Three-dimensional model of spray forming by fringe element reconstruction method

A three-dimensional spray forming process model was developed to predict the general transient shape of deposited material. The distribution of the spatial droplet flow rate was modeled by an axisymmetrical Gaussian function, and the shadowing effect was utilized for accurate prediction of the deposited shape. In order to construct the three-dimensional meshes applicable to various numerical analyses, the fringe element reconstruction method was employed to calculate the shape of deposited material. In order to verify the developed method, the simulation results were compared with the available experimental data in the literature. Good agreement was obtained between the numerical and experimental results. Finally, the effect of the withdrawal velocity of the substrate was investigated.