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The L-type flange joint is widely used to attach steel tower segments to each other. However, tolerances on the flange surface flatness may occur during its fabrication, leading to a negative impact on the bolt stress distribution. This study evaluates the influences of the flange surface flatness on the behavior of L-type flange joints through numerical simulations. First, the finite element model of a 5 MW L-type flange joint is established, and its accuracy is verified based on comparison with an experimental test. Using the same loading conditions and material properties, the influences of geometrical imperfections (i.e., flange-sided gap, tower-sided gap) on the structural response are investigated. Furthermore, the impact of the flange gap opening length is reported. The results show that the flange-sided gap outperforms the tower-sided gap, resulting in reduced stress concentration in the bolt. In addition, the stresses in flange-sided gapping joints increase with an increase in the opening length.

This paper focuses on the design modification of L-type flange joint geometry in wind towers, aiming to enhance its structural safety. For this aim, current design issues of existing flange joints are discussed. The numerical simulations indicate that the threaded bolt and flange-to-shell junction are critical locations where failure may happen. Further discussion to improve structural safety is applied for an existing 5 MW flange joint. Through parametric studies, the major factors influencing ultimate strength are identified. The results show that the aspect ratio plays an important role in increasing the structural safety of the flange joints, while the width of the flange segment weakens the stiffness of the flange-to-shell junction. The findings in this study are expected to provide a useful reference for designing the L-type flange joints in practical engineering fields.

Critical components in support structures for wind turbines, flange joints, are fundamental to ensure the structural integrity of mechanical assemblies under varying operational conditions. This paper investigates the structural performance of L-type flange joints, focusing on the influence of bolt grades and bolt pretension through a finite element analysis (FEA) study of its key performance indicators, including stress distribution, deformation, and force–displacement behaviors. This paper studies two high-strength bolt grades, Grade 10.9 and Grade 12.9, and two main steps—first, bolt pretension and, second, external loading (tower shell tensile load)—to investigate the influence on joint reliability and safety margins. The novelty of this study lies in its specific focus on static axial loading conditions, unlike the existing literature that emphasizes fatigue or dynamic loads. Results show that the specimen carrying a higher bolt grade (12.9) has 18% more ultimate load carrying capacity than the specimen with a lower bolt grade (10.9). Increased pretension increases the stability of the joint and reduces the micro-movements between A and B (on model specimen), but could result in material fatigue if over-pretensioned. Comparative analysis of the different bolt grades has provided practical guidance on material selection and bolt pretension in L-type flange joints for wind turbine support structures. The findings of this work offer insights into the proper design of robust flange connections for high-demand applications by highlighting a balance among material properties, bolt pretension, and operational conditions, while also proposing optimized pretension and material recommendations validated against classical analytical models.