Lubrication System
Lubrication System
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Design and Development of a Dry Sump Lubrication System for a Formula SAE
Race Car
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Citation: Khanna, R., Kumar, A.B., Vijaykumar, K., Gopal, K.N. et al., “Design and Development of a Dry Sump Lubrication System
for a Formula SAE Race Car,” SAE Technical Paper 2019-26-0026, 2019, doi:10.4271/2019-26-0026.
Abstract
whole assembly the dry sump system. The design procedure
A
Formula student team aims to develop and improve makes use of software like MATLAB, Star CCM+ and
their designs every year, as far as the powertrain SolidWorks. From the simulations and calculations using
aspect is considered performance output and MATLAB an increase of 0.13G was seen in the maximum
enhancement is the primary aim, and for engine to perform lateral acceleration. Sloshing Analysis of the sump pan was
better, the health of the engine is the most important param- carried out and the pick-up points for the dry sump pan
eter; hence the lubrication system of the vehicles powertrain was decided based on the simulation results. The validation
should be improved to get the most out of the engine. The was carried out with the help of a data acquisition module.
primary challenge for the development of a new lubrication The parameters such as volume of reservoir tank, design of
system was the inability to replicate the performance given sump pan, scavenge or oil pump selection and compatibility,
by stock wet sump with the self-designed custom dry sump. etc. were taken into consideration. To validate the whole
However, the advantages can outnumber the cons of imple- design, EOP sensor was used to monitor the oil pressure
menting a custom dry sump lubrication system. The work during varied lateral and longitudinal acceleration values as
brought together in this paper highlights the meticulous well as for the full range of RPM. After validation a deviation
design procedure for implementing a custom made dry sump of only 5 psi was seen on either side of the stock EOP values
system onto a 4-cylinder in-line Honda CBR600RR engine. with the custom dry sump system. Moreover, a decrease of
Moreover, the research paper brings about the extensive 26.5 mm in CoG height was recorded between the stock and
process undertaken which includes theoretical calculations, custom lubrication systems which directly translates to better
computational analysis and experimental validation of the dynamic performance.
Introduction
points of sump pan and the other to supply oil to the system
L
ubrication system is an important engine performance from the reservoir tank. Varied types of dry sump systems
parameter. It predominantly comprises of the sump are implemented for different sizes and engine speeds and are
pan, oil pump, oil pressure sensor, pressure relief valve classified according to the scavenge pump used. The sump
oil filter and oil cooler which function together to circulate pan design depends on the number of pickup points required,
the required amount of oil throughout the engine. which in turn depends on the amount of oil that has to
Wet sump lubrication system is the most rudimentary be circulated throughout the engine. The volume of the sump
system that is widely incorporated in almost all the internal pan is reduced such that the height of the pan is at a minimum
combustion engines. This fundamental system is more so that the engine can be mounted as low on the chassis as
compact and easier in application which makes it a popular possible. This lowers the overall CoG which in turn improves
choice in the automotive market. It is more cost effective as vehicle dynamics by reducing roll moment, increase peak
well as easier to handle. The simple design enables engineers lateral acceleration, reduces pitching moment and reduces
and manufacturers to aim for a lighter design. Moreover, less chassis deflection. Taking engine performance into consider-
number of components makes the target weight of the system ation the dry sump results in reducing sloshing at high lateral
achievable without compromising reliability and perfor- and longitudinal accelerations and curbs the power losses due
mance. The sump pan acts as a reservoir for lubricant. to windage.
