An overview of liquid spray modeling formed by high-shear nozzle/swirler assembly

A multi-dimensioanl model is being increasingly used to predict the thermo-flow field in the gas turbine combustor. This article addresses an integrated survey of modeling of the liquid spray formation and fuel distribution in gas turbine with high-shear nozzle/swirler assembly. The processes of concern include breakup of a liquid jet injected through a hole type orifice into air stream, spray-wall interaction and spray-film interaction, breakup of liquid sheet into ligaments and droplets, and secondary droplet breakup. Atomization of liquid through hole nozzle is described using a liquid blobs model and hybrid model of Kelvin-Helmholtz wave and Rayleigh-Taylor wave. The high-speed viscous liquid sheet atomization on the pre-filmer is modeled by a linear stability analysis. Spray-wall interaction model and liquid film model over the wall surface are also considered.     

On the breakup mechanisms of air-assisted drops in a high speed air

An experimental study was performed to investigate break-up mechanisms of liquid drops injected into a transverse high velocity air jet. The range of conditions included the three drop breakup regimes previously referred to as bag, shear or boundary layer stripping, and ‘catastrophic’ breakup regimes. The results show that the break-up mechanism consists of a series of processes in which dynamic pressure effects deform the drop into a thin liquid sheet. The flattened drop subsequently breaks up into small droplets. At high relative velocity, in the ‘catastrophic’ breakup regime, drops are flattened and fragmented by relatively large wavelength waves whose wavelengths and growth rates are consistent with estimates from Rayleigh-Taylor instability theory. The minute drops that are also produced at this high relative velocity appear to originate from short wave length of Kelvin-Helmholtz waves growing on the larger liquid fragments.     

Breakup of cavitation bubbles within the diesel droplet

Supercavitation in the diesel nozzle increases the instability of droplets in part due to the two-phase mixture, while the effect of cavitation bubbles on the instability of drops is still unclear. In order to investigate the breakup of cavitation bubbles within the diesel droplet, a new mathematical model describing the disturbance growth rate of the diesel bubble instability is developed. The new mathematical model is applied to predict the effects of fluids viscosity on the stability of cavitation bubbles. The predicted values reveal that the comprehensive effect of fluids viscosity makes cavitation bubbles more stable. Compared with the viscosities of air and cavitation bubble, the diesel droplet＇s viscosity plays a dominant role on the stability of cavitation bubbles. Furthermore, based on the modified bubble breakup criterion, the effects of bubble growth speed, sound speed, droplet viscosity, droplet density, and bubble-droplet radius ratio on the breakup time and the breakup radius of cavitation bubbles are studied respectively. It is found that a bubble with large bubble-droplet radius ratio has the initial condition for breaking easily. For a given bubble-droplet radius ratio （0.2）, as the bubble growth speed increases （from 2 m/s to 60 m/s）, the bubble breakup time decreases（from 3.59 gs to 0.17 ps） rapidly. Both the greater diesel droplet viscosity and the greater diesel droplet density result in the increase of the breakup time. With increasing initial bubble-droplet radius ratio （from 0.2 to 0.8）, the bubble breakup radius decreases （from 8.86 trn to 6.23 tm）. There is a limited breakup radius for a bubble with a certain initial bubble-droplet radius ratio. The mathematical model and the modified bubble breakup criterion are helpful to improve the study on the breakup mechanism of the secondary diesel droplet under the condition of supercavitation.     

Numerical study on bouncing and separation collision between two droplets considering the collision-induced breakup

The main purpose of the present study is to perform numerical study on bouncing and separation collision between two droplets considering the collision-induced breakup. In this study, the collision model proposed in our previous study is used for simulation of collision-induced breakup, and we modify this model to consider the effect of liquid property on the behavior of droplet-droplet collision. This collision model is based on the conservation laws for mass, momentum, and energy between before and after collision and provides several formulae for post-collision characteristics of colliding droplets and satellite droplets. Improving the accuracy of the model, in this study, appreciate criterion for bouncing collision is added and dissipation energy during collision process is newly modeled. To validate the new model, numerical calculations are performed and their results are compared with experimental data published earlier for binary collisions of water, propanol, and tetradecane droplets. It is found from the results that the new model shows good agreement with experimental data for the number of satellite droplets. It can be also shown that the predicted mean diameter by the new model decrease with increasing the Weber number because of the collisioninduced breakup, whereas the O’Rourke model fails to predict the size reduction via the binary droplet collision.     

