Optimization of Sandblasting Gun

Abstract

The use of CFD and optimization cycles is becoming fundamental for saving time and reducing design costs in industrial applications where fluid dynamics plays a critical role. This work presents a CFD-based optimization methodology for sandblasting gun geometry, aimed at maximizing output velocity and media supply rate.

The optimization strategy employed a two-phase approach. First, a preliminary validation of the numerical method was performed against experimental tests on the reference configuration, achieving satisfying agreement. The optimization cycle was then executed considering only the air flow, with the best configurations subsequently verified through Discrete Element Method (DEM) simulations including material injection.

The gun geometry was parameterized using 21 design variables. The optimization workflow integrated modeFRONTIER as the optimization platform, Matlab for workflow management, CATIA V5 for parametric CAD modeling, and StarCCM+ for CFD simulations. The dual objectives were to maximize both the output velocity and the mass flow rate of the media supply tube.

The optimization process explored 4,364 geometric configurations, of which 1,421 were valid and 1,274 showed improvement over the reference design. The three best configurations—optimized for highest output velocity, highest sand supply, and best compromise between both parameters—were validated through complete DEM simulations, confirming the effectiveness of the optimization approach.