In comparison to the wet sump, dry sump lubrication McKenna, S. et al. explained the challenge of using a
system is a more sophisticated system, which is usually used 600-cc motorcycle engine intended predominantly for road
in race cars to improve the performance. The system consists use in FSAE competition. In a motorcycle, these engines infre-
of two loops which are integrated with each other and each quently suffer from oil starvation stimulated by lateral accel-
loop involves a pump, one to recover the oil from the pickup eration as the engine tilts with the motorcycle during cornering
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2 DESIGN AND DEVELOPMENT OF A DRY SUMP LUBRICATION SYSTEM FOR A FORMULA SAE RACE CAR
thereby keeping the oil pickup points inundated in the oil. Primarily, the foremost motive to shift to a dry sump
Though, when installed in the race car, the engine is system was to improve the vehicle dynamics performance by
constrained in the horizontal plane and is also subjected to lowering the CoG. This could be efficiently achieved by
higher lateral accelerations which causes oil surge amid lowering the engine which is the heaviest single component
cornering and results in nearly immediate and calamitous in the car. The goal could be only attained by implementing
engine failure [1]. A sensitivity analysis is completed by the dry sump system which in turn helped reducing the height
Deakin, A. et al. on essential design constraints of a race car of the pan considerably. The volume reduced was compensated
including mass, CoG height, static load distribution, engine by using an external oil reservoir tank. A two channel scavenge
power and aerodynamic forces. This is achieved by looking at pump was selected based on the requirements of our system.
specific manoeuvres such as acceleration, braking, straight The rotor shaft of the scavenge pump had to be mechanically
line and steady state cornering to ascertain the comparative linked to the stock pump of the engine which is driven by the
effect of the corresponding parameters [2]. The paper presented crankshaft. Hence, the major concern of maintaining equal
by Lo, R. S. gives a systematic method of simulating an auto- mass flow rate throughout the system was eliminated. Sloshing
motive engine lubrication system. It graphs down oil flow rates analysis was done using Star-CCM+ which ensured minimal
and distribution in a typical V-8 engine; subsequently starvation of oil at pickup points. Finally, the whole system
performing a comprehensive analysis of crucial components. was tested statically as well as dynamically at wide-ranging
Basic hydraulic illustrations and the lubrication circuit RPM values and diverse g-forces in various directions.
analysis are designated with functioning equations [3]. Mian, The objective of this research is to ensure that the engine
M.A., in his paper gives design methods and strategies for and vehicle performs at its paramount condition. A safe and
pump sizing and flow balance, including allowance for the reliable system has to be designed with utmost consideration
worn engine applicable to a variety of engine classes. Methods and keeping in mind the safety of the driver as well as the
presented can be used to design lubrication systems for people working on it. The lubrication system has to be rule
optimum and practical specification of oil pump size, pressure compliant as FSAE standards. Ease of manufacturing and cost
relief valves, by-pass filtration, gallery sizes, oil flow through are fundamental parameters that would be taken
bearings in the cylinder head and cylinder block and piston into consideration.
cooling jets as well as calculating parasitic losses in the engine Within this context the present study aims to propose a
due to hydrodynamic pumping [4]. Jinning Li et al. presents systematic approach to develop an efficient lubrication system
an article containing a detailed computational method for the that can enhance the performance of a formula student race
flow network analysis of the lubrication circuit is developed car. The inimitable method involved in coming onto a partic-
based on the hydraulic theory, and the flow resistance through ular volume of the sump pan was influenced by the engine
the oil pipes and orifices is also taken into consideration [5]. sump profile and the height limitation defined in the rulebook
Engine lubricants are complex and highly engineered fluids as mentioned above. Also, while going through the literature
that are designed to allow perfect and proper engine perfor- survey it was seen that performance aspect of the dry sump
mance over a long service time. As per Sivarao et al. research lubrication hasn’t been tapped in to a great extent. The papers,
to meet this goal, the lubricant is required to perform varieties articles and books referred do not mention the in depth effects
of protective and functional jobs so as to provide hydrody- of dry sump lubrication system on engine as well as vehicle
namic film between moving components, including heat performance. One of the major gaps in literature is the lack
dispensing, suspending contaminants, acid neutralization, in quantitative data regarding the effects of dry sump system
and preventing corrosion and so on [6]. Korcek, S. et al. in the on the performance of the car. Thus, this paper aims at devel-
study “Automotive lubricants for next millennium” describes oping a system that is not only reliable but also uses various
expected improvements and changes in lubricant technology sensors and the Data Acquisition system to gather data
and points out the need for development of “breakthrough” regarding the performance of the vehicle (lateral acceleration
technologies which could satisfy the near-term requirements potential, roll moment reduction, etc.). For the same reason
and eventually in the long term, in combination with novel this research tries to explain all the aspects that influence a
surface technologies and engine design changes, lead to fill- dry sump lubrication system and its ancillary units with
for-life engine lubrication [7]. The keynote address by Simon proper quantitative data from experimental validation.
