微注塑成型充模流动中的表面张力EI北大核心

微尺度通道中的高聚物熔体流动行为与宏观熔体流动有许多不同。基于对微注塑成型中的熔体充模流动特性的理论分析,建立了微小通道中熔体流动的表面张力模型,并以不同的表面张力系数和不同接触角,对矩形微通道中的熔体流动速度分布进行了数值模拟。结果表明,接触角小于90°时,熔体在通道壁面附近具有最大速度;接触角大于90°时,熔体在壁面处具有最大速度。无表面张力时,熔体填充流动所需时间明显长于有表面张力时的填充时间,即表面张力对微小通道中的熔体流动具有促进作用。     

微注塑成型流动中熔体壁面滑移的研究

基于宏观熔体流动的基本理论及其流动过程中壁面滑移机理的分析,针对微注塑成型模具中熔体充模流动时的壁面滑移行为,建立了微小通道中高聚物熔体流动的壁面滑移理论模型。并用数值模拟方法,对不同滑移系数时微小通道中熔体的壁面滑移对流动速度、熔体压力等的影响进行了研究。结果表明,微小通道中的壁面滑移可使壁面处熔体的流动速度增加,压力损失减小,有利于熔体的充模流动。     

基于压力法的微通道表面润湿性调控技术

利用激光加工和自组装分子膜技术制备具有不同润湿性的微通道壁面,将其中具有微通孔的壁面粘接到带有气体容腔的调控通道内,通过调节气体容腔压力控制壁面处的气液接触状态,从而改变壁面的润湿性,利用动态接触角比值对壁面的润湿性进行表征,并结合数值计算方法对壁面润湿性调控机理进行了分析.结果表明,基于压力法能够快速改变壁面处气液接触状态,实现润湿性的有效调控,静态接触角为122°和131°的壁面的实际润湿性实现了强疏水和弱疏水之间的可逆调控,静态接触角为143°和155°的壁面实现了超疏水和疏水之间的可逆调控,调控效果明显,重复性好.     

液氦温区微小漏孔流动特性研究

低温环境下系统器件的密封性能至关重要,对于低温密封研究,了解低温下微小漏孔泄漏的流动特性很有必要。本文构建了具有随机粗糙度壁面的二维微通道,应用仿真软件研究液氦温区漏孔微通道内气流的流动特性,计算分析通道内各物理量的分布和变化。结果表明随机粗糙度壁面对速度分布的扰动在近壁面影响最大,随着远离壁面的方向减小,对中心区域流动几乎无影响;低温导致氦气粘滞系数下降,微通道内气体流速增加;压力分布也因通道特征尺寸变化而发生波动;液氦温区漏孔的质量流量比常温下大两个数量级,并且当进出口压力比超过临界值后漏孔质量流量不再变化。对于低温系统的漏率预测、泄漏预防和低温检漏、密封研究具有理论意义和实用价值。     

微尺度效应对聚合物熔体壁面滑移影响的研究

在分析聚合物熔体的壁面滑移机理和微通道中尺度效应对壁面滑移的影响基础上,通过对Hatzikiriakos所建壁面滑移模型滑移系数的修正,建立了微通道的壁面滑移模型.采用修正前和修正后壁面滑移模型,通过数值模拟,计算出了直径为0.5mm的微通道中在不同剪切速率下的滑移速度和压力降.对比计算结果,修正后的滑移模型计算出的滑移速度减小了,而压力降增加了.通过与试验测得的压力降对比,根据修正后的壁面滑移模型计算出的压力降更接近试验值.     

纵向超声波辅助微注塑方法

微注塑过程中,聚合物熔体在微小腔体中流动时充模阻力比常规注塑大,这影响了熔体填充效果,同时热量损失的不均衡性和不确定性容易导致注塑精度不高．提出了纵向超声波辅助微注塑方法,并对超声波振动对聚合物熔体的作用机理进行了探讨,分析了超声换能器结构对应力、振幅和响应频率的影响．基于对微注塑过程的模拟结果,开发了纵向超声波辅助微注塑装置．通过在微注塑过程中纵向超声波对熔体的能量作用降低熔体黏度,改善了熔体流动和充填性能．为了验证超声波辅助微注塑的效果,进行了菲涅尔透镜实际注塑实验．实验结果表明,相同的注塑工艺条件下,超声辅助微注塑过程中聚合物熔体的充填性能提高了6．91％．     

微注塑充模流动中的粘性耗散效应

微注塑成型中的粘性耗散效应引起的熔体充模流动行为变化,直接影响微塑件的成型质量。应用双料筒毛细管流变仪与微尺度口模和高精度温度传感器等组成的测量装置,对丙烯腈-丁二烯-苯乙烯共聚物(ABS)熔体以不同剪切速率和口模入口温度,流经直径350μm和500μm而长径比不同口模时的粘性耗散效应进行了实验测量和数值模拟。结果表明,微通道中的熔体粘性耗散效应随剪切速率的增加而明显增强,随通道直径的减小和入口熔体温度的升高而减弱;但通道直径一定时,长径比的增大也会导致粘性耗散作用增强。     

