A methodology for performance optimization of torque converters is put forward based on the one-dimensional (1D) flow model. It is found that the inaccuracy of 1D flow model for predicting hydraulic performance at the low speed ratio is mainly caused by the separation phenomenon at the stator cascade which is induced by large flow impinging at the pressure side of the stator blades. A semi-empirical separation model is presented and incorporated to the original 1D flow model. It is illustrated that the improved model is able to predict the circumferential velocity components accurately, which can be applied to performance optimization. Then, the Pareto front is obtained by using the genetic algorithm (GA) in order to inspect the coupled relationship among stalling impeller torque capacity, stalling torque ratio and efficiency. The efficiency is maximized on the premise that a target stalling impeller torque capacity and torque ratio are achieved. Finally, the optimized result is verified by the computational fluid dynamics(CFD) simulation, which indicates that the maximal efficiency is increased by 0.96%.
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