C Tung et al. provides a comprehensive overview of various
lubrication aspects of a typical powertrain system including
the engine, transmission, driveline, and other components,
as well as the integration of these lubrication and surface engi- Design Description
neering concepts into a unified automotive powertrain system
[8]. Research presented by Neu, E. et al. states that the entire In this section, the design approach is described. The contour
engine lubrication system has been represented by a series- profile of the sump needs utmost accuracy as it must align
parallel network of flow passages and flow elements. The with the holes. The profile was derived from the CAD model
pressure distribution and flow rates in the network were of the Honda CBR600RR engine. Once the profile was final-
computed according to pressure-flow characteristics of each ized, the next step was to decide the volume of the sump. Our
element. The pressure-flow relationship for each network aim was to contain as much volume of the lubricant as
element was estimated using empirical pipe friction, expan- possible in the sump and at the same time maintain its height
sion, and bend loss coefficients, as well as by using test rig as low as possible. Various iterations performed are mentioned
results and a steady-state journal bearing model [9]. in Table 1.
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DESIGN AND DEVELOPMENT OF A DRY SUMP LUBRICATION SYSTEM FOR A FORMULA SAE RACE CAR 3
TABLE 1 Iterations of Dry Sump Design FIGURE 1 CAD Model of the Custom Dry Sump Pan
4 DESIGN AND DEVELOPMENT OF A DRY SUMP LUBRICATION SYSTEM FOR A FORMULA SAE RACE CAR
FIGURE 2 Honda CBR600RR Engine Stock Oil Pump FIGURE 4 Oil sloshing analysis performed using Star-CCM+
DESIGN AND DEVELOPMENT OF A DRY SUMP LUBRICATION SYSTEM FOR A FORMULA SAE RACE CAR 5
FIGURE 5 Variation of Dynamic Weight with Percentage FIGURE 7 Variation of Maximum Lateral Acceleration with
Front Roll Stiffness (Dry Sump) COP Bias (Wet Sump)
same roll gradient. A MATLAB code was fabricated to inter- greater loads due to the reduced CoG height in the dry
link different vehicle dynamics parameters of the car using sump system.
theoretical models and relevant data is showcased through To determine the effect on the overall handling capabilities
graphs. A greater CoG results in a greater rolling moment. To of the car, the peak lateral acceleration was determined for both
achieve the desired value of the roll gradient to control body cases (wet sump and dry sump) including the effect of the
roll, the value of target roll stiffness increases. A steady state downforce provided by the aerodynamic package of the car
weight transfer model was created applying a constant value containing front wing, rear wing and side pods.
of lateral force as obtained from the tire data. As shown in the Thus, it was noted that at the value of maximum lateral
graphs, the inner wheels have greater loads due to the reduced acceleration at the optimum value of CoP bias for the car with
CoG height in the dry sump system. aerodynamic effects included was found to be 2.15g’s with the
Figures 5 and 6 shows graphs of the dynamic weight v/s dry sump system installed and 2.02g’s when the wet sump
distribution of total roll stiffness at the peak lateral accelera- system would be involved. Thus, the theoretical maximum
tion condition of the vehicle for both the wet sump as well as lateral acceleration is significantly improved by adopting a dry
dry sump lubrication system. It is seen from the figure that sump lubrication system. The increase was found to be 0.13G.
front outer and rear inner roll stiffness increases with In Figures 7 and 8 illustrate these observations which in the
increasing dynamic weight. Also, front inner and rear outer form of two graphs for wet sump and dry sump system were
roll stiffness shows opposite trend and decrease with increase contracted from the MATLAB calculations in the form of two
in dynamic weight. From the graphs, the inner wheels have graphs for wet sump and dry sump system.
