PURPOSES OF LUBRICATION

reduction of wear (higher operating life)

- reduction of friction between moving parts
reduction of power losses (higher efficiency)

- removal of heat from engine parts that cannot be cooled by the cooling system
- protection of metal surfaces against rust and corrosion, by means of an oil film
- removal of particles of dirt, thanks to a filtered flow of oil
- help in gas-tight seal between piston rings and cylinder liner
- lubrication and feeding of auxiliaries, such as turbocharger, hydraulic valve lifters, etc.

TYPES OF INTERNAL COMBUSTION ENGINE LUBRICATION

WITH FLOW GENERATION UNIT WITHOUT FLOW GENERATION UNIT

- wet sump: in most automotive engines
- dry sump: in sports cars, racing cars,
aerobatic aircrafts, four-stroke motorcycles,
off-road vehicles
- splash lubrication: in small four stroke
engines for outboards, lawn-mowers, etc.
- mixture lubrication (total loss system):
in two stroke engines

File name
lubintro
Date
17 Jan 2014
 MECHANICAL LOSSES
FRICTION
ENGINE BEARINGS (25%)
Hydrodynamic lubrication, except at start up and shut down.
Bearings are designed to provide a minimum film thickness of about 2 m.

PISTON RINGS (45%)

Hydrodynamic lubrication in most of the piston stroke.
It tends to become elasto-hydrodynamic, mixed and finally boundary as the piston approaches the
dead centres due to reduction of piston velocity.

VALVE TRAIN ASSEMBLY (10%)

Mainly boundary lubrication, but also mixed and elasto-hydrodynamic.
Most of the friction occurs in the contact cam-lifter due to the high load and small contact area.

AUXILIARIES (20%)
Oil pump, water pump, injection pump, etc.
In such case not all power is "lost", because the
auxiliaries generate also a useful power, e.g. a
flow of oil under pressure. However such power is PERCENTAGES ARE PURELY INDICATIVE
not available at the wheels.
File name
regimelub2_eng
Date
15 Jan 2014
 WET SUMP LUBRICATION: CIRCUIT LAYOUT
Group of hydraulic users connected in series and / or in parallel
Circuit
Return to engine sump (by gravity) (journal bearings, cooling jets, etc.)

Fluid conditioning unit:

Oil filter (+ heat exchanger)

Flow generation unit:

- Fixed displacement pump
with pressure relief valve
or (recently)
p* - variable displacement pump
with absolute pressure limiter
p*
The pump is driven by the
engine sump = tank crankshaft (variable speed)

File name
wetsump
Date
08 Jan 2014
EXAMPLE OF WET SUMP CIRCUIT: 16 VALVES GASOLINE ENGINE

1. oil pump
2. pressure relief valve
3. oil level indicator
4. oil sump
5. oil temperature transducer
6. oil pressure switch
7. filter and oil cooler support
8. water-oil heat exchanger
9. oil filter
10. main gallery
11. crankshaft bearings
12. conrod bearings
13. crankshaft drillings for feeding
conrod bearings
14. piston cooling jets
15. counterbalance shaft bearings
16. camshaft bearings
17. oil return

File name
circthema_eng
Date
20 Nov 2013
EXAMPLE OF WET SUMP CIRCUIT: 8 VALVES SUPERCHARGED DIESEL ENGINE

1. oil pump
2. pressure relief valve
3. oil level indicator
4. oil sump
5. temperature transducer
6. thermostatic valve
7. oil pressure switch
8. oil filter support
9. oil filter
10. oil radiator
11. turbocharger inlet
12. turbocharger outlet
13. oil radiator outlet
14. oil radiator inlet
15. main gallery

File name
circlub8v_eng
Date
17 Feb 2010
 SIMPLIFIED CIRCUIT LAYOUT (4 cylinders - 8 valves Diesel engine)

vacuum pump camshaft bearings

H H H H H H H H hydraulic lash adjusters

conrod bearings
turbocharger

crankshaft bearings

piston cooling jets

lubrication circuit

flow generation unit

fluid conditioning unit

1 0
P T File name
layoutcirc_eng
Date
20 Nov 2013
 DRY SUMP LUBRICATION: CIRCUIT LAYOUT
The oil is stored in a tall and narrow external tank. The engine sump is kept "dry"

