Liquid Atomization Processes are complex (Fluid properties, wall-fluid interaction, turbulence, etc.). The challenge here is to design nozzles that produce the right particle size distribution and spray angles as needed by the industrial process. Most design work has shifted from test benches to Simulation tools. The CFD tools use several models to predict the spray characteristics but require correct practice of these tools to predict satisfactory results. 

This Application Best Practice (ABP) will guide you on how to setup a computational model in Ansys Fluent® fluid simulation software, converge it and post process the data. The focus will be on two most common configurations: A liquid jet in cross flow and a pressure swirl nozzle that produces a swirling sheet that breaks up into ligaments and then smaller droplets downstream due to flow instabilities. 

Learning Outcomes:

Following completion of this course, you will be able to:

• Set up high-fidelity liquid atomization simulations in Ansys Fluent software, including CAD preparation, meshing strategy, and turbulence model selection. 
• Apply VOF, DPM, and VOF‑to‑DPM transition models to accurately capture primary breakup, spray formation, and droplet evolution. 
• Implement robust numerics, boundary conditions, and dynamic mesh adaption to ensure stable, converged transient solutions. 
• Analyse spray behavior using in‑situ monitors, animations, DPM sampling, and postprocessing techniques to extract SMD, spray angle, and other key metrics. 
• Optimize computational efficiency by using mesh refinement strategies, load balancing, split‑analysis workflows, and DPM data‑reduction tools. 

Prerequisites:

• Familiarity with interface resolving schemes like the VOF model.
• Post-processing inside the DPM model.
• Ansys Fluent Meshing with Watertight Geometry Workflow
• Ansys Fluent Multiphase Flow Modeling

Please note: These training materials were developed and tested in the 2025R2 release.