Design Optimization of Lubrication System for a Four-Cylinder Diesel Engine

Lubrication system plays a very vital role in engine durability. Engine designers show utmost care in designing and validating the lubrication system. If not properly designed engine components will be subjected to pre-mature failure in the field incurring loss to the manufacturer pulling down the “brand image” which is considered sacrosanct. In the current work, the authors carry design exercise of the lubrication system for a four-cylinder diesel engine. Concept design, design optimization and thorough validation activities are carried out and captured in detail. Oil pressure distribution is simulated for the concept design. Based on the simulated results, design optimization is carried out through simulation and extensive validation under various boundary conditions. Different design iterations are done to alter the oil pressure levels and validate it at various oil galleries. The results of oil pressure at various oil galleries are neatly captured to optimize the lubrication system design, the process of which is explained in this paper.