ELSEVIER JSAE Review 15 ( 1994~ 31)9-314

Improvement of prediction accuracy for torque converter performance:

One-dimensional flow theory reflecting the stator blade geometry
Masaaki Kubo, Eiji Ejiri, Haruo Kumada, Yoshihiko Ishii
~is,~an Research Center, Nissan Motor Co.. Ltd., 1 Natsushima-cho, Yokosuka-shi, Kanax~awa, 237.1apart

Received 15 February 1994

Abstract

Specific fuel consumption is a key word these days, and the torque converter can play an important role in impro',ing it. This makes it
essential to improve the accuracy of methods for predicting torque converter performance. In this work, the accuracy of performance
predictions was improved by replacing the flow angle and total pressure loss in the angular momentum theory with corresponding values
obtained by analyzing the flow around the stator using a general flow analysis code. A quick and highly accurate prediction of torque
converter performance is made possible with this method.

1. Introduction mensional flow lines, and torque converter performance is

The percentage of passenger cars equipped with an
automatic transmission has exceeded 70% in Japan in
recent years, and there have been increasingly stronger
demands for automatic transmissions that are smaller and
lighter and deliver higher performance. In this connection,
the performance requirements for torque converters have
also risen. Specifically, there is a need to shorten the axial
length, i.e.. achieve a flatter design, to facilitate easier
mounting in front-wheel-drive cars. There is also a need to
improve torque converter performance to obtain better fuel
economy. To meet these requirements, it is necessary to
have analytical tools that yield accurate performance pre-
dictions in the shortest time possible.
Predictions of torque converter performance have been
made by Abe et al. [1] and Fujitani et al. [2] using
three-dimensional models to analyze the pump, turbine and
stator, the three elements of a torque converter. With the
present level of technology, however, their approach is not
entirely practical because of the enormous time needed to
prepare a calculation grid and perform the calculations.
A simpler approach employed heretofore has been to
make performance predictions using the one-dimensional
angular momentum theory [3]. With this approach, flow
through a torque converter is expressed in terms of one-di-
predicted using equations of angular momentum and con-
servation of energy. These equations are solved using
empirical values for the friction loss coefficient and outlet
flow angle of each element. One disadvantage of this
method is that it cannot fully predict the effects on torque
converter performance of minute modifications made to
the stator blade geometry as a result of tuning the perfor-
mance characteristics of the stator. The reason for this is
that the stator, like the pump and turbine, is assumed to be
a flow channel, even though it would be more rational to
treat it as a cascade.
Attempts have been made to overcome this problem by
treating the stator as a cascade and analyzing flow around
it as the basis for making performance predictions. Minato
et al. [4] used the finite difference method to analyze
two-dimensional flow around the stator: the outlet flow
angle thus obtained was then incorporated in the one-di-
mensional angular momentum theory to predict torque
converter performance.
In this work, the authors used the finite volume method
to perform a two-dimensional analysis of flow around the
stator. In addition to the outlet flow angle of the stator,
stator loss, which is thought to have the largest influence
on torque capacity characteristics, was also incorporated in
the one-dimensional angular momentum theory to make

11389-4304/94/$07.1t0 ;e 1994 Society of Automotive Engineers of Japan, Inc. and Elsevier Science B,V. All rights rcserved
SSD11)389 4304[ 94 )[1[)1)31-N JSAE9434866
310 M. K u b o el al. / ./,%~E Ret iew 15 G 974) 3 0 0 - 714

Energy Equation
3
~.~,Ti co i/~o g Q =h 1+h2+~3
t --1 Flow Analvsis
_. Ptlinp - "~ PeCifications of stato-r-t
h: (h;sx head) f
•Turbine ..... esh to be generated |
L~, ~ (outlet 11(),,'~anglc~i ~ ,~221 112 (boSS[Itcatl}
............ ~ - i : > :
S*',tor iwo inlet flow angle a 31_.j~-. . . . . . . . .

i f,Dd]TF~(((~P / ~ .7 (outlet flow angle)[

outlet flow angle a 32 ]

~ :1, ~ I l l ~ i
Torque Converter
total pressure loss coefficient ,; i

Fig. 1. Characteristics of proposed method.

