Tutorial Spray Paint

Spray Paint Modeling Using ANSYS Fluent
1. Introduction
The purpose of this tutorial is to provide guidelines and recommendations for setting up and solving a spray paint
case using the discrete phase model (DPM) of ANSYS Fluent.
2. Prerequisites
This tutorial is written with the assumption that you have completed the Tutorials Introduction to ANSYS
Fluent in ANSYS Workbench: Fluid Flow and Heat Transfer in Mixing Flow , and Modeling
Evaporating Liquid Spray from ANSYS Fluent Tutorial Guide, and that you are familiar with the ANSYS
Fluent navigation pane and menu structure. Some steps in the setup and solution procedure will not be
shown explicitly.
In this tutorial, you will use the standard k-ε turbulence model and the discrete phase model. If you have not used
these models before, it would be helpful to first refer to chapters Modeling Turbulence and Modeling Discrete
Phase from ANSYS Fluent User’s Guide.
3. Problem Description
Water is injected onto a cylinder to form a wall-film on the cylinder.
4. Preparation
1. Copy the mesh file spray_paint.msh.gz to your working directory.
2. Start the 3D double precision version of ANSYS Fluent.
For more information about Fluent Launcher see Section Starting ANSYS Fluent Using Fluent Launcher from
ANSYS Fluent User’s Guide.
5. Initial Setup and Solution

You will setup and run this case without DPM first.
Step 1: Grid
1.1. Read the grid file
File → Read → Mesh
Select the file spray_paint.msh.gz from the Files list and then click on OK.
1.2. Check the mesh
Setup → General → Check
Click on Check under Mesh (Figure 2).
© 2016 ANSYS, Inc. All rights reserved Page 1 of 21

Figure 2. General panel
Fluent will perform various checks on the mesh and will report the progress in the console. Make sure that the
minimum volume reported is a positive number.
1.3. Display the mesh (Figure 3)
Setup → General → Display
Figure 3. Mesh

Step 2: Materials
2.1. Define the materials.
Setup → Materials...
Keep the default air material.
Step 3: Models
3.1. Select Pressure Based solver.
Setup → General→ Solver
Select Pressure-Based under Type, Transient under Time (Figure 3).
3.2. Enable Energy equation.

Setup → Models→ Energy
3.3. Specify Turbulence model. This tutorial will be solved by using Standard κ-ε model.
Setup → Models→ Viscous
Select k-epsilon (2 eqn) under Model and Standard under k-epsilon Model list, keep the default settings (Figure
4).
Step 4: Operating Conditions

Setup → Boundary Conditions → Operating Conditions
Keep 101325 Pa for Operating Pressure, enable Gravity and enter the 9.81 m/s2 in z-direction, 288.16 K as
Operating Temperature, as shown in Figure 5 below.
Step 5: Boundary Conditions

Setup → Boundary Conditions...
Keep the default values under the momentum and thermal tabs for the boundary and wall boundary zones.
Step 6: Solution Methods/Controls

6.1. Set the Solution Methods
Solution → Solution Methods...
Keep the default solution methods: you will use SIMPLE, LSQ gradients, 2nd order for pressure, momentum and
energy, and first order for turbulence.
6.2. Set the Solution Controls
Solution → Solution Controls
Keep the default solution controls.

Figure 5. Operating Conditions panel
Figure 4. Turbulence model settings
Step 7: Initialization of the Solution

7.1. Initialize the solution
Solution → Solution Initialization...
Use the Standard Initialization with the default values.
Step 8: Iterate
8.1. Run calculation
Solution → Run Calculation...
Enter 0.001 for the Time Step Size, 10 for the number of iterations, and 50 for the Max Number of
Iterations/Time Step. Click on Calculate, Figure 6.
8.2. Save the case and data files with the name spray_paint_ini.gz
File → Write → Case&Data...

