A full 3D numerical model of the industrial electrostatic coating process for moving targets

In this paper, a full three dimensional FLUENT numerical model of the electrostatic coating process as used in the automotive industry is presented and selected parametric studies on the numerical model have been conducted. The model incorporates a moving mesh capability in order to simulate movements of the target. The target follows piecewise linear motion and the entire area of the target has been coated in multiple passes. All the dominant mechanical and electrical phenomena were taken into account and cases with both neutral and charged particles were examined. It was confirmed that the transfer efficiency increases when the electrical forces are present in the model and that the coating uniformity improves with the movement of the target. The deposition pattern corresponds to the motion of the target and gradually builds up in a cumulative manner. Due to the aggregation effect associated with the target movement, the deposition uniformity is dramatically improved.