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Electrostatic rotary bell atomizers are commonly used in several engineering applications, including the automobile industry. A high-speed rotating nozzle operating in a strong background electric field atomizes paint into charged droplets that range from a few micrometers to tens of micrometers in diameter. The atomization process directly determines the droplet size and droplet charge distributions which subsequently control the transfer efficiency and the surface finish quality. We have previously developed a tool to perform high fidelity simulations of near-bell atomization with electrohydrodynamic effects. In this work, we perform simulations employed with a droplet ancestry extraction tool to analyze previously inaccessible information and understand the physical processes driving atomization. We find that the electric field accelerates breakup processes and enhances secondary atomization. The total number of droplets, the ratio of secondary to primary droplets, and the ratio of coalescence to breakup activity are all much higher when operating in an electric field. We analyze the droplet velocity, local Weber number and charge density statistics to understand the complex physics in electrically assisted breakup. The results of the study have helped us gain insights into the physics of atomization in electrostatic rotary sprays.
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This content will become publicly available on March 1, 2026
Prediction of the Atomization Process in Respimat® Soft MistTM Inhalers Using a Volume of Fluid-to-Discrete Phase Model
This study investigates the atomization process in Respimat® Soft MistTM Inhalers (SMIs) using a validated Volume of Fluid (VOF)-to-Discrete Phase Model (DPM) to simulate the transition from colliding liquid jets to aerosolized droplets. Key parameters, including colliding jet inlet velocity, surface tension, and liquid viscosity, were systematically varied to analyze their impact on the atomization, i.e., aerosolized droplet size distributions. The VOF-to-DPM simulation results indicate that higher jet inlet velocities enhance ligament fragmentation, producing finer and more uniform droplets while reducing total atomized droplet mass. The relationship between surface tension and atomization performance in colliding jet atomization is not monotonic. Reducing surface tension plays a complex dual role in the atomization process. On the one hand, lower surface tension enhances the likelihood of liquid jet breakup into a liquid sheet, leading to the formation of smaller ligaments under the same airflow conditions and shear forces. This increases the probability of generating more secondary droplets. On the other hand, reduced surface tension also destabilizes the liquid surface shape, decreasing the formation of fine, high-sphericity droplets in regimes where surface tension is a dominant force. Viscosity also influences atomization through complex mechanisms, i.e., lower viscosity reduces resistance to ligament breakup but promotes droplet interactions and coalescence, while higher viscosity suppresses ligament fragmentation, generating larger droplets and reducing atomization efficiency. The validated VOF-to-DPM framework provides critical insights for enhancing the performance and efficiency of inhalation therapies. Future work will incorporate nozzle geometry, jet impingement angles, and surfactant effects to better understand and optimize the atomization process in SMIs, focusing on achieving preferred droplet size distributions and emitted doses for enhanced drug delivery efficiency in human respiratory systems.
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- PAR ID:
- 10587508
- Publisher / Repository:
- MDPI Bioengineering
- Date Published:
- Journal Name:
- Bioengineering
- Volume:
- 12
- Issue:
- 3
- ISSN:
- 2306-5354
- Page Range / eLocation ID:
- 264
- Format(s):
- Medium: X
- Sponsoring Org:
- National Science Foundation
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