Design and Implementation of a Reliable Dry Sump Lubrication System for a High-Performance CBR600RR Engine

Formula SAE is an annual engineering design competition by SAE International where contestants design, construct and test an open-wheeled, single-seater Formula-style race car. Formula Manipal, the official institute Formula SAE team, has been designing, building and racing cars at these events. The cars were equipped with a CBR600RR engine, featuring a 710-cc displacement and a high power-to-weight ratio. However, these engines experienced oil starvation and high-pressure loss during corners, risking engine failure due to the pickup port exposure from sloshing caused by lateral and longitudinal g-forces. This study analysed and assessed a dry sump lubrication system for the CBR600RR engine to address these issues. The dry sump system prevented pressure loss from sloshing and lowered the engine's centre of gravity by storing oil in a tall, vertical reservoir instead of the sump. The study also aimed to develop a reliable dry sump using a Control Area Network-based communication system and select appropriate oil for the lubrication system. CFD simulations using Siemens Star CCM+ software optimized the oil ports. The findings showed the dry sump system was more effective than the stock wet sump system, with engine oil pressures varying by no more than 2 psi across the speed range and a 2 BHP increase in engine output compared to the traditional stock wet sump system. The study provided valuable insights into enhancing engine reliability by resolving oil starvation and pressure loss issues caused by sloshing.