ABOUT SCAVENGE PUMPS:

Circuit  suction from engine sump
tank + air/oil separator  number of stages: 1 ... 5
 high displacement (greater than
lubrication pump displacement)
 suction of mixture oil + air
 need of air/oil separation

scavenge lubrication
pumps pump

ADVANTAGES with respect to wet sump circuit:

 improvement of lubrication pump suction
(no oil starvation)
 engine placed closer to the ground
(improvement of car stability and
aerodynamics)
 lower oil contamination
 windage reduction
(improvement of engine efficiency)
sump
File name
drysumpcircuit
Date
08 Jan 2014
 OIL PATH INSIDE THE CRANKSHAFT

(cj) (cj)

(CJ) (CJ) (CJ) (CJ) (CJ)

main gallery

(cj) (cj)

cylinder block

1 crankshaft bearing
(fixed)
1
3

2-3
crankshaft journal
2 (CJ)
4-5 4
circumferential groove conrod journal
for feeding the conrod (cj)
bearing
drilling conrod bearing 5
File name
Note: from 2 to 3 the oil moves lubalbero_eng
against the centrifugal force conrod big end
Date
08 Jan 2014
 PRESSURE DISTRIBUTION INSIDE THE CRANKSHAFT
dx Fcsin  equilibrium along the x axis:
(p+dp)A
centrifugal force:
pA

r
x integrating
 between x 0 and x:
z 
rotating pipe

centrifugal pressure distribution

p2 conrod bearing supply hole

minimum pressure (at r min )

conrod journal
r2
pmin p
p2 bearing
p1 r min feed
pressure
r1 p1 
to increase pmin , p1 must be incremented
 patm
File name
x pcentrifuga_eng

oil inlet crankshaft journal Date

air release 05 May 2015
 HYDRODYNAMIC LUBRICATION
Navier-Stokes equation
lubricated gap
(incompressible 2 (fixed)
Newtonian fluid)
z vy
y
uy 1
=0 vx
=0 uz
Hypotheses:
 steady state flow ux h x
 laminar Regime (Re <<1) B
 h << L and B
(some terms of Laplacian can neglected L
and the variation of p along z is negligible)

integrating with respect to z: boundary conditions:

ux = vx for z = 0 ux = 0 for z = h

Poiseuille flow Couette flow

flow rate along x axis

per unit width
(the same along y)

File name
hydrolub
Date
22 Dec 2015
 THE LINEAR SLIPPER

p - p0 the flow rate per unit width is:

where Q is constant
0
z x

integrating with respect to x:

h1


h

h2

p0 p0

but
x
x v0

L boundary conditions:
for x = 0 p = p0 and h = h 1
for x = L p = p0 and h = h 2

load capacity for unit width:

File name
pattinolineare
Date
03 Jan 2014
LOAD CAPACITY AS FUNCTION OF GAP HEIGHT

File name
pattino_lin_eng
Date
22 Jan 2014
 REYNOLDS EQUATION
CONTINUITY EQUATION
(incompressible fluid) in a gap where h << B, L

z 2 (fixed)

z
y
uy 1
dy vx
ux uz
ux h x
dx B
x L
dz

y infinitesimal net flow rate along x,y,z

Reynolds eq.