i ~"=f( a 31) i
performance predictions. The results obtained indicate that ,_i j
i one-dimensional
this approach improves the accuracy of torque converter [" ----~ angula
ular momentum
performance predictions. i theory
I characteristics --q
of torque converter _j

2. Calculation method II

2.1. Outline
Fig. 2. Flowchart of proposed method.
A notable feature of the method proposed here is that it
uses the results of flow analysis in addition to the outlet
flow angle and loss of the stator, the two values conven- outlet flow angle, 0t32, in relation to the inlet flow angle,
tionally employed in the one-dimensional angular momen- 0~3~, of the stator. The total pressure loss coefficient, (,
tum theory (Fig. 1). A flowchart of the overall method is here is given by
shown in Fig. 2. The following sections describe in detail
the procedures used in analyzing flow around the stator _£= Pt i -- P t 2 ) / P t 2 (I)
and in predicting torque converter performance.

2.2. Flow analysis around stator

In the flow analysis, the stator was treated as a two-di-

mensional developed cascade in the design path. The
analysis was performed with STAR-CD, a general flow
analysis code based on the finite volume method. The
standard k - e model was used as the turbulent model, and
the log law was employed to find the flow velocity distri-
bution near the wall. Figure 3 shows the grid distribution
around the stator. The grid used in this analysis consisted
of 3400 cells. To obtain better calculation accuracy, a fine
mesh was used in the vicinity of the wall.
The boundary condition in each region was defined as
follows (Fig. 4):
Region 1: uniform inlet flow condition (calculations
were performed for varying inlet flow angles);
Region 2: constant pressure condition (P2 = 0);
Region 3: cyclic condition with region 4 (pressure and
flow velocity of corresponding mesh locations coincided);
Region 5: wall (flow velocity = 0).
A flow analysis was conducted under the foregoing
conditions to find the total pressure loss coefficient, ~', and Fig. 3. Grid distribution around stator.
 ,44. K u b o et al. / . I S A E Re~'iew 15 (1994) 3 0 g - 3 1 4 311

Region3
Blade A Blade B I
Region I ~egion5
inlet 0 inlet
-36' %
Region4~ I Region2
:outlet
Fig. 4. Boundarycondition.

where ~" and ~_~ are defined by the following expressions

~ = 58.3 ~
~ / outlet
'~" _68 °

as functions of ~<:
Fig. 6. Stator specification',.
¢-F(,~3~ ), (2)
,~: = G(~ l )" (3) where
The functions F and G are found as blade characteristics
unique to each stator. hf, = X , c : / ( 2 g ) . {1 + (tan-~o~,,l + tan~h.: ) / 2 }, (9)
h~i = & f ( 2 g ) . { ( r , . , % - c tan o~,.1)
2.3. P e r f o r m a n c e predictions
---(F i 1.2(Di i - - c t a n c t 1.2)(ri 1.2/Yi,l) (10)
The performance of a torque converter is predicted from where A~ and &i are the friction loss coefficient and the
the following equations of angular momentum and conser- shock loss coefficient, respectively. For thc stator, loss is
vation of energy: expressed in terms of the total pressure loss coefficient, ~",
Equation of angular momentum: and the outlet flow angle, a3,, and is given by
3
~f=0. (4) h3 = ( ' / ( 2 ,g ) - c-'( 1 + tan-'a3._,). ( I 1)
i I

where
T = pQ{( rm_ % - c tan ~i.:)rl.a
(r, l.ato i c tan oq l.e)ri 1,-'}; (5)
Equation of conservation of energy:
3
;2, - y_, T,,oi//,,~O (6)
i I

where It I is the sum of the loss heads of the three

elements and is given bv
h L = tt I + h~ + h,~. (7)
For the pump and turbine, loss is expressed as the sum of
the friction loss head, hf, and the shock loss head, h~, and
is given by
e=0 (Blade A) e=0.8 (Blade A)
2
h 1 +]12= E ( h l i q - h , , i ) (S)
t I
,'5,

I. e=0 (Blade B) e=0.8 (Blade B)

Fig. 5. R c l a t m n of end wall area to blade surface area. Fig. 7. S t r e a m l i n e around stalors.
312 M. Kubo et at./JSAE Reciew 15 U994) 309-314

1" [an &, -~!

