20th International Forgemasters Meeting - IFM 2017

In recent years, global wind turbine market is increasing every year and wind turbine systems are getting larger to increase efficiency of power generation. With this trend, it is essential to manufacture lightweight and cost-effective main shafts which are main components of wind turbines. In this study, an attempt to design optimal hollow shaft and forge the component was performed. The relationship between shape parameters and stress distribution was derived by finite element analysis and optimal shape was designed on the viewpoint of structural strength by optimal design technique. Weight reduction of hollow main shaft shows more than 30% compare with solid shaft. Process design was performed to manufacture sound hollow products and the part was forged by 15,000ton press. Mechanical properties and micro structures were analyzed. Fabricated hollow main shaft satisfies the components requirements specification. With the results obtained by this study, an opportunity to be a world competitive company can be provided.