Modeling of generation of uniform metal droplet during drop-on-demand spray forming

In order to predict the generation of uniform molten aluminum droplets by a pulse argon gas, the level set method is used to simulate the flow field of two-phase flow consisting of liquid metal and surrounding gas. The case of a 500 μm diameter orifice and a 10 kPa pulse argon gas during 5 ms is studied in a two dimensional axial symmetry under a fixed structured grid composed of quadrilateral elements. In this case, the influence of the duration of pulse argon gas on the initial velocity and volume of droplets generated is analyzed in detail. The simulation results show that the initial velocity distribution in generated droplets is non uniform, which can be used to explain the resultant oscillation of droplets during falling. As durations of pressure peak of pulse argon gas are prolonged, the diameter of droplets generated increase. This research will further the understanding of generation of uniform molten metal droplet on drop-on-demand mode.