Design of a Double-Nozzle Air Spray Gun and Numerical Research in the Interference Spray Flow Field

Abstract

Spray painting robots equipped with air spray guns have been widely used in the painting industry. In view of the low efficiency of single-nozzle air spray guns when spraying large targets, a new double-nozzle air spray gun structure was designed in this paper based on the Coanda effect of double jets. Firstly, a 3-D physical model of the double-nozzle air spray gun was built in Solidworks, in which unstructured grids were generated for the computational domain by ICEM. Secondly, the spray painting process was numerically modeled with the help of the computational fluid dynamics (CFD) software ANSYS-Fluent 16.0. The two-phase spray flow was calculated by coupling a discrete phase model (DPM) and the Taylor analogy breakup (TAB) method. The TAB model was applied to predict the secondary break-up. The DPM model was applied to predict the droplet trajectories. The geometry of an air spray gun has a significant influence on the spray flow field characteristics. The influence of the air spray gun geometry on the interference spray flow field characteristics and coating film thickness distribution were investigated by changing the values of the distance between the centers of the two paint holes (L) and the angle between the axes of the two paint holes (θ). Numerical results show that the smaller L and θ are, the stronger the interference effect between the two jets, while the more concentrated the paint is in the central region of the target surface, the easier it is for overspray to occur. With increasing L and θ, the interference effect gradually decreased and the extension distance of the coating film along the x-axis gradually increased. However, if L and θ are too large, the interference effect will become too weak and the shape of the coating film will become a concave, with more paint on both side regions and less paint in the central region, which will cause an uneven coating film. From the simulation results, it can be concluded that a more uniform coating film can be obtained when L = 30 mm and θ = 10°. The effective coating width of the double-nozzle air spray gun was increased by 85.7% compared with the single-nozzle air spray gun, which improved the spraying efficiency.

Optimal design of a pneumatic atomizer using response surface method to obtain more uniform coatings

“…After that, the TAB model was used to predict the secondary breakup and the child droplets’ diameters. According to references, 8,10 after the computational results of gas phase tend to convergence, 120 non-Newtonian liquid particles at the paint hole were injected into the gas flow field. These particles have a diameter of 65 μm with Rosin–Rammler distribution and an initial velocity of 10 m/s (i.e.…”

“…Therefore, the liquid paint is easily concentrated in the plate center, which leads to uneven coatings with the overspray happening from time to time. [8][9][10] To solve this problem, a repeatable and comprehensive design for the pneumatic atomizer must be done, which means the interactions between the influential factors should be considered simultaneously. 9 Many experimental and numerical investigations on spray coatings using the pneumatic atomizer have been carried out in recent years, [11][12][13][14] referring mainly to the influence of the geometrical structure and operating conditions.…”

“…They also pointed out that the greater the center pressure was, the easier it was to cause overspray. Wang et al 8 proposed a double-nozzle atomizer and thought that uneven coatings with overspray easily happened when the distance between the two paint holes and the angle between the axes of the paint holes were both small. Conversely, the coating film shape became a concave that would slightly cause uneven coatings.…”

“…Therefore, the liquid paint is easily concentrated in the plate center, which leads to uneven coatings with the overspray happening from time to time. 8–10 To solve this problem, a repeatable and comprehensive design for the pneumatic atomizer must be done, which means the interactions between the influential factors should be considered simultaneously. 9…”

An Atomization Model of Air Spraying Using the Volume-of-Fluid Method and Large Eddy Simulation

“…Only the TAB (Taylor analogy breakup) model is reported to model paint atomization. The TAB model was first used to predict fuel atomization [14,15], and recently, Li et al [16] and Wang et al [17] have applied it to paint an atomization simulation of air sprays. However, the TAB model only considers the secondary atomization and requires empirical initial conditions to solve the model.…”