To reduce pesticide waste caused by uneven airflow distribution, the geometry parameters of axial air-assisted sprayer deflectors were investigated for potential influence on air outlet velocities. Computational fluid dynamics (CFD) was employed to simulate the complex interactions between the airflow discharged from the air-assisted sprayer and the neighboring environment, investigating the effects of the length and mounting angles of the upper and lower deflectors on the airflow distribution. The validated CFD model was combined with the response surface methodology (RSM) with root mean square error of 1.461 m s−1 and mean relative error of 22.01%, respectively. RSM with four factors and five levels was employed to optimize the geometric parameters of the sprayer deflectors, including upper deflector length, upper deflector mounting angle, lower deflector length and lower deflector mounting angle. Based on the least squares analysis of RSM, the influence of each factor and their interactions on the airflow distribution from the sprayer outlet were estimated. The optimal values of upper deflector length, upper deflector mounting angle, lower deflector length and lower deflector mounting angle were 495 mm, 65°, 205 mm and 15°, respectively. The coefficient of variation (CV) of the air velocities from the optimized sprayer outlet was reduced by 29.95%, indicating an improvement in the uniformity of the airflow distribution and an enhancement in pesticide utilization.
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