Design and Optimization of Torque Converter

NUMECA, a New Wave in Fluid Dynamics

Project Objective
Re-design and optimization of the stator of an existing torque converter with objective to increase the torque ratio between the converter turbine and pump.

http://www.numeca.com

Customer Profile
The customer, is a global automotive parts supplier and a technological leader for various components of the automotive drive train system
One fourth of cars in the world are equipped with components from the company. Employing several thousands people worldwide with various sites located in all continents: Europe, America, Asia and Africa.

Testimonial
This optimization study met my expectations. I had this study done to prove the capability of FINE/Design3D and FINE/Turbo to correctly model an automotive torque converter....Our engineers found your staff to be extremely capable...They understood all of the details of our analysis, and were able to offer useful suggestions in every conversation. The project was completed on time, and 100% of our requests were filled to our satisfaction...Our team is very pleased with the results, and we really enjoyed the experience. (Director of Engineering)

Torque Converter Design Consideration at LuK

The torque converter has been utilized as a proven coupling element between the engine and automatic transmission. The available torque amplification (torque ratio) improves acceleration and performance. The torque converter development is accomplished through an integrated design approach, incorporating analytical simulation, testing, and optimisation.

NUMECAs Advanced Technology FINE/Design3D & FINE/Turbo

To meet the customer stringent requirements, NUMECA International offers an integrated analysis, design and optimization solution through the CFD package FINE/Turbo and the design and optimization suite FINE/Design3D. The 3D blade shape of the torque converter has been succesfully optimized to obtain an increase of the torque ratio.

Design and Optimization of Torque Converter

NUMECA, a New Wave in Fluid Dynamics

Design and Optimization process

Design tool: FINE /Design3D

An integrated design and optimization process has been carried out using NUMECAs products: FINE/Turbo for flow analysis, AUTOBLADE* for parametric blade modeling, DESIGN3D* for optimization tasks. *AUTOBLADE and DESIGN3D are included in the FINE/Design3D package. FINE/Design3D applies a knowledge-based method for the automatic design improvement to turbomachinery blade and flow path geometry parameterized by using AUTOBLADE. An Artificial Neural Network (ANN) is used to construct an approximate model (response surface) using a database containing Navier Stokes solutions for all previous designs. This approximate model is used by a genetic algorithm for the optimization of the blade geometry which is then analyzed by a NavierStokes solver (FINE/Turbo). This procedure results in a considerable speed-up of the design process by reducing both the interventions of the operator and the computational effort. FINE/Design3D allows the designer to improve performance, while satisfying both aerodynamic and mechanical constraints. The design, analysis and optimization processes is characterized by:
INITIAL FLOW PATH OPTIMIZED FLOW PATH

Design and Optimization cycle

300k nodes mesh generated for the entire torque converter,

68 parameters used to represent the stator geometry, including 36 optimization variables, 100 CFD calculations for database generation, 5 hours CPU /calculation on PC 1GHz, 10 optimization iterations including 1 CFD computation/iteration.

INITIAL GEOMETRY

OPTIMIZED GEOMETRY

By applying an integrated process of analysis, design and optimization using NUMECAs solutions in the Torque Converter development activities, the customer has considerably reduced time and cost and improved the performances of their products.
NUMECA USA, Inc. 1204 E. Baseline Rd., Suite 202 Tempe, AZ 85282, USA Tel: +1 480 456-9662 E-mail: allan-grosvenor@numeca-usa.com

Contact:

NUMECA International s.a. Av. Franklin Rossevelt 5 B-1050 Brussels, BELGIUM Tel: +32 2 643.3570, Fax: +32 2 647.9398 E-mail: info@numeca.be