Figure 6. Run Calculation panel
6. Setup and Solution: Modeling Non-Evaporating Spray

Step 9: Define the Discrete Phase Model
9.1. Enable Discrete Phase Model (see Figure 7).
Setup → Models → Discrete Phase
In the Discrete Phase Model panel:
a) Under Interaction, enable Interaction with Continuous Phase.

b) Under Tracking tab, keep the Max. Number of Steps to 500 and Step Length Factor to 5.
c) Under Physical Models tab, enable Stochastic Collision and Breakup. Coalescence will be selected
automatically after clicking on Stochastic Collision.
d) Retain the default values for the other parameters.
e) Hit on OK.
Step 10: Injection

10.1. Open Injection panel.
Setup → Models → Discrete Phase → Injections

Open the Injections panel from the tree, or click on Injections button (Figure 7). When the Injection panel opens
hit on Create to define the injection properties.
Figure 7. DPM settings panel

10.2. Set the injection properties (see Figure 8).
a) Select solid-cone Injection Type

b) Set 5 for the Number of Streams
c) Under Particle Type retain the default selection of Inert
d) Select water-liquid from the pull-down Material selection list
e) Under Point Properties tab enter the properties following the table below.
f) Under the Physical Models:
i. select dynamic-drag from the Drag Law drop-down list
ii. Under Breakup Model select Wave
iii. Under Breakup Constants, set B1 to 15
g) Retain the default values for the other parameters.
h) Hit on OK on Set Injections Properties panel and Close the Injection panel.
Parameter Value
X-Position [m] -0.2
Y-Position [m] 0
Z-Position [m] 0
Diameter [m] 0.001
Temperature [K] 300
Start Time [s] 0
End Time [s] 1000
Azimuthal Start Angle [deg] 0
Azimuthal Stop Angle [deg] 360
X-Axis 1
Y-Axis 0
Z-Axis 0
Velocity Magnitude [m/s] 50
Cone Angle [deg] 4
Radius [m] 0
Total Flow Rate [kg/s] 0.01
Step 11: Materials

11.1. Define the materials.
Setup → Materials → Inert Particle
11.2. Select water-liquid material to open the Create/Edit Materials panel.

11.3. Under Properties, select piecewise-polynomial from Droplet Surface Tension dropdown list. The Piecewise-
Polynomial Profile panel opens.
11.4. Click OK to close the Piecewise-Polynomial Profile panel.
11.5. Click Change/Create (Figure 9).

12.1. Set the boundary conditions for the wall.

Figure 8. Setting the injection properties

Figure 9. Setting of the water-liquid inert particle properties

a) Click the DPM tab and under Discrete Phase Model Conditions, select wall-film as the Boundary Cond. Type
(Figure 10).
Figure 10. Setting the DPM conditions on the wall boundary
Step 13: Particle History Data Export

Solution → Calculation Activities → Automatic Export → Create → Particle History Data Export

In the Automatic Particle History Data Export panel (Figure 11):

13.1. Select CFD-Post File type
13.2. Select injection-0
13.3. Open the Exported Particle Variables panel, add Particle Diameter variable, OK to close the panel
13.4. Keep 1 for Frequency (Time Steps)
13.5. Enter spray_paint_inert.xml for the name of the file.
13.6. Hit on OK to close the panel.
Figure 11. Setting of Automatic Particle History Data Export
Step 14: Iterate

14.1. Save the case and data file with the name spray_paint_inert_ini.gz
14.2. Run Calculation
You will continue running the case, at this point you do not need to initialize the flow.

Iterations/Time Step. Click on Calculate.
14.3. Save the case and data file with the name spray_paint_inert_end.gz
Step 15: Post-Processing

15.1. Post-processing in Fluent
Results → Graphics
a) Click on Options, enable Lights On with Gouraud light

b) Display the contours of Wall Film Height as shown in the panel (Figure 12).
c) Display the particle tracks. Select Particle Tracks. In the Particle Track panel:
i. Check the Draw Mesh, in the Display Mesh panel select the wall with Faces option. Display
and Close the panel
ii. Select sphere Track Style
iii. Under Attributes panel use a constant diameter of 0.003m and enter 12 for Detail
iv. Select Particle Diameter category under Color by
v. Select the injection-0 from the Release from Injections list box
vi. Display (see Figure 13).
vii. You can display the injection summary.
viii. Close the Particle Tracks panel
Figure 12. Contours of Wall Film Height at 0.07 s
15.2. Post-processing in CFD-Post
You will create animations of the particles in CFD-Post.
a) Load the file spray_paint_inert_end.dat.gz in CFD-Post

File → Load Results.
b) Import the PT data history spray_paint_inert.xml
File → Import → Import FLUENT Particle Track File.

