2019 Volume 2019 Pages 20190014
A novel numerical electrodeposition (ED) model for high accuracy automotive ED simulation is proposed. In contrast to the conventional ED models, the newly proposed ED model is based on the new basic ED experiments replicating actual manufacturing line conditions. The new basic ED experiment introduces an external resistor so that the time history of the surface potential on the cathode is similar to that of the actual lines. The proposed ED model consists of two submodels: a film resistance model and a a film growth model to decide the electric resistance and the thickness growth rate of the coated film, respectively. The new resistance model considers the flow rate dependency of the paint as well as the film thickness dependency. Meanwhile, the new growth model considers the concentration diffusion of paint particles before the initial film deposition. Some finite element analyses of the basic experiments including the 4-plate box test show that the results with the proposed model are more accurate than those with the conventional model.
