摘要
为提升机器人喷涂自动化水平及涂膜质量,本研究通过构建空气喷涂成膜过程的高精度数值模型,系统揭示了雾化特性与成膜机理的耦合作用规律,并提出工艺参数优化策略。基于欧拉-拉格朗日方法,结合KHRT液滴破碎模型与壁面捕捉模型,建立了涵盖离散相运动、连续相湍流及气液两相耦合作用的涂料沉积过程数值模型。通过网格无关性验证确保计算精度,并采用实验标定的雾化锥角与喷射初速度作为初始参数,综合分析喷涂高度、初速度及雾化锥角对涂膜厚度分布、均匀性及涂料效率的影响机制。研究发现:粒子撞击速度是影响雾化效果与成膜质量的关键中间变量,其值随喷涂高度增加呈线性下降,导致有效涂膜范围扩大,均匀性显著提升,但涂料逃逸率增加。喷射初速度存在最优区间,过高时液滴逃逸加剧,过低则导致雾化不充分,需权衡均匀性与喷涂效率。雾化锥角增大显著降低喷涂效率,且引发粒径分布不均,但过小锥角因局部动能集中导致均匀性劣化,需通过锥角优化平衡覆盖范围与成膜质量。实验验证表明了模型可靠性。本研究首次将雾化过程与成膜特性纳入统一分析框架,阐明工艺参数对涂膜质量的非线性调控机制,研究结果对喷涂工艺开发具有重要工程指导价值。
To enhance robotic spraying automation and coating quality,this study established a high-precision numerical model of the air spraying film-forming process,systematically revealing the coupling mechanism between atomization characteristics and film formation dynamics,and proposed a process parameter optimization strategy.Based on the Euler-Lagrange method,a numerical model for paint deposition was developed by integrating the KHRT droplet breakup model and a wall-capturing model,incorporating discrete phase motion,continuous phase turbulence,and gas-liquid coupling effects.Grid independence verification ensured computational accuracy,while experimentally calibrated spray cone angles and initial velocities were adopted as boundary conditions.The influence mechanisms of spray distance,initial velocity,and spray cone angle on film thickness distribution,uniformity,and transfer efficiency were comprehensively analyzed.Key findings include:(1)Droplet impact velocity serves as a critical intermediate variable affecting atomization and film quality,decreasing linearly with increasing spray distance,which expands effective coating coverage and improves uniformity but elevates paint escape rates.(2)An optimal range exists for initial velocity—excessive velocities intensify droplet escape,while insufficient velocities cause inadequate atomization,requiring trade-offs between uniformity and efficiency.(3)Larger spray cone angles significantly reduce transfer efficiency and induce uneven particle distribution,whereas overly narrow angles degrade uniformity due to localized kinetic energy concentration,necessitating cone angle optimization to balance coverage and quality.Experimental validation confirmed model reliability.This work pioneers a unified analytical framework integrating atomization dynamics and film formation characteristics,elucidating the nonlinear regulatory mechanisms of process parameters on coating quality.The results provide critical engineering guidance for spray process development.
作者
万俊豪
曾勇
祝欣怡
向琼瑞
WAN Jun-hao;ZENG Yong;ZHU Xin-yi;XIANG Qiong-rui(School of Mechanical Engineering,Yancheng Institute of Technology,Yancheng 224051)
出处
《制造业自动化》
2026年第1期113-126,共14页
Manufacturing Automation
关键词
空气喷涂
成膜特性
雾化特性
欧拉-拉格朗日法
喷涂工艺参数
air spraying
film formation characteristics
atomization characteristics
Euler-Lagrange method
spray process parameters