Leibniz Integral Rule

File name
ReynoldsEQ
(divergence) Date
22 Dec 2015
 JOURNAL BEARINGS
Reynolds eq. in cylindrical coordinates
bearing h min
radial clearance

eccentricity ratio
vp 
e peripheral speed

Re  Ri minimum film thickness
 h

journal bearing
 h min
h

vp journal

but and

gap height as
function of theta

File name
meato_cuscinetti
Date
09 May 2016
 PRESSURE DISTRIBUTION - SOMMERFELD BEARING
"infinitely" wide bearing

Hypothesis:

y
simplified Reynolds equation


 
by integration
with Reynolds
pressure

boundary condition

half
solution

Half Sommerfeld solution (no flow conservation)

p
0 p = p 0 if p < p 0
0 90  1 180 2 270 360 Reynolds boundary condition (flow conservation)

full p(0) = p( 2 ) = p 0 
solution

File name
Sommerfeld
angle theta Date
15 Jan 2014
 PRESSURE DISTRIBUTION - OCKVIRK BEARING
B (flows per unit length)
short bearing

0
Ockvirk-Dubois hypothesis: but does not
ux y imply that
negligible with respect to Couette flow


Qy simplified Reynolds equation

Q

boundary conditions: p = p 0 for

pressure (half solution)

moreover

p0

B/2

0
360° File name
axial length y 270°
180°
-B/2 0 90° Ockvirk
angle theta Date
15 Jan 2014
 LOAD CAPACITY

load capacity attitude angle

For a given geometry F grows with:
- speed
- viscosity
- eccentricity



W r dimensionless load capacity
F
Sommerfeld bearing (half solution)
F
es

dA
ntr
ce

F d
in g


oin
ej
lin

Ockvirk bearing (half solution)

File name
caricocuscinetti1

pressure field in the gap Date

14 Dec 2015
 LOAD CAPACITY

low load
constant speed and viscosity
F

h1

F2 2 3
F1

high viscosity
F1 1 For high values of  the lubrication regime
becomes mixed or boundary
low viscosity
high load
h2 h3 h1 h min

2
h
mixed hydrodynamic 
lubrication lubrication


to balance a high external load the viscosity must be increased: F2

 with a higher SAE grade oil
 by reducing the local temperature in the gap File name
caricocuscinetti2
Date
15 Dec 2015
 JOURNAL BEARINGS FEEDING
It is necessary to ensure a continuous flow of oil for:
- keeping the gap full of oil, compensating the flow rate through bearing sides
- removing the heat (influence on viscosity and therefore on load capacity)

Axial pressure distribution

TYPES OF FEEDING without groove with groove

- with circumferential groove - with feed hole

complete partial
pf

The groove interrupts the pressure distribution

(reduction of load capacity). It is used only when B B
downstream a conrod bearing must be supplied
same load capacity of
2 bearings with width
The feed hole must be located in the divergent File name
region to not interrupt the pressure distribution alimentcuscinetti
Date
15 Jan 2014
 FLOW RATE THROUGH JOURNAL BEARINGS
Q p : feed-pressure flow Q H : hydrodynamic flow
only due to the pressure difference p - p due to the relative velocity bearing-journal and
f 0
to the pressure distribution inside the gap
Depends on: feed pressure and viscosity Depends on: angular speed and viscosity
With complete circumferential groove oil forced out due

0
to drag action

h
Q0

F
With single circular hole [Martin, Lee - 1982]

h f : film height at

hole location

single hole with groove Q

h
p0 p0

the total flow rate is < Q p + Q H

hf

pf pf
formula proposed by Martin:
p0

df a
File name
B portatacuscinetti
Date
09 May 2016
 PISTON COOLING JETS
Purposes:
- removal of heat
- lubrication of contact piston rings - cylinder liner
- generation of oil film for helping in gas-tight seal

inlet
The check valve stops the flow if the main gallery pressure
outlet is dangerously low (priority to bearing lubrication)

p* = 1.2 - 1.5 bar

viscosity
flow rate

to cylinder head
ga llery p* pressure
main
Typical required flow rate: about 0.08 L/min / kW

File name
to crankshaft bearing cooljet_eng
Date
15 Jan 2014
PISTON COOLING AND LUBRICATION

piston pin lubrication

File name
pistoncool_eng
Date
20 Nov 2013
 MECHANICAL VALVE LIFTER

clearance
cam
valve pad

bucket tappet

valve
 the clearance is necessary to compensate the
thermal dilatation of the valve stem
 a high clearance generates noise
 the clearance must be taken under control by
substituting the valve pad periodically

