Enhancing oil pressure dynamics in a high-performance racing engine with innovative lubrication system tuning

Abstract

This work focuses on fine-tuning the oil pressure dynamics of a single-seater formula car, a participant in international engineering competition organized by the Society of Automotive Engineers (SAE). Adhering to competition guidelines, the Honda CBR600RR 05-06® motorcycle engine, renowned for its 600 c.c. displacement and exceptional power-to-weight ratio, emerges as a popular choice. However, as this engine is originally equipped with a wet sump lubrication system (featuring deep wet sumps to prevent oil starvation during turns), this presents challenges when adapted to Formula Society of Automotive Engineers (FSAE) cars. Cornering leads to significant pressure drops, as sloshing exposes the pickup port, causing consequential engine issues. To tackle sloshing-related challenges and pressure loss during lateral and longitudinal g-forces, a dry sump lubrication system was introduced in the Formula car. The dry sump system also lowers the engine’s center of gravity, by reducing sump height. However, transitioning to the dry sump system and integrating it with the existing engine demanded extensive design modifications to various components, including the oil reservoir, lubrication lines, scavenging pump, and oil ports. These adjustments were essential to achieve the targeted elevation in oil pressures at higher engine RPMs. A relationship between the engine oil pressure and the engine RPM was developed as part of the study.