The case study will explain the optimization of the lubrication system for a dry sump Formula 1 gearbox by experimental method, using RAPID PROTOTYPING and RAPID CASTING technologies.

The main targets are:

• optimization of the oil pick up
• reduction of the flowing oil volume
• reduction of the dissipated power

These main goals have to be obtained besides other issues, such as a low weight of the case since it is a suspended mass and a maximum overall stiffness. In fact the case is the major component for the suspension mountings and brackets and is connected to the engine: its stiffness is fundamental in order to get the minimum deflection, therefore providing the best car’s stability and performance.

The chosen method is the optimization of the internal volume and the flow rate balance of the various G/box oil pick up, all this through the best manufacturing technology in order to leave maximum freedom to the geometry design for the internal casing dimensions.