-2
--[,
....................
I
+ . . . .
z ~-t--

0,8- High speed ratio o s~ Low speed ratio

Blade A |
0,6- -l i Blade A
-1..51 ................... ~ ......
0.'t-
High speed r a t i o N . ~/~Low speed rmio 24 [1lade B

/ -2 5. i t,
4"
./

f2 -1 ; i
tart a 3~

Fig. 8. T o t a l p r e s s u r e loss c o e f f i c i e n t .
Fig. 9. O u t l e t f l o w a n g l e

In this work, the value of ff was found by analysis, of these end walls is proportional to their area (Fig. 5) and
treating the starer as a two-dimensional cascade in the can be expressed by
design path. For an actual stator, however, it is necessary m = 1 + cos /3/(0-. a). (13)
to take into account the effects of the end walls of its
upper and lower surfaces [5]. To do that, if' is corrected Torque converter performance can be calculated by
using the correction factor m and is given by simultaneously solving the system of Eqs. (4)-(12). In this
work, certain given values were assumed for the friction
~" = ~'X m. (12)
loss coefficient, shock loss coefficient and slip angle of the
It is also assumed that the increased loss due to the effects pump and turbine.

4.0 i
. Present Calculation

1
3.8 1
. . . . . Conventional Calculation
3.6 \x. o---o Experimental
3.4) \.

Present Calculation 32
-- Conventional Calculation
3.0 1)
6.0 F 3.0 3.o I
5"6 1- 28
2.8
2.8 ~
\,,,r
~-'E2.6 2,6
5.2 I" 2.6
2.4
4.8~- 24 2.4
2.2 2.2
O "

100
~ 2.0 - o2.0 I00

90 " ~,1.8 90
a.61-~ 1.8 ~16 80
80 cr " " ~1.6
I-'-
I- 1,4 - 14 70
70
1.2
~ 2.4 i- 12 6o~ - 1.2
}
).,..
so~ 1.0 - 1.0

/
2.0 1.0
"D
I 0.8 - 0,8 4 0tu
~
1.6 I- 0.8
0.6 - 0.6 t I** 30
1.2 [- 0.6 30
0.4 - 0.4 20
0.8[- 0.4 20
0.2 - 0.2 i0
10
0 0
0
I , I I I I I I I I

' 01.2 01.3 o,I o'., o',

0.1 6 o.'8 o'9 to 0+1 0.2 0.3 014 0mS 0.6
Speed Ratio
0.7
o
0.8 0.9 110
Speed Ratio e

