A novel geometric simulation method for rapid prediction of accessibility and drainage in the electro-dip coating process

Abstract The electro-dip coating (ED-coating) process plays a pivotal role in achieving superior finishes on automotive bodies and parts. Optimizing this process involves reducing liquid carryover between baths and enhancing accessibility within the baths. A novel geometric simulation method based on connectivity, designed to predict accessibility and drainage of liquid, is introduced. It addresses the intrinsic challenges of varying scales, where small gaps and holes must be resolved on large objects over long dipping motions, making physics-based simulations infeasible. Validation with a car door shows close agreement between simulations and experiments. The different grid refinement levels provide valuable insight into the resolution necessary for achieving accurate results. Furthermore, application of the method to a car body demonstrates its ability to handle the complex geometries and motions associated with the ED-coating process. The analysis predicts a total of 0.61 liters of trapped air and 0.41 liters of trapped liquid within the car body. The presented work offers a valuable tool for assessing and optimizing accessibility and drainage in the ED-coating process, thereby improving corrosion protection and product quality. It also contributes to sustainable manufacturing practices by enhancing process efficiency and minimizing material waste.