Spray formation by like-doublet impinging jets in low speed cross-flows

Breakup and spray formation by impinging liquid jets introduced into a low-speed cross-flow are experimentally investigated. Effects of the cross-flows on the macroscopic and microscopic spray parameters are optically measured in terms of jet Weber number and liquid-to-gas momentum ratio. The liquid stream undergoes Rayleigh jet breakup at lower jet Weber numbers and bag/plume breakup at higher momentum ratio through Kelvin-Helmholtz instability. In particular, the first and the second wind breakup occur at an intermediate jet Weber number. At higher jet Weber numbers, the hydrodynamic impact waves commands and the effect of the convective gas flows is insignificant. The breakup length rises in proportion to the jet Weber number, but starts to decrease when the jet Weber number further rises over 1000. The cross-flow promotes the jet breakup and renders a finer spray in an entire range of injection velocities. This paper was recommended for publication in revised form by Associate Editor Gihun Son Woong-Sup Yoon is a Professor in the School of Mechanical Engineering at Yonsei University. His current research interests are in wave instabilities, unusual spray formation, emission control, and propulsion system modeling. He received a BS degree from the Department of Mechanical Engineering, Yonsei University, in 1985; an MS degree from the Department of Mechanical Engineering, University of Missouri-Rolla, in 1989; and a Ph.D degree from the Department of Mechanical and Aerospace Engineering, the Unversity of Alabama in Huntsville, in 1992. Sang-seung Lee received his B.S. degree in Weapons Engineering from Korea Military Academy, Korea, in 2002. He then received his M.S. degrees from Yonsei University, in 2006. Mr. Lee is currently a Lecturer at the School of Weapons Engineering at Korea Military Academy in Seoul, Korea. He serves as an Editor of the Journal of Mechanical Science and Technology. Mr. Lee’s research interests include Ramjet, Atomization of injector. Won-ho Kim received his B.S. degree in Mechanical Engineering from Yonsei University, Korea, in 2003. Mr. Kim has then gone on to do graduate work at the Ph.D in the School of Mechanical Engineering at Yonsei University in Seoul, Korea. Mr. Kim’s research interests include Atomization of 2phase flow and Dust collection efficiency.     

Spray formation by a swirl spray jet in low speed cross-flow

Breakup and spray formation of swirl liquid jets introduced into a low-speed cross-flow are experimentally investigated. Effects of the cross-flows on the macro and microscopic spray parameters are optically measured in terms of jet Weber number and liquid-to-gas momentum ratio. At lower jet Weber numbers, the liquid stream undergoes Rayleigh jet breakup. At higher momentum ratios, bag breakup occurs and tends to distort the liquid column into a loop-like structure. As the jet Weber number rises, stronger aerodynamic interaction and secondary flows cause multi-mode breakup. Regardless of the momentum ratio, the spray profile is hardly altered at higher jet Weber numbers. The cross-flow promotes the jet breakup and renders a finer spray in an entire range of injection velocities.     

Comparison of experimental and predicted atomization characteristics of high-pressure diesel spray under various fuel and ambient temperature

The aim of this study is to investigate the effects of the fuel temperature and the ambient gas temperature on the overall spray characteristics. Also, based on the experimental results, a numerical study is performed at more detailed and critical conditions in a high pressure diesel spray using a computational fluid dynamics (CFD) code (AVL, FIRE ver. 2008). Spray tip penetration and spray cone angle are experimentally measured from spray images obtained using a spray visualization system composed of a high speed camera and fuel supply system. To calculate and predict the high pressure diesel spray behavior and atomization characteristics, a hybrid breakup model combining KH (Kelvin-Helmholtz) and RT (Rayleigh-Taylor) breakup theories is used. It was found that an increase in fuel temperature induces a decrease in spray tip penetration due to a reduction in the spray momentum. The increase of the ambient gas temperature causes the increase of the spray tip penetration, and the reduction of the spray cone angle. In calculation, when the ambient gas temperature increases above the boiling point, the overall SMD shows the increasing trend. Above the boiling temperature, the diesel droplets rapidly evaporate immediately after the injection from calculation results. From results and discussions, the KH-RT hybrid breakup model well describes the effects of the fuel temperature and ambient gas temperature on the overall spray characteristics, although there is a partial difference between the experimental and the calculation results of the spray tip penetration by the secondary breakup model.     