File name
puntmecc_eng
Date
12 May 2015
 HYDRAULIC LASH ADJUSTER (HLA)
1. tappet
2. piston
3. plunger cam
4. piston guide
5. cage

1
3

V1
4 V0

oil inlet

V2
2
5

3 5
4 2 3 1
valve stem

2
File name
puntidraul_eng
Date
11 May 2015
 HYDRAULIC LASH ADJUSTER

1 3

p
1  x0 x  x0

p
2

When the lift ends, the chamber returns at the initial value File name
Due to the leakages, a pressure drop occurs puntidraul2_eng
--> the check valve opens and the oil refills the chamber Date
11 May 2015
 OIL FILTER
layout suitable for "heavy-duty" engines

full flow filter by-pass - high separation efficiency

full flow filter filter - 3-10 % of total flow
- filter or centrifuge
1

1
2
3
1: check valve
2: cartridge 3
3: by-pass valve
File name
filtrolio
Date
17 Jan 2014
 WATER-OIL HEAT EXCHANGER "Modine"
The oil flows in parallel through the plates.
The coolant (from engine cooling system)
circulates around the oil filled plates.

1. COOLANT SIDE
2. OIL SIDE oil filter
3. OUTLET MANIFOLD

pump outlet circuit

File name
scambcal
Date
12 May 2015
 THERMOSTATIC VALVE
low temperature: high temperature:
valve open valve shut

rubber

wax

stroke of thermostatic element vs. temperature

1 0
stroke (mm)

File name
valvtermo

temperature (°C) Date

12 May 2015
 THE LUBRICATING PUMP

external
- fixed displacement gear pump crescent pump
internal
gerotor
vane pump fixed
- variable displacement - pressure setting 2 levels
"pendulum" pump variable
continuously
- variable timing
ENGINE CONNECTION
CHARACTERISTICS
- crankshaft driven:
- wide speed range (500 8000 rpm)
transmission ratio = 1
- wide temperature range (- 40 +150 °C)
more compact / low displacement
- low pressure (1 8 bar)
- high fluid contamination cheaper
- solid - off-axis:
- gaseous <1 cars
transmission ratio
- small size >1 trucks
- high reliability (pump failure = engine failure)
- low cost less compact / higher displacement
higher mechanical efficiency
NUMBER OF STAGES more expensive
- single stage
File name
- double stage reqpompa_eng
Date
20 Nov 2013
 INTERNAL GEAR LUBRICATING PUMPS
P
P

crankshaft crankshaft
mounted mounted
gerotor crescent
pump pump

T oil filter seat

T

pressure
relief
valve

File name
recirculation duct
ingintpump_eng
Date
20 Nov 2013
 EXTERNAL GEAR LUBRICATING PUMP

P
filter

T
driven gear driver gear

port plate
File name
ingexter_eng
Date
20 Nov 2013
 DRIVE TYPES
crankshaft mounted off-axis (sprocket-chain drive)
P
with oil
filter P
support

P
without
filter
support

File name
asserinv_eng

T Date
20 Nov 2013
 REMOTE PILOT

p* p*2
2 RV (safety valve)
RV2 (safety valve)

SC
SC
p*1
RV1
F2
F2
p*1

F1
X F1

Advantage: the desired pressure p*1 is ensured in the

T P circuit, regardless the pressure loss in the filter
(variable with temperature)

The valve RV2 limits the pressure at pump outlet

during engine cold start
Y

File name
pilrem_eng
RV1 X Date
21 Nov 2015
 DOUBLE STAGE SCAVENGE PUMP (DAYLEY ENGINEERING)
INLET PORTS

OIL
OUTLET

AIR OUTLET DRIVE SHAFT

ROOTS TYPE
ROTORS

File name
scavenge
Date
21 Nov 2013
 SCAVENGE PUMP - EXPLODED VIEWS
STAGE 1 STAGE 2 FOAMY OIL FROM STAGES 1 AND 2

CENTRIFUGAL AIR-OIL SEPARATOR AIR

OIL

File name
scavenge2
Date
21 Nov 2013