Figure 13. Contours of Particle Traces at 0.07 s
c) Select wall from the tree and change the color to white
d) Uncheck the Default Legend View
e) Click on FLUENT PT for Water Liquid
f) Under the Geometry tab:
i. Increase the Max Tracks to 500
ii. Enable Filter
iii. Check Diameter
iv. Select ‘<’ symbol and enter 0.0006m
g) Under the Color tab:
i. Switch to Variable mode
ii. Select Velocity variable
iii. Local Range
h) Under the Symbol tab:
i. Check Show Symbols
ii. Select Ball
iii. Uncheck Show Tracks
i) Apply
j) Open the Animation panel (See Figure 14)
i. Select the FLUENT PT for Water Liquid object
ii. Click on the playback arrow to display the animation
iii. Alternatively, you can save the animation of the particles
7. Setup and Solution: Modeling Evaporating Spray

Step 16: Models
16.1. Read case and data spray_paint_inert_ini.gz files
File → Read → Case&Data...
16.2. Enable Species Transport model with Inlet Diffusion and Diffusion Energy Source options and default
settings (Figure 15).
Setup → Model → Species → Species Transport

Figure 14. Creation of an animation from the injection-0
Step 17: Materials

17.1. Select mixture-template
Setup → Materials → Mixture
17.2. Under Properties, click on Edit adjacent to Mixture Species, the Species panel will be open
In the Species panel:
a) remove n2 and o2 from the Selected Species list
b) add air from Available Materials list.
The final Species panel is shown in Figure 16
c) OK to close the Species panel
17.3. Change to ideal-gas density
You will get a warning on the operating density for compressible flows with buoyancy, you will fix this in
the next step
17.4. Change/Create on Create/Edit Materials panel (Figure 17)

Figure 15. Species Model panel
Figure 16. Species panel

Figure 17. Materials panel
Step 18: Operating Conditions

Setup → Boundary Conditions → Operating Conditions
18.1. Keep the previous settings
18.2. Check the Specified Operating Density
18.3. Enter 0 for Operating Density (see Figure 18)
Figure 18. Operating Conditions

Step 19: Injections


19.3. Copy this injection
The injection-1 will be created.
19.4. In the new Set Injection Properties panel (Figure 19):
a) Select Droplet Particle Type
b) Retain the other values
c) OK to set and close the panel
You will change later the Material for this injection
19.5. Select injection-0 and click on Delete to remove this injection.
Step 20: Materials

20.1. Select droplet-particle in the Material Type drop-down list
Setup → Materials → Droplet Particle
20.2. Add water-liquid from Fluent Data Base:

a) Click Fluent Database… to open the Fluent Database Materials panel
b) Select droplet-particle in the Material type drop-down list
c) Select water-liquid (h2o<l>) from Fluent Fluid Materials list.
d) Click Copy
Click OK in the New Material Name panel that asks you to rename this material.
e) Under Properties, select piecewise-linear in the Saturation Vapor Pressure dropdown list.
Click on OK in the Piecewise-Linear Profile that opens
f) Select piecewise-polynomial in the Droplet Surface Tension drop-down list
Click on OK in the Piecewise-Polynomial Profile that opens
g) Click Change/Create in the Materials panel (see Figures 20).
Step 21: Injections


21.2. Select water-liquid-new in the Material drop-down list (see Figure 21).
21.3. Under Physical Models tab, switch to KHRT breakup model, retain the default constants.
21.4. OK.

Figure 19. Set Injection properties for the new injection-1

22.1. Set the boundary conditions for the wall.
22.2. Under Thermal tab select Temperature under Thermal Conditions.
22.3. Set temperature to 273K.
Step 23: Particle History Data Export

Solution → Calculation Activities → Automatic Export → Create → Particle History Data Export
Review/Repeat Step 13, 13.5. Enter spray_paint_evaporation.xml as the name of the particle history file.
Step 24: Iterate

24.1. Save the case and data file with the name spray_paint_evaporation_ini.gz
24.2. Run the calculation
You will continue running the case, at this point you do not need to initialize the flow.

