Browse Publications Technical Papers 2019-26-0026

Design and Development of a Dry Sump Lubrication System for a Formula Student Racecar 2019-26-0026

The powertrain department for a Formula Student team always aims to enhance the performance output from the engine and in turn the vehicle. For refining and sustaining the engine performance, the health of the engine is one of the most predominant aspects. Hence, the lubrication system of the vehicle should be optimized to achieve that objective. The primary challenge for the development of a superior lubrication system is the inability to replicate the performance given by stock wet sump with the self-designed custom dry sump. However, the advantages can outnumber the drawbacks 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 of the dry sump system. The design procedure makes use of software like MATLAB, Star CCM+ and SolidWorks. The validation is carried out with the help of a DAQ 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 in the study. To validate the whole design, engine oil pressure sensor was used to monitor the oil pressure during varied lateral and longitudinal acceleration values as well as for the full range of RPM. The results were then quantitatively compared with the stock oil pressure values and a deviation of less than 5% was recorded. By incorporating the new dry sump design in the vehicle, some performance parameters of the vehicle were monitored and the improvements were documented.


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