箭型排布矩形微槽平板表面降膜流动换热特性

基于VOF(Volume of Fluid)算法,采用Fluent软件建立箭型排布的矩形微槽平板表面的液膜流动换热模型,考虑表面张力和固液接触角对液膜流动的影响,计算分析不同雷诺数下不同角度的箭型微槽平板与光板表面的液膜换热特性。计算结果表明:箭型微槽可以增强平板表面的降膜换热效果;换热效果最好的是60°箭型结构,其平板表面局部Nu是光板表面的1.1倍;雷诺数为5 000时,60°箭型结构无量纲出口温度是光板的1.6倍。     

纳米尺度通道中气体粘度的分子动力学模拟

利用非平衡分子动力学方法模拟了气体在纳米尺度通道中的运动特性,统计获得通道中流动的速度剖面和剪切应力分布,并利用牛顿粘性定律首次获得了纳米尺度通道中的等效粘度分布。结果表明,纳米尺度通道中的粘度不是一个常数。在壁面附近,由于壁面原子和气体分子的相互作用,存在壁面效应,气体的粘度较小;而通道中心区域的粘度与实验结果符合较好,壁面对粘度的影响范围为20 nm左右。通道高度对中心区域粘度的影响很小,而温度对其的影响较大,粘度值随温度的增加而增大。不同通道高度下,壁面附近粘度的分布几乎一致;不同温度时,壁面附近粘度的分布随温度的增加而增加。     

微液滴铺展动力学模型及实验验证

为了研究壁面的润湿动力学行为,通过对离散化的液膜进行力学平衡方程推导,提出了一种液滴沿壁面铺展的动力学模型;模型以加速度方程表示铺展的动态变化,避免从能量角度计算复杂性的问题;利用动态接触角分析仪进行润湿实验,比较数值计算与实验结果。计算结果表明:得到的接触角随时间呈指数规律变化;液滴表面张力越小液膜越容易铺展,且所需的铺展时间越短;液滴度对铺展起阻碍作用,且缩短铺展时间;接触角动态变化规律整体一致,标准偏差在1.5°以内,说明本模型能够准确地反映液滴铺展的动态过程。     

铝及其合金熔体的增黏及泡沫化特性

研究了纯铝、普通铝硅合金和新型多组元铝合金的增黏和泡沫化特性．这三者加入Ca增黏后的物相组成和发泡后的气泡壁微观组织以及三者熔体的表面张力．结果表明：Ca加入后，经过搅拌形成的大量弥散分布的细小Al-Ca中间化合物颗粒快速增加了纯铝以及新型多组元铝合金熔体的黏度，而Ca加入普通铝硅合金中与Si等元素形成较大的颗粒，因而增黏效果不如前两者；Ca的加入也显著降低新型多组元铝合金和纯铝熔体的表面张力，普通铝硅合金降低不多；在相同的表观黏度下，表面张力的差异是引起纯铝．普通铝硅合金、新型多组元铝合金等三种熔体泡沫化特性差异的主要原因．     

A multiphase Eulerian approach for modelling the polymer injection into a textured mould

Micro-injection moulding is frequently used for the fabrication of devices in many different fields such as micro-medical technologies, micro-optics and micro-mechanics thanks to its effectiveness for mass production. This work focuses mainly on offering numerical methodology to model the injection into textured moulds. Such approach can predict the different filling scenarios of the micro-details and consequently can provide optimal operating conditions (mould and melt temperatures, flow rate) according to the desired final part quality. In fact, numerical simulations made with industrial software can only describe the injection process at the macroscopic scale where the micro details are not detected. Although the melt temperature and front evolution are tracked throughout time, neither the micro details nor the local heat transfer are properly represented. Since the latter impacts the local viscosity and solidification, simulation of both mould and cavity temperature evolutions is primordial to insure a complete and accurate representation of textured mould filling. The present computations are made at both macro- and micro- scales by using a full Eulerian approach in which the three phases (melt, mould and air) are described by level-set functions. Our numerical approach is checked to the replication of a textured mould for which two dimensional computations are relevant. This replication is properly modelled by taking into account viscosity dependence with temperature in the thermal boundary layer at the melt/mould interface. In particular the expected solidification below a specific temperature is taken into account by either increasing drastically the viscosity or by imposing a vanishing velocity by penalty method. The influence of flow rate and mould temperature are also analysed whereas it is shown that the surface tension can be neglected during injection stage.     

