Simulation of a metal pellet spraying generator driven by micro-air pressure

Molten metal droplet techniques are one of the important technologies for printing micro-metal parts. At present, the equipment developed for this technology faces some challenges, such as the requirement for a micro-oxygen environment during operation and a complicated manufacturing process. Consequently, a micro-air-pressure driven metal pellet spraying (MPS) 3D printing generator was designed and manufactured using the drop-on-demand technique, which uses simple and low-cost equipment in an atmospheric environment. A 2D axisymmetric model has been proposed to study the mechanism of droplet generation by using a micro-pneumatic MPS generator. In addition, a proprietary pneumatic MPS generator was also used to conduct droplet generation experiments. The validity of the proposed model was verified through the simulation results of the droplet pattern and droplet diameter, which were in good agreement with the experimental ones. The analysis shows that in the droplet injection forming process, surface tension is dominant for low viscosity liquids at a very small Ohnesorge number (Oh < 0.01). The surface tension was conducive to the maintenance of the molten form of the projectile. During droplet injection, the phenomenon of oblate–prolate oscillation occurs due to the non-uniform distribution of pressure inside the droplet. This phenomenon exerts an influence on the accuracy of the droplet flight trajectory and deposition position. This study serves as a good reference for selecting the suitable settings for producing metal droplets using the MPS generator.