Experimental and Numerical Modeling of a Cross-Flow Turbine Runner Made of HDPE: Experimental and Numerical Approach
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This study investigates the viability of high-density polyethylene (HDPE) as a sustainable, low-cost alternative to conventional metallic materials for Cross-flow turbine runners in micro-hydropower systems. The primary goal is to design, manufacture, and validate the hydrodynamic and structural performance of an HDPE runner. A three-stage methodology was applied: CAD-based design, thermoforming fabrication, and performance evaluation through computational fluid dynamics (CFD) and finite element analysis (FEA) using ANSYS. Numerical predictions were validated against experimental data obtained from a hydraulic test bench. Mesh refinement and turbulence modeling were included to ensure numerical reliability. Results show that the HDPE runner achieved efficiencies of 80-83% compared to a geometrically identical steel runner under similar operating conditions. Structural analysis confirmed von Mises stresses (8.5 MPa) and deformations (0.12 mm) remained well below HDPE’s yield strength (22 MPa), validating its mechanical integrity. Statistical comparison revealed a deviation of less than 4% between numerical and experimental results. This research provides a validated framework for using recyclable HDPE in turbine manufacturing. It demonstrates that HDPE can deliver comparable power output to steel while reducing manufacturing costs and environmental impact, offering a sustainable pathway for rural electrification.
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