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6 DESIGN AND DEVELOPMENT OF A DRY SUMP LUBRICATION SYSTEM FOR A FORMULA SAE RACE CAR
Experimental Validation FIGURE 11 Experimental Testing Rig for CoG Height Test
Results of a Lowered Centre of Gravity The plays a major role in determining the dynamic performance
second step in the design process was to validate the change capabilities of a vehicle. The method used to measure CoG
in the value of CoG. As it is mentioned before, CoG height height experimentally is the one described by Milliken in
his book ‘Race Car Vehicle Dynamics’ [10]. The front axle
of the car is elevated at an angle and the corresponding
FIGURE 9 Comparison of Oil Pressures for Wet Sump
weight transfer in the rear is noted. The test rig setup is
(stock) and Dry Sump (custom) Lubrication System. shown in Figure 11.
Tables 4 and 5 displays the findings of the CoG test
performed on the vehicle using a dry sump lubrication system
and a wet sump lubrication system respectively. As it is clearly
© SAE International and © SAE India
seen that the CoG heights are significantly lower while using
a dry sump lubrication system than when a wet sump lubrica-
tion system is being used.
Following this it was seen that there was a difference in
26.5 mm between the CoG heights of the vehicle with the
dry sump and the one with wet sump. Hence the car with
the dry sump will give significantly better performance char-
acteristics than the car with the wet sump due to the low
CoG position.
To measure the gain in performance and to validate the
FIGURE 10 Engine RPM v/s EOP Plot theoretical estimations, an IMU was mounted at the CoG and
the vehicle was tested on a constant radius skid-pad track.
Skid-pad is one of the events at every Formula Student
Weighing Scale
Angle of Elevation Reading CoG Height
15 60.85 294.2
30 62.235 292.7
45 64.143 284
Average: 290.3
© SAE International and © SAE India
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DESIGN AND DEVELOPMENT OF A DRY SUMP LUBRICATION SYSTEM FOR A FORMULA SAE RACE CAR 7
TABLE 5 CoG Height Test Results (with Wet Sump) FIGURE 14 Skid-Pad Data from IMU for Dry Sump System
Weighing Scale
Angle of Elevation Reading CoG Height
15 67.36 317.4
Conclusion
In this paper about dry sump lubrication system, the pan attached
to the engine block is designed and the sloshing trend of the
© SAE International and © SAE India
References
© SAE International and © SAE India
8 DESIGN AND DEVELOPMENT OF A DRY SUMP LUBRICATION SYSTEM FOR A FORMULA SAE RACE CAR
3. Lo, R.S., “Digital Simulation of Engine Lubrication Systems,” 10. Milliken, W.F. and Milliken, D.L., Race Car Vehicle Dynamics
SAE Technical Paper 710205, 1971, doi:10.4271/710205. (Warrendale: Society of Automotive Engineers, 1995).
4. Mian, M.A., “Design and Analysis of Engine Lubrication 11. “2017-18 Formula SAE® Rules,” Apr. 11, 2016.
Systems,” SAE Technical Paper 970637, 1997,
doi:10.4271/970637.
5. Li, J., Ma, Z., Jiang, M., Zhang, Y. et al., “Optimized Design
Contact Information
of the Flow Network in the Lubrication System for the Heavy Dr. Ashok B.
Vehicle Transmission,” Advances in Mechanical Engineering Department of Automotive Engineering
9(4):1687814017696414, 2017. School of Mechanical Engineering
6. Samsudin, A.R., Tin, S.L., Alif, A., Robert, K.M. et al., VIT University, Vellore, 632014, Tamil Nadu, India.
“Promising Techniques of Automotive Engine Lubrication ashok.b@vit.ac.in
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Definitions/Abbreviations
Lubrication and Tribology 52(5):209-220, 2000. FSAE - Formula Society of Automotive Engineers
8. Tung, S.C. and McMillan, M.L., “Automotive Tribology CoG - Center of Gravity
Overview of Current Advances and Challenges for the CoP - Center of Gravity
Future,” Tribology International 37(7):517-536, 2004.
EOP - Engine Oil Pressure
9. Neu, E.A., Wade, J.A., and Chu, A.C., “Simulating the
Lubrication System of a Diesel Engine,” SAE Technical Paper CAD - Computer Aided Design
770032, 1977. RPM - Revolutions Per Minute
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