Numerical Simulation of Taylor Bubble Formation in Micro-channel by MPS Method

Moving Particle Semi-implicit (MPS) method uses particles and their interactions to simulate incompressible flow and it is a promising meshless method for multiphase flow simulation. In order to simulate the micro-bubble generation in micro-channel, surface tension model in MPS is improved by introducing fourth order central difference scheme for the calculation of unit normal vector. Numerical results for the oscillation of macro and micro droplets are in good agreement with theoretical prediction, which confirmed the validation of our model. By introducing the improved surface tension model into MPS method, the micro-bubble generation in T-shaped micro-channel was simulated successfully. The reasonable agreement between numerical simulations with visualization experiment confirmed the capacity of MPS with the improved surface tension model for the microgravity or micro-scale two-phase flow, which is dominated by surface tension effect. Finally, micro-bubble generations in different micro-channels are simulated. It is found that bubble size will decrease with increasing liquid flow rate and increase with increasing gas flow rate. Compared with 45° bifurcation micro-channel, T-shaped micro-channel can generate bubble smaller and faster.     

Inhibition of the surface levelling of thermosetting polyester powder coatings caused by surface tension gradients

Previous theoretical and experimental work has shown that surface tension gradients in liquid layers create surface defects and inhibit the levelling of an uneven surface. In coatings deposited from thermosetting polyester powders, which are studied here, small amounts of a low molecular-weight acrylate are incorporated to act as a flow agent. We find that this additive lowers the surface tension of the polymer melt and has a minor effect on the melt viscosity. A slower rate of levelling results from the decreased surface tension. We provide experimental evidence that lateral gradients in the surface tension of the polymer melt, resulting from the non-uniform distribution of the flow agent, inhibit the levelling of the surface. Specifically, the surface roughness of a powder coating is up to three times greater when a steep surface tension gradient is purposely created through powder blending. Surface tension gradients might also be responsible for the greater surface roughness (observed with atomic force microscopy on lateral length scales of 100 m) that is found in coatings that contain flow agent.     

流动聚焦微气泡流型分布及控制参数实验

介绍了一种基于毛细管流动聚焦方法制备微纳米量级气泡的流动聚焦微流控芯片．以水和空气为工质,在一定的压力和流量下,利用高速摄影技术研究微气泡的尺寸、发生频率和形成过程．分析了表面张力、气体压力、液体流量等参数对微气泡直径和发生频率的影响．实验结果表明,该微流控芯片可以稳定产生直径微米量级的微气泡,操作简单,在微反应器和生物、医药等领域有良好的应用前景．     

高温氧化物熔体中表面张力对流效应研究实验

利用高温实时光学观察方法,实时地观察了高温氧化物熔体中的表面张力对流效应．稳态的热毛细对流流线呈轴对称形式,非稳态的热毛细涡流运动伴随熔液温度呈周期性变化,同时还观察到另一种由熔体自由表面的弯月面曲率的变化引起的非稳态的热毛细对流现象．最后测定了相对熔液温度下非稳态热毛细对流的振荡频率．     

Meshfree particle simulation of micro channel flows with surface tension

This paper presents a study of micro channel flows using a meshfree particle approach. The approach is based on smoothed particle hydrodynamics (SPH) and its variant, adaptive smoothed particle hydrodynamics (ASPH). The incompressible flow in the micro channels is modeled as an artificially compressible flow. The surface tension is incorporated into the equations of motion. The classic Poiseuille flow and a practical micro channel flow problem of flip-chip underfill encapsulation process are investigated. It is found that the adaptive kernel can well match the computational geometry with long channels and can greatly save computational time. The simulation results are in close agreement with the analytical solutions.     

Deciphering the flow structure of Czochralski melt using Partially Averaged Navier–Stokes (PANS) method

Czochralski melt flow is an outcome of complex interactions of centrifugal, buoyancy, coriolis and surface tension forces, which act at different length and time scales. As a consequence, the characteristic flow structures that develop in the melt are delineated in terms of recirculating flow cells typical of rotating Bénard–Marangoni convection. In the present study, Partially Averaged Navier–Stokes (PANS) method is used for the first time to study an idealized Czochralski crystal growth set-up. It is observed that with a reduction in the PANS filter width, more turbulent scales are resolved and the present PANS model is able to resolve almost all the characteristic flow structures in the Czochralski flow at a comparatively lower computational cost compared with more advanced turbulence modelling tools, such as Direct Numerical Simulation (DNS) and Large Eddy Simulation (LES).     

多晶硅真空定向凝固过程Marangoni对流对铸锭质量的影响研究

对于多晶硅垂直布里奇曼真空定向凝固过程,熔体自由表面张力引起的Marangoni对流对晶体生长质量有着明显的影响。本文通过建立多晶硅真空定向凝固过程的热场-流场-应力场多场耦合数学物理模型,采用数值模拟和实验研究了Marangoni对流作用下熔体传热特性、熔体流动行为、铸锭热应力等因素对硅晶体生长质量的影响。结果表明：Marangoni对流会增强硅熔体流场的流动强度,使得硅熔体平均流速增大3倍左右,进而影响硅熔体内部的对流换热能力,使硅熔体和硅固体温度分布更加均匀,硅熔体温度梯度降低4.8%-9.9%,硅固体温度梯度降低2.1%-2.6%,使多晶硅铸锭过程产生更小的热应力和更少缺陷。