CFD Simulation of Conical Injection Color Spraying on Wall

This study presents a computational fluid dynamics simulation of color spray application on a wall surface using a conical injection method, analyzed through Ansys Fluent software.

Model Development

The three-dimensional computational domain was created using SpaceClaim software, consisting of a 3m × 3m × 4m rectangular space. The computational mesh was generated in Ansys Meshing with an unstructured grid configuration comprising 254,934 cells to ensure accurate resolution of the spray dynamics.

Simulation Methodology

A one-way Discrete Phase Model (DPM) approach was implemented to simulate the paint particles, with the following key parameters:

• Injection type: Conical pattern
• Particle velocity: 10 m/s
• Cone angle: 30 degrees
• Particle material: Color Spray
• Particle classification: Inert type

The simulation was configured with several fundamental assumptions:

• Pressure-based solver implementation
• Unsteady (transient) time treatment
• Negligible gravitational effects
• Laminar flow regime

Boundary Conditions and Solution Setup

The boundary conditions were defined as:

• Primary wall and back wall: Stationary with “escape” condition for particles
• Top wall: Stationary with “trap” condition for particles

The numerical solution utilized:

• SIMPLE pressure-velocity coupling
• Second-order pressure discretization
• Second-order upwind momentum discretization
• First-order upwind modified turbulent viscosity
• Standard initialization method

Results and Analysis

The simulation successfully captured the conical spray pattern of paint particles as they traveled from the injection source toward the target wall surface. The 30-degree cone angle effectively determined the spray coverage area on the wall, demonstrating how injection parameters directly influence the paint distribution pattern.

This analysis provides valuable insights for industrial coating applications, allowing optimization of spray parameters for desired coverage characteristics and material efficiency in painting processes.