This content is not included in your SAE MOBILUS subscription, or you are not logged in.
Design and Development of a Dry Sump Lubrication System for a Formula SAE Race Car
ISSN: 0148-7191, e-ISSN: 2688-3627
Published January 9, 2019 by SAE International in United States
This content contains downloadable datasetsAnnotation ability available
A Formula student team aims to develop and improve their designs every year, as far as the powertrain aspect is considered performance output and enhancement is the primary aim, and for engine to perform better, the health of the engine is the most important parameter; hence the lubrication system of the vehicles powertrain should be improved to get the most out of the engine. The primary challenge for the development of a new lubrication system was the inability to replicate the performance given by stock wet sump with the self-designed custom dry sump. However, the advantages can outnumber the cons of implementing a custom dry sump lubrication system. The work brought together in this paper highlights the meticulous design procedure for implementing a custom made dry sump system onto a 4-cylinder in-line Honda CBR600RR engine. Moreover, the research paper brings about the extensive process undertaken which includes theoretical calculations, computational analysis and experimental validation of the whole assembly the dry sump system. The design procedure makes use of software like MATLAB, Star CCM+ and SolidWorks. From the simulations and calculations using MATLAB an increase of 0.13G was seen in the maximum lateral acceleration. Sloshing Analysis of the sump pan was carried out and the pick-up points for the dry sump pan was decided based on the simulation results. The validation was carried out with the help of a data acquisition module. The parameters such as volume of reservoir tank, design of sump pan, scavenge or oil pump selection and compatibility, etc. were taken into consideration. To validate the whole design, EOP sensor was used to monitor the oil pressure during varied lateral and longitudinal acceleration values as well as for the full range of RPM. After validation a deviation of only 5 psi was seen on either side of the stock EOP values with the custom dry sump system. Moreover, a decrease of 26.5 mm in CoG height was recorded between the stock and custom lubrication systems which directly translates to better dynamic performance.
CitationKhanna, R., Kumar, A., Vijaykumar, K., Gopal, K. et al., "Design and Development of a Dry Sump Lubrication System for a Formula SAE Race Car," SAE Technical Paper 2019-26-0026, 2019, https://doi.org/10.4271/2019-26-0026.
Data Sets - Support Documents
|[Unnamed Dataset 1]|
|[Unnamed Dataset 2]|
|[Unnamed Dataset 3]|
|[Unnamed Dataset 4]|
|[Unnamed Dataset 5]|
- McKenna, S., McKeown, C., Sloan, G., McCullough, G. et al., “Dry Sump Design for a 600cc Yamaha YZF-R6 Engine,” SAE Technical Paper 2011-32-0617, 2011.
- Deakin, A. and Crolla, D., “Fundamental Parameter Design Issues which Determine Race Car Performance,” SAE Technical Paper 2000-01-3537, 2000, doi:10.4271/2000-01-3537.
- Lo, R.S., “Digital Simulation of Engine Lubrication Systems,” SAE Technical Paper 710205, 1971, doi:10.4271/710205.
- Mian, M.A., “Design and Analysis of Engine Lubrication Systems,” SAE Technical Paper 970637, 1997, doi:10.4271/970637.
- Li, J., Ma, Z., Jiang, M., Zhang, Y. et al., “Optimized Design of the Flow Network in the Lubrication System for the Heavy Vehicle Transmission,” Advances in Mechanical Engineering 9(4):1687814017696414, 2017.
- Samsudin, A.R., Tin, S.L., Alif, A., Robert, K.M. et al., “Promising Techniques of Automotive Engine Lubrication Oil Monitoring System-a Critical Review towards Enhancement,” Int. J. Eng. Sci. 1(2):228-233, 2012.
- Korcek, S., Sorab, J., Johnson, M.D., and Jensen, R.K., “Automotive Lubricants for the Next Millennium,” Industrial Lubrication and Tribology 52(5):209-220, 2000.
- Tung, S.C. and McMillan, M.L., “Automotive Tribology Overview of Current Advances and Challenges for the Future,” Tribology International 37(7):517-536, 2004.
- Neu, E.A., Wade, J.A., and Chu, A.C., “Simulating the Lubrication System of a Diesel Engine,” SAE Technical Paper 770032, 1977.
- Milliken, W.F. and Milliken, D.L., Race Car Vehicle Dynamics (Warrendale: Society of Automotive Engineers, 1995).
- “2017-18 Formula SAE® Rules,” Apr. 11, 2016.