SHELL HELIX TRIBOLOGY AWARD

Lubrication contributes greatly to the performance and durability of four-stroke engine.

With no oil means the friction loss becomes larger. Friction loss will reduce the efficiency of the
engine output. Oil also helps the piston rings and piston to maintain that there are no leaks in the
combustion chamber to provide sealing on the piston and rings. The durability of the engine is
also determined by the quality and quantity of oil. The absence of heat transfer fin and oil will
make the engine temperature soaring, so this also make durability and efficiency decreases.
Rapid rise in engine temperature is needed for the engine to perform stop and go system. To
make it happen, the oil must maintain the engine in it’s ideal temperature. Therefore, the
lubrication system must be regenerated. And also must specify the right type of oil that
appropriate enough for our custom engine, to reduce friction loss and maintain engine durability

Outlines of the research can be gathered into a few questions:

1. What kind of Lubrication system is the most appropriate for the research?
2. What type of oil that best fits the selected lubrication system ?
3. What are the benefits?

Some simple existing lubrication systems that can be made an option those are splash
system, oil pump, and a gravity feed system and splash. Splash system is widely used in the lawn
mower, the system works like the part of crankshaft made of thin rods, so this thing will rotate
then reach a puddle of oil in the carter, then the oil will squirt into other parts of the engine such
as pistons and bearings. This system may not be used due to lower crankcase cavities, so the oil
will drain out. Crankshaft 125 kph is also not designed for it, add the counterweight rod will
change character of the engine.

There are three types of oil pump system such as electric pump, gear pump, and Trochoid.
Electric pump is prohibited in this event. Crankshaft driven gear pump will be a burden to the
engine, other than that it is hard to find under 1 kg gearpump in our country. While Trochoid
pump may not be used either. With such condition then our team develop gravity feed
lubrication. This system drains oil by the effect of grafitation,it is done by putting an oil tube
above the engine.
 Oil tank

Hose (oil flow trough hose because grafity)

Engine (crankcase)

Gravity feed system must be adapted to engine that require an increase in temperature up to
90 ⁰ c. This is based on an research about an ideal combustion temperature of 2013, that the most
efficient combustion ideal temperature is 90 ⁰ c. lubricant must be able to maintain the ideal
temperature within 30 minutes or as long as the race lasts. With this background our team do a
simple research to select a suitable lubricant. The used method is the method of friction with
steel rods and holes media. Between the rod and the hole was given a gap of 0.02. And the rod is
rotated until 6000 rpm. The purpose of time test of oil drops is to see a filming quality of some
parts. Performed by dipping steel round and calculate the time since it was lifted until the oil
drops.

N VISCOU DROP REACH 90C

O OIL BRAND SITY TIME (S) (S)
SHELL ADVANCE
1HX5 0.5 4.1
SHELL ADVANCE
2HX7 0.7 3.6
SHELL ADVANCE
3AX7 2 5.4
4 SHELL HELIX 1.6 3.7
5 MOTUL 300V 3 7.3
PERTAMINA
6ENDURO RACING 1.1 1.2
 With the results of these studies, the chosen two types of oil are MOTUL 300v and shell
advance ax 7. To determine the oil that will be used. Still using the same method on the testing
temperature, but the data collections are more detail per unit time.

temperature oil changes

200
temperature(c)

150

100
shell advance ax 7
50 motul 300v
0
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
time (second)

Based on the graphic then selected shell advance ax 7, because the faster the engine
temperature rises, so the ideal combustion achieved faster.

Future studies will determine the amount of oil used. By reducing the amount of oil to a
minimum will reduce the total weight of the car. The method used is the inclusion of a number of
oil into the crankcase and turn on the engine for 40 second at 3000 rpm, 3000 rpm is the highest
rpm that is used in our cars. Defects scratch area on the block and piston as a reference. For the
validity of the data used 3 pieces of original cylinder and piston honda to reduce data errors. NS:
no scratch S: scratch DS: deep scratch

AMOUNT
(ml) 5 4 3 2 1 0.8 0.6 0.5 0.2
CYLINDER
1 NS NS NS NS S S S DS DS
CYLINDER
2 NS NS NS NS NS S S S DS
CYLINDER
3 NS NS NS NS NS NS DS DS DS
 based on the data it can be concluded that engine should consume 1 ml of oil each ignition.
Total laps sem 2014 is 10, and the total engine starts are 28 times, then the oil is needed for all
races is 28 ml. but when the road test done, until the end of the race the engine temperature has
not reached 90 c. This is due to cooling by the air when the car is running, whereas when the test
has no blowing at all. So as to achieve a temperature in the range of 90C we reduce the amount
of oil to 20 ml of each race. Reduction of as much as 8 ml had no effect on engine durability.

The chosing of systems and oil is able to improve the performance and efficiency of the
engine. The increase in engine temperature reaches 90C in 4 seconds and with oil that capable to
maintain it’s temperature at it’s ideal temperature even longer, making the engine do not need
warming up. Engine warm up reduces the life time of the engine parts that have been extremely
modified, and also wasting of fuel. With no warm-up can increase the lifetime of spare parts and
reduce the pollution generated by the car.

Improved performance is affected by gravity feed lubrication system with shell AX7 oil is
the use of forgings piston with a “piston to wall clearance” is wider than the piston casting. Wide
“piston to wall Clearance” reduces friction between the piston and cylinder liner so that loss can
be reduced. Wide “Piston to wall clearance” must be supported with good oil sealing in order to
prevent leakage compression when engine in an expansion step. Sealing compression can only
be given by the oil with good filming quality, Shell advance AX7 is able to provide it.

Piston forging is stronger to withstand compression loads than cast pistons , so that
compression can be increased up to 14 : 1 with 95 octane fuel . Standard piston ring consists of
three pieces , two compression rings and one oil ring , but in this engine only the top
compression ring mounted , without any leakage of fuel in oil chamber , compression leakage
and piston scratch due to lack of oil . Two rings those were not installed to reduce piston friction
to liner as much as 60 % of the total friction caused by the piston rings . Our engine in 2013 were
overheated when overlap camshaft eliminated . This year overlap camshaft can be removed
without any overheating problems due to the quality of the oil from the shell that can maintain
the stability of engine temperature. No overlap means no Scavenge proces that throw fresh gas
out of exhaust , so that the CO levels decreased by 10 % . Overlap is eliminated by means of
speeding up ex valve and slowing this valve in closing , this will increase the active compression
in cylinder that would make more complete combustion . Small cam duration below 200 degrees
will change the peak power and torque at 3000 rpm so the engine will match with the car design
that requires only 3000 rpm to run . With low rpm, combustion cycle is reduced , and will reduce
fuel consumption .

Air fuel ratio that above the stoichiometric of 14.7: 1 is the requirement of low
consumption fuel engine, but when AFR is above stoichiometric, the engine temperatures will
soar and will have a risk of overheating. But our team engine using the AFR of 17: 1 without
any overheating, and the ignition timing can be advanced to 50 BTDC, and high compression 14:
1 without any symptoms of detonation. With a blend of three things above engine power can
increase 1 hp at 3000 rpm, rpm rise rapidly. so that the top speed of 45 km / h can be achieved
only in 5detik. Change of lubrication system can improve mileage as much as 200 kpl, in 2013,
250kpl became 400kpl. And also helps to reduce pollution due to incomplete combustion.