3D Virtual Simulations of Crankcase Dynamics for Oil Pan Aeration Analysis

This research employs advanced Unsteady Reynolds-Averaged Navier-Stokes (URANS) simulations to analyze the transient multiphase flow dynamics within a four-cylinder inline (I-4) engine, with a focus on gas-liquid interface interactions and oil distribution phenomena. Utilizing a commercial three-dimensional Computational Fluid Dynamics (CFD) software suite, the study incorporates detailed crankshaft rotational kinematics and piston reciprocation to accurately model oil drawdown and retention across various operational conditions. A Volume of Fluid (VOF) approach is applied to assess the impact of crankshaft rotational speeds of 5000 rpm and 6500 rpm on oil distribution and aeration in the oil pan. Comprehensive computational analyses characterize oil-air distribution patterns, quantify oil flow rates through drainback pipes, and elucidate bubble formation dynamics within the sump. The study also examines the relative contributions of crankshaft rotation, piston pumping, and balance shaft gear movements to sump aeration levels. Additionally, the impact of two different windage plate designs on oil management and aeration is evaluated through a detailed design assessment. Computational predictions are compared against experimental data, to assess the predictions accuracy and reliability. This work provides a three-dimensional computational framework that can significantly advance the understanding of crankcase oil dynamics and aeration performance, serving as a valuable tool for optimizing engine design and enhancing conventional testing methodologies.