Mathematical modeling of spray forming process of tubular preforms: Part 1. Shape evolution

A three-dimensional mathematical model, tracing the coordinates of the moving surface of a growing deposit for geometry simulation, is presented in this study. This model may be used to predict the geometry and dimensions of a growing tubular product during spray forming. A back face culling algorithm was incorporated into the model to check the visibility of the surface during deposition. Geometrical evolution of the tubular deposit in spray forming and its circumferential profiles have been investigated. The shape modeling has been validated by different algorithms and experimental investigations as well. Finally, the influence of principal spray forming parameters on the geometry and dimensions of tubular deposits have been studied and discussed. Based on the shape model, a numerical study of the thermal field and properties will be presented in the second part of the publication.