Torque Converter Analytical Program for Blade Design Process 2000-01-1145

In this paper, an integrated torque converter design process is described which improves converter performance while reduces the design cycle time and number of hardware iterations. The process utilizes a suite of tools to achieve the objectives. For quick and flexible geometry layout, the TORUS DESIGN TOOL is employed to create the underlying 2D-torus geometry with given packaging constraints. The BLADE DESIGN TOOL is subsequently used to generate 3D sheet-metal type profiles for the impeller, turbine, and reactor blades. The tool is equipped with a parametric capability for blade curvature and blade angle control to meet the performance requirements. The AIRFOIL DESIGN TOOL utilizes a sophisticated, parameterized algorithm to generate the desired airfoil shape around the reactor camber-line for improved performance. The OPTIMIZATION TOOL provides a fast method for the selection of optimized design parameters by matching test data to coefficients set for searching and optimizing the target performance. To achieve consistent and accurate performance predictions, an automated CFD procedure is implemented for mesh generation, problem setup, job execution, and performance data analysis. The predicted results provide feedback for the converter design optimization. The CFD results also supply pressure loading for downstream FEA durability analysis on relevant components. The optimized design is interfaced with an appropriate CAD package for solid modeling and rapid prototyping. All the tools are integrated into a graphical user interface to make the process intuitive and easy to use. In this paper, we focus on tool applications in the design process and the results of design iterations. We'll address in a separate paper the issues of numerical accuracy with respect to physical sub-models, mesh quality, and toroidal flow interactions. This process has been proven a key enabler for reduced hardware testing and to facilitate faster converter product development timing.