of both types. In addition, as a result of the FEA, the spatial distribution of stresses on the rotor has revealed that the greatest concentrations of these occurs in the teeth of the head wheel in 'Sardinero', reaching a value of 12 MPa, and at the base of the masts in the case of the 'San Francisco', with a value of 24 MPa. Also, this analysis evidences that simple, effective designs to reinforce the masts absorb a great concentration of stresses that would otherwise cause breakage. Furthermore, it was confirmed that the oak wood from which the rotors were made functioned properly, as the windmill never exceeded the maximum admissible working stress, demonstrating the effectiveness of the materials used in this period.