微域保护气对金属微滴喷射过程影响机制研究

金属微滴喷射3D打印过程需在低氧环境(氧含量低于50 ppm)下进行,现有设备常采用带除氧系统的密闭手套箱来维持低氧环境,但因其空间受限,操作不便,很难适应该技术向应用领域拓展。在微滴喷射出口处构建微域低氧环境,既可保护微滴喷射时不被氧化,又能扩大该技术应用范围并提高操作灵活性,是促进金属微滴喷射3D打印技术工程化应用的一个关键。但施加保护气会产生气流扰动,不利于微滴稳定喷射和精确沉积。为解决现有微域保护技术不足,设计开发一种新型环形射流微域保护装置,结合微域保护下的锡合金微滴喷射试验与微域气流流场模拟,揭示氧化和气流动力学对微滴喷射过程作用机制。研究发现当保护气供应不足时,金属射流由于氧化表面张力降低、黏度增大(即Oh数增大),会断裂为带锥形拖尾的单颗熔滴;当保护气供应过大时,气流在射流根部产生二次涡,使射流二次断裂,并生成多颗熔滴。最终在合适参数下打印出较长沉积距离熔合良好、堆叠整齐的锡合金立柱和尺寸均匀、落点准确的凸点阵列,证实环形射流微域保护装置的有效性。研究成果可为金属微滴喷射3D打印技术的推广应用提供关键技术支持和理论基础。     

气动式微滴喷射中液滴稳定生成的动力学特性研究

微滴喷射增材制造技术作为制造领域的新兴前沿技术有着广泛的应用前景,微滴生成特性对增材制造中微滴在基板铺展、搭接、凝固等过程影响较大,研究微滴生成特性对于提高液滴生成尺寸、频率和稳定性有重要意义。通过试验研究气动按需喷射作用下的微滴喷射行为,探究喷嘴尺寸、黏度和供给压力等因素对射流断裂过程及液滴生成稳定性的影响关系,并进一步研究形成角的变化对液桥断裂顺序及卫星液滴产生的影响关系。研究结果表明,随着喷嘴直径减少,韦伯数(We)显著减少,当喷嘴直径减少到100μm时,We变为0.33,液滴尺寸与喷嘴直径的比值急剧增大;随着黏度的增加,射流颈缩段的液桥显著增长,液滴尺寸明显增大。在保证生成单个液滴的压力条件下,当供给压力较小时,液桥两端先后断裂形成卫星滴,并最终与半月面融合;随着压力的增大,液桥只发生一次断裂,剩余射流回缩到喷嘴内。在气动式喷射方式中由于上形成角始终大于下形成角,所以液桥总是在靠近液滴端首先断裂,该研究结果有助于提高气动式微滴喷射装置的液滴生成质量。     

气动式微滴喷射过程仿真与尺寸均匀性试验研究

为使气压驱动式微滴喷射装置能产生均匀的微滴和稳定的喷射过程,使用FLUENT建立了二维轴对称计算模型并对微喷过程进行了模拟仿真。研究了气压驱动式微滴按需产生过程及腔体内压力峰值对单颗微滴成形的影响规律,利用构建的喷射系统对水进行喷射试验,并对产生微滴的均匀性进行了研究。仿真获得了单颗微滴的成形过程并得到了腔体内较低压力峰值有利于提高微喷稳定性的结论。实验结果表明,产生的微滴附着直径最大变化率为1.82%,均匀性较好。     