(a) Blade A (b) Blade B

Fig. 10. P e r f o r m a n c e p r e d i c t i o n s .
 M. Kubo et al./JSAE Rel'iew 15 (1994) 309-314
3. Analysis results
3.1. Test stator
Figure 6 shows the profiles of the two stator blade
geometries used in the analysis. Blade A was a thick type
of blade, capable of maintaining a low loss level over a
wide range of speed ratios. Blade B was a thin type of
blade, designed to reduce loss to a very low level within a
narrow range of speed ratios.
3.2. F l o w analysis results
Figure 7 compares the stream lines around the two
stator blades for speed ratios of e = 0 and e = 0.8. Fig. 8
shows the relationship between the total pressure loss
coefficient and the stator inlet flow angle. Fig. 9 shows the
stator outlet flow angle in relation to the inlet flow angle.
In Fig. 7, it is seen that separation occurred behind the
suction side of stator blade A at a speed ratio of e = 0.
Also, a region showing an exceptionally slow flow veloc-
ity formed on the pressure side at a speed ratio of e = 0.8.
The effect of this separation is thought to have caused the
sharp increase in stator loss seen in Fig. 8 on the both the
high and low speed ratio sides.
In contrast, since blade B achieved a smooth flow with
little resistance (Fig. 7), it showed much less loss in the
high speed ratio region (Fig. 8). However, as the incident
angle was increased, separation occurred from the front of
the stator suction side at around a speed ratio of e = 0.5,
and the separation region soon extended over the entire
suction side. As a result, loss increased sharply once the
incident angle coefficient ( = tan o~3~) exceeded 0.5, as
indicated in Fig. 8.
As seen in Fig. 9, the stator outlet flow angle of both
blades A and B increased as the inlet angle increased,
except when the inlet angle of blade B was large. That is,
the slip angle, representing the difference between the
outlet blade angle and the outlet flow angle, increased as
the speed ratio decreased. Yet, no large change is observed
in the outlet flow angle overall. This is attributed to the
fact that the separated flow became reattached behind the
stator.
4. Performance predictions
Using the results described in the previous section,
performance predictions were made and the predicted per-
formance was compared with experimental data for an
actual torque converter. The results obtained with the
method proposed here are compared in Fig. 10 with perfor-
mance predictions made with the conventional one-dimen-
sional angular momentum theory. To facilitate this com-
parison, the same friction loss coefficients were applied to
all three elements in the latter performance predictions as
313
the values of the friction loss coefficients used for the
pump and turbine in the predictions made with the pro-
posed method. In comparison with the conventional
method, the method proposed here achieved virtually the
same prediction accuracy for the torque ratio and effi-
ciency of both blades A and B. With regard to torque
capacity, the proposed method showed a flat characteristic
curve, i.e., torque capacity displayed little change as the
speed ratio increased, in the low to medium speed ratio
range. That torque capacity characteristic was obtained
because the proposed method made it possible to calculate
the sharp change in loss resulting from the flow separation
that occurred behind the stator.
However, the proposed method tended to underestimate
the speed ratio at which separation occurred. As a result,
the predicted capacity differed somewhat from the experi-
mental data. The following can be considered as possible
reasons for that difference:
(1) The point of separation in the flow around the stator
was not calculated accurately in the flow analysis.
(2) Even though the flow showed a tendency to sepa-
rate, the effect of that separation was not fully calculated
(a problem of three-dimensionality). That tendency might
have been caused by lower solidity of the periphery of the
stator than at the design path or by stagnation of a low-en-
ergy secondary flow. These are points that need to be
examined in future work.
5. Conclusion
The present work focused on flow around the stator,
which has the largest effect on the torque capacity charac-
teristics of a torque converter. An attempt was made here
to improve the prediction accuracy of the conventional
one-dimensional angular momentum theory by applying
the results obtained in a two-dimensional flow analysis.
The following points were made clear as a result.
(1) This improved method makes it possible to predict
changes in torque capacity characteristics due to flow
separation that occurs on the suction side of the stator. It
has not been possible to identify such changes heretofore
in one-dimensional performance predictions.
(2) Because the method proposed here uses a general
flow analysis code, it enables performance predictions to
be made easily and in a relatively short period of time.
Consequently, it is sufficiently practical for use in design-
ing actual stators for torque converters.
Nomenclature
= torque (Nm)
w, = angular velocity (rad/s)
c = circular flow velocity ( m / s )
Q = volumetric flow rate (m3/s)
rij = radius (m)
314 M. Kubo et al./.ISAE Ret'iev~ 15 (1994) 309-314

~£ii :
inlet and outlet f l o w angle (deg)
]7 = pressure (Pa)
Pt = total pressure (Pa)
p density of fluid ( k g / m :')
g = acceleration o f gravity ( m / s : )
total pressure loss coefficient
hi = loss head (m)
angle relative to axial direction of blade chord
1 = length o f blade chord (m)
A -- pitch (m)
H = blade height
¢F : solidity ( l / s )
aspect ratio ( H / l )

Subscripts
= 1: p u m p
2: turbine
3: stator
= 1: inlet
2: outlet

f-

References

[1] K. Abe et al., Three-Dimensional Simulation of Flow Through a

Torque Converter, (in Japanese), Proceedings of JSAE, 902, October
1990.
[2] K. Fujitani et al., Computational Study on Flow Through a Torque
Converter, SAE Paper No. 881746.
[3] T. Ishihara, A Study of Hydraulic Torque Converters, Report of the
Institute of Industrial Science, University of Tokyo.
[4] K. Minato et al., A Performance Prediction of Hydrodynamic Torque
Converter, SAE Paper No. 900555.
[5] W.L. Stewart et aL, A Study of Boundary-Layer Characteristics ol
Turbomachine Blade Rows and Their Relation to Overall Blade Loss,
Rolls Royce, Maserati, Saab, Aston Journal of Basic Engineering, Transactions, ASME, pp. 588-592
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