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Efficient modelling of complex multi-phase fluid-flows is one of the most common engineering challenges nowadays. The majority of the commonly used CFD solvers are based on Eulerian approaches (grid-based). These methods are, in general, efficient with some drawbacks, e.g. it is necessary to handle additionally the location of the interface or free-surface within computational cells. Very promising alternatives to the Eulerian methods are Lagrangian approaches which, roughly speaking, discretize fluid instead of the domain. One of the most common methods of this kind is the Smoothed Particle Hydrodynamics (SPH) method, a fully Lagrangian, particle-based approach for fluid-flow simulations. One of its main advantages, over the Eulerian techniques, is no need for a numerical grid. Consequently, there is no necessity to handle the interface shape because it is directly obtained from the set of computational particles.

The development of entire car bodies benefits from simulations, especially if they are performed at an early stage of development because they lower the costs for required car body modifications. This paper focuses on a dip paint simulation and describes the simulation process as an e-coat (electric coating) thickness simulation which considers gas bubbles, drainage and buoyancy forces. This paper points out the advantages of this technology by explaining the theory behind this. A new hydrodynamic method is used which performs about 1000 times faster as standard computational fluid dynamics (CFD) solvers. In addition, this method allows executing the computation on standard desktop machines, i.e. no high performance computer (HPC) is needed. In addition we introduce a simple method to calculate the static buoyancy forces of arbitrary homogeneous objects and a simple model movement of an engine hood induced by buoyancy and drag forces.

The development of entire car bodies benefits from simulations, especially if they are performed at an early stage of development. Simulations lower the costs for required car body modifications. This paper focuses on dip painting simulation and describes the simulation process by detecting badly painted areas and liquid carry overs. A new hydrodynamic method has been benchmarked to CFD and real-life results. Results will be shown together with case examples. The solver is similar to, and as accurate as, standard CFD solvers; it is faster in its computation speed by a factor of at least 1000. The electrophoretic deposition (ELPO) of an entire car body can be simulated overnight with ALSIM. How is this possible? This paper points out the reason for all of this.