- Design High Performance Axial Turbine Stages with More Uniform Exit Flow
- Design of High Performance Pump Stage
- Hydraulic Design Optimisation of a Torque Converter
- Design High Performance Centrifugal Compressor Impellers
- Design Optimisation of a Strongly Interacting Diffuser Pump Stage
- Redesign of an Industrial Compressor Stage
- Design of a 3 Stage Axial LP Turbine for Aeroengine Applications
- Design High Efficiency Impellers with Splitter Blades
- Design High Performance Centrifugal Compressor Vaned Diffusers
- Design of a Cooling Fan
- Design of a Double-Suction Fan Stage
- Design of a Double-Suction Volute Pump
- Design of Refrigeration Compressor Stage in R134a
- Multi-Objective Optimisation of a Centrifugal Pump Stage by Means of Design of Experiment Coupled with Inverse Design Method
- Design of an Inducer Pump with High Suction Performance and Backflow Control
- On the Role of Three-Dimensional Inverse Design Methods in Turbomachinery Shape Optimization
- On 3-D Inverse Design of an Automotive Torque Converter Pump Impeller in Shear Flow
- Investigation of an Inversely Designed Centrifugal Compressor Stage - Part II: Experimental Investigations
- Investigation of an Inversely Designed Centrifugal Compressor Stage - Part I: Design and Numerical Verification
- Suppression of Secondary Flows in a Turbine Nozzle with Controlled Stacking Shape and Exit Circulation by 3D Inverse Design Method
- TURBOdesign1 is Extensively Used at Voith Turbo for the Design of Hydrodynamic Torque Converters
- China North Engine Research Institute rapidly designs Centrifugal Compressor using 3D Inverse Design Methodology
- Development of New Vertical Line Shaft Pumps
- Soler & Palau develops new fan design in less time using TURBOdesign1
- TURBOdesign1 an efficient design tool for the development of compact fan guide vanes at ebm-papst
Design of an Automobile Torque Converter
TURBOdesign1 has been applied to the design of a three-component automobile torque converter. Due to the strong curvature of the flow passages and high loading, the flow behavior is extremely complex and difficult to optimize using a conventional design approach. Using TURBOdesign1, it is possible to achieve the best matching between the components, control secondary flows, and suppress flow separation.
Each component such as a pump or turbine is designed separately, but the effects of upstream components are included in the design by specifying the appropriate inlet boundary conditions. The design and analysis of the full machine using CFD have to be repeated a few times because of the coupling between the inlet and outlet boundary conditions. However, the use of logical flow related input parameters for TURBOdesign1 greatly accelerates the optimization process.
The blade loading parameters and stacking condition are key to the optimization of the three-dimensional flow field, as well as maintaining ease of manufacture. Figure 2 shows a typical blade loading distribution for a pump designed with zero incidence. Figures 3 and 4 show the static pressure contours in 3-D and 2-D respectively, and Figure 5 the blade surface static pressure distribution showing a very smooth pressure rise across the blade.
A conventionally designed torque converter was evaluated using CFD. Although experiments confirmed that this conventional torque converter already had reasonably high efficiency, large areas of flow separation were still observed on both pump and turbine blade suction surfaces (Figure 6). The CFD prediction revealed the three-dimensional flow-field to be of an extremely complex nature, having interactions of secondary flows, which are beyond the control of a conventional design.
The torque converter was redesigned using TURBOdesign1. The CFD prediction confirmed that the areas of flow separation on both the pump and turbine blade suction surfaces had been suppressed, as shown in Fig.7. CFD predicts 1.7 points improvement in overall torque converter efficiency. Such an improvement will have a very big impact on the fuel consumption of automobiles. Through the careful control of the blade loading and vortex pattern specified, a good compromise between performance improvements and the manufacturability of the three dimensional blades is possible.
Fig.6: CFD results of the conventionally designed torque converter with areas of flow separation in the pump and the turbine.
TURBOdesign1 gives the user more freedom to control the three dimensional flows, and it should be possible to improve the performance of more compact torque converters with high flatness ratio using this method.