基于微量润滑磨削的双喷口喷嘴雾化仿真分析

为了减小磨削时砂轮表面气障层的影响,提高磨削液润滑和冷却的效果,设计了一种双喷口结构的喷嘴。分析了微量润滑雾化机理,采用二级雾化理论建立了雾化数学模型,对双喷口喷嘴的雾化过程进行了仿真分析,并对仿真结果进行了验证。研究结果表明：双喷口喷嘴能有效减小雾滴直径,提高磨削液的雾化效果;辅助喷口雾滴可以扰乱砂轮表面的空气环流,减小气障层对主喷口雾滴流向的影响,促使主喷口喷出的雾滴能顺利进入磨削区。     

液滴撞击多孔表面动力学特性研究进展

液滴与多孔表面碰撞时，多孔表面的孔隙所引起的毛细力作用将对液滴的动力学行为产生一定的影响。研究液滴撞击多孔表面后的铺展、渗透、蒸发、传热等问题对调控多孔表面液滴的铺展以满足不同领域的应用需求具有重要的意义。总结归纳了液滴撞击多孔表面的理论、数值和实验方面的研究方法，对液滴撞击速度、液滴直径、孔隙率、孔径、韦伯数、黏度和表面张力等主要因素对液滴撞击动力学特性的影响规律进行综述，提出液滴在多孔表面的研究可从更加符合液滴撞击多孔介质的理论模型建立，新型多孔介质内部液滴特性及热物理参数测试技术等方面进行。     

Numerical study of droplet breakup and merging in a microfluidic channel

Droplet breakup and merging in a microfluidic channel, which are applied to lab-on-a-chip devices for biomedical testing and synthesis, are simulated numerically by solving the conservation equations of mass and momentum. The droplet surface is computed using the volume-of-fluid method of the commercial code FLUENT. The numerical simulation demonstrates that the variation of obstacle geometry in a microchannel determines the droplet breakup pattern and the volume fraction of split droplets. The computation also shows that droplet merging depends on the channel-chamber width ratio. The effect of microchannel and obstacle configuration on the droplet motion is investigated to find the optimal conditions for droplet breakup and merging.     

Four degree of freedom liquid dispenser for direct write capillary self-assembly with sub-nanoliter precision

Capillary forces provide a ubiquitous means of organizing micro- and nanoscale structures on substrates. In order to investigate the mechanism of capillary self-assembly and to fabricate complex ordered structures, precise control of the meniscus shape is needed. We present a precision instrument that enables deposition of liquid droplets spanning from 2 nl to 300 μl, in concert with mechanical manipulation of the liquid-substrate interface with four degrees of freedom. The substrate has sub-100 nm positioning resolution in three axes of translation, and its temperature is controlled using thermoelectric modules. The capillary tip can rotate about the vertical axis while simultaneously dispensing liquid onto the substrate. Liquid is displaced using a custom bidirectional diaphragm pump, in which an elastic membrane is hydraulically actuated by a stainless steel syringe. The syringe is driven by a piezoelectric actuator, enabling nanoliter volume and rate control. A quantitative model of the liquid dispenser is verified experimentally, and suggests that compressibility in the hydraulic line deamplifies the syringe stroke, enabling sub-nanoliter resolution control of liquid displacement at the capillary tip. We use this system to contact-print water and oil droplets by mechanical manipulation of a liquid bridge between the capillary and the substrate. Finally, we study the effect of droplet volume and substrate temperature on the evaporative self-assembly of monodisperse polymer microspheres from sessile droplets, and demonstrate the formation of 3D chiral assemblies of micro-rods by rotation of the capillary tip during evaporative assembly.     

MODELING OF A SOLID CONE PRESSURE-SWIRL ATOMIZER

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均匀液滴喷射过程仿真与试验研究

针对液滴喷射增材制造试验参数调整困难、实施难度较大的现存问题,基于流体体积(Volume of fluid,VOF)两相流模型,建立均匀液滴喷射过程流场的计算模型。采用数值模拟的方法,对液滴喷射过程中的液滴流形态、压力场和速度场及其影响因素进行了研究,揭示了形成均匀液滴流的内在变化规律,得到了均匀液滴喷射过程的最优频率。在模拟结果的基础上,建立了液滴喷射装置并配置了相应的高速拍照系统,对射流断裂形态、喷射过程、喷射速度进行了试验研究。结果表明,射流速度主要取决于喷射压强,液滴流均匀性主要取决于扰动频率和扰动振幅,射流的压力场则呈周期性变化。模拟结果与试验结果吻合较好,说明所提出的建模方法是可行的,为不同情况下射流内部流场的计算提供了实用的方法,也为液滴喷射增材制造技术的应用奠定了理论基础。     