Figure 20. Definition of the water-liquid droplet particle

Figure 21. Final injection-1 properties
Iterations/Time Step. Click on Calculate.
24.3. Save the case and data file with the name spray_paint_evaporation_end.gz
File → Write → Case&Data..
Step 25: Post-Processing

Repeat the post-processing tasks from Step 15.
Figures 22 bellow show the contours of wall film height and surface heat transfer coefficient and the particle
traces at t=0.07s extracted from Fluent post-processor. Figure 23 shows the particle trace with iso-surface of
mass fraction of h2o at 0.001 iso-value. Figure 24 depicts a screen shot of the particle trace animation extracted
from CFDPost.
8 Summary
In this tutorial, we performed a numerical simulation of spray paint process using inert and droplet DPM from
ANSYS Fluent. Fluent post-processor, and CFD-Post have been used for post-processing of the results.

Figure 22. Contours of wall film height and surface htc, and particle traces colored by particle diameter
and particle temperature obtained from Fluent post-processor

Figure 23. Iso-value of 0.001 mass fraction of water and particle trace colored by particle diameter
obtained from Fluent post-processor
Figure 24. Snapshot of particle trace animation from CFD-Post

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Spray Paint Modeling Using ANSYS Fluent

5. Initial Setup and Solution

© 2016 ANSYS, Inc. All rights reserved Page 1 of 21

Figure 2. General panel

© 2016 ANSYS, Inc. All rights reserved Page 2 of 21

Keep the default air material.

3.2. Enable Energy equation.

Step 4: Operating Conditions

Step 5: Boundary Conditions

Step 6: Solution Methods/Controls

Solution → Solution Methods...

6.2. Set the Solution Controls

Solution → Solution Controls

Keep the default solution controls.

© 2016 ANSYS, Inc. All rights reserved Page 3 of 21

Figure 5. Operating Conditions panel

Figure 4. Turbulence model settings

Step 7: Initialization of the Solution

Solution → Solution Initialization...

Use the Standard Initialization with the default values.

Solution → Run Calculation...

© 2016 ANSYS, Inc. All rights reserved Page 4 of 21

Figure 6. Run Calculation panel

6. Setup and Solution: Modeling Non-Evaporating Spray

Setup → Models → Discrete Phase

In the Discrete Phase Model panel:

a) Under Interaction, enable Interaction with Continuous Phase.

Step 10: Injection

Setup → Models → Discrete Phase → Injections

© 2016 ANSYS, Inc. All rights reserved Page 5 of 21

Figure 7. DPM settings panel

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10.2. Set the injection properties (see Figure 8).

a) Select solid-cone Injection Type

Step 11: Materials

11.2. Select water-liquid material to open the Create/Edit Materials panel.

Step 12: Boundary Conditions

12.1. Set the boundary conditions for the wall.

© 2016 ANSYS, Inc. All rights reserved Page 7 of 21

Figure 8. Setting the injection properties

© 2016 ANSYS, Inc. All rights reserved Page 8 of 21

Figure 9. Setting of the water-liquid inert particle properties

Figure 10. Setting the DPM conditions on the wall boundary

Step 13: Particle History Data Export

© 2016 ANSYS, Inc. All rights reserved Page 9 of 21

In the Automatic Particle History Data Export panel (Figure 11):

Figure 11. Setting of Automatic Particle History Data Export

Step 14: Iterate

14.2. Run Calculation

Solution → Run Calculation...

© 2016 ANSYS, Inc. All rights reserved Page 10 of 21

Step 15: Post-Processing

a) Click on Options, enable Lights On with Gouraud light

Figure 12. Contours of Wall Film Height at 0.07 s

15.2. Post-processing in CFD-Post

You will create animations of the particles in CFD-Post.

a) Load the file spray_paint_inert_end.dat.gz in CFD-Post

© 2016 ANSYS, Inc. All rights reserved Page 11 of 21

Figure 13. Contours of Particle Traces at 0.07 s

7. Setup and Solution: Modeling Evaporating Spray

© 2016 ANSYS, Inc. All rights reserved Page 12 of 21

Figure 14. Creation of an animation from the injection-0

Step 17: Materials

© 2016 ANSYS, Inc. All rights reserved Page 13 of 21