Electrophoreticdeposition (EPD) coating is one of the key processes in automotive manufacturing. Here, car bodies are moved through a tank of paint in which electrically charged paint particles lead to a successive increase of the paint film thickness on the car body. This paint film is used to protect the car body from corrosion. However, in order to properly protect the car body from corrosion, it is required that the whole surface area is covered by a certain paint film thickness. To ensure that, there is a high demand for an accurate simulation tool, which not only avoids the need for expensive prototypes but also allows to detect potential problems in early development stages. To that end, in this work, we are proposing a novel simulation tool based on the finite difference method (FDM). The proposed tool considers exact physics and employs a dedicated overset grid methodology to allow for a high resolution discretization of entire car bodies. Based on this overset grid scheme, the whole domain is modeled in a coarse resolution, whereas the space around the car body is discretized using a high resolution grid. Employing this scheme eventually allows for an accurate and efficient simulation of industrial EPD coating processes. Experimental evaluations based on an analytical analysis and an industrial scenario confirm the accuracy and scalability of the proposed methods.

电泳沉积（EPD）涂层是汽车制造中的关键工艺之一。在此，使车身穿过涂料罐，其中带电的涂料颗粒导致车身上漆膜厚度的连续增加。该漆膜用于保护车身免受腐蚀。但是，为了适当地保护车身不受腐蚀，要求整个表面被一定的涂膜厚度覆盖。为了确保这一点，迫切需要一种精确的仿真工具，该工具不仅可以避免使用昂贵的原型，而且可以在开发的早期阶段发现潜在的问题。为此，在这项工作中，我们提出了一种基于有限差分法的新型仿真工具（FDM）。提出的工具考虑了精确的物理原理，并采用了专用的覆盖网格方法，可以对整个车身进行高分辨率离散化。基于这种过高的网格方案，整个域以粗分辨率建模，而车身周围的空间则使用高分辨率网格离散化。采用这种方案最终可以对工业EPD涂层工艺进行准确而有效的仿真。基于分析分析和工业场景的实验评估证实了所提出方法的准确性和可扩展性。