Generation of Janus droplets for enhanced mixing in microfluidics

microfluidic channel system to generate Janus droplets is designed and fabricated, where the term Janus droplet refers to a chemically biphasic droplet. It is demonstrated that Janus droplets are formed from elongational breakup of coflowing core fluids which are constrained by a sheath fluid on both sides of them. Rhodamine B is adopted as an indicator to indentify generated Janus droplets. Monodisperse Janus droplets have been generated in a controllable manner such that those with average diameters of 26 ± 1.24 μm, 31 ± 1.44 μm and 34 ± 2.28 μm are formed in accordance with flow rate ratios between the sheath fluid and the core fluids, 30.7, 36.4 and 44.4, respectively. Generation of Janus droplets, demonstrated in the present study, has seen a new application in the areas of biotechnology and bioengineering, where enhanced mixing inside the micro bubbles can be utilized without the aid of other means of droplet generation and merging.     

Investigation of design parameters for droplet generators driven by piezoelectric actuators

This paper presents a numerical analysis of a drop-on-demand (DOD) piezoelectric (PZT) actuated droplet generator. A finite difference numerical model was established to analyze the design parameters of droplet ejection. First, we discussed the influence of the driving conditions on the droplet ejection characteristics, such as the driving time and the driving volume change in the pressure chamber. The volume factor, an important design parameter, was proposed from the analysis. The ejected droplets can maintain the same ejection velocity at different nozzle diameters, as long as the volume factor remains the same. Two empirical formulas, based on the analysis data, are suitable for the design of PZT actuated droplet generator. The first empirical formula is a linear relationship between the droplet velocity and the volume factor with a slope of 0.3422 for different nozzle diameters. The second empirical formula defines the driving volume of PZT and nozzle diameter to eject the desired droplets. The geometrical design parameters of droplet generator, such as the nozzle thickness, the pressure chamber width and depth, as well as the driving conditions of the PZT actuator, are all included in the analysis. The sensitivity of geometrical design parameters which affect the droplet volume, the droplet velocity, and the lowest driving condition is established. The quantitative criterion for ejection of droplet, liquid jet, and no droplet is presented. The proposed empirical formula and figures provide easy-to-use tool for design of DOD PZT actuated droplet generators.     

Improvements on a laser scattering technique for droplet size measurements applied to a gas-liquid separation equipment

The knowledge of droplet size distributions in a gas-liquid separation equipment is of high relevance due to the importance of removal efficiency in these systems. Different techniques could be used to measure droplet size, being one of them the diffraction of a laser beam. The laser is located behind glasses, being the formation of droplets on the glasses one of the main problems encountered when using this technique.Due to this major problem, different innovative solutions have been proposed and implemented to the gas-liquid separation column in order to obtain satisfactory results. A shutter mechanism, a purge gas and combination of these two solutions were tested. It was shown that the modified technique is suitable for liquid droplet measurements under ambient conditions.It has been also shown that the combination of these two solutions reduced considerably the amount of droplets that interacts with the glasses, allowing getting better data.     

A proposal for diesel spray model using a TAB breakup model and discrete vortex method

A hybrid model consisting of a modified TAB (Taylor Analogy Breakup) model and DVM (Discrete Vortex Method) is proposed for numerical analysis of the evaporating spray phenomena in diesel engines. The simulation process of the hybrid model is divided into three steps. First, the droplet breakup of injected fuel is analyzed by using the modified TAB model. Second, spray evaporation is calculated based on the theory of Siebers’ liquid length. The liquid length analysis of injected fuel is used to integrate the modified TAB model and DVM. Lastly, both ambient gas flow and inner vortex flow of injected fuel are analyzed by using DVM. An experiment with an evaporative free spray at the early stage of its injection was conducted under in-cylinder like conditions to examine an accuracy of the present hybrid model. The calculated results of the gas jet flow by DVM agree well with the experimental results. The calculated and experimental results all confirm that the ambient gas flow dominates the downstream diesel spray flow.