Numerical modeling and experimental measurements of water spray impact and transport over a cylinder

This study compares experimental measurements and numerical simulations of liquid droplets over heated (to a near surface temperature of 423 K) and unheated cylinders. The numerical model is based on an unsteady Reynolds-averaged Navier–Stokes (RANS) formulation using a stochastic separated flow (SSF) approach for the droplets that includes submodels for droplet dispersion, heat and mass transfer, and impact on a solid surface. The details of the droplet impact model are presented and the model is used to simulate water spray impingement on a cylinder. Computational results are compared with experimental measurements using phase Doppler interferometry (PDI). Overall, good agreement is observed between predictions and experimental measurements of droplet mean size and velocity downstream of the cylinder.     

Numerical analysis of secondary droplets characteristics due to drop impacting on 3D cylinders considering dynamic contact angle

This study is investigating three-dimensional numerical simulation of a Newtonian droplet impact and break on two square cylinders based on dynamic contact angle of droplet at the spatial interface between two solid–fluid phases. The droplet impact details and morphology studied in the present work could provide ideas for the spray wall impingement modeling in the simulation of many industrial applications, such as spray painting and liquid cooling of surfaces. The droplet impact is investigated on two square cylinders in 9 different modes with different droplet diameters and physical conditions such as different positions of droplet. The volume of fluid (VOF) method was used with open-source software. The results have been compared and validated quantitatively and qualitatively with the experimental results. Results represent droplet diameter into cylinder dimension and velocity profiles are affected on number of broken droplets, break times and droplet deformation. Also, mean velocities of droplet after impact on two square cylinders at first break time were 0, 0.025, 0.12, 0.47, 0.11, 0.08, 0.2, 0.012, 0.19 m/s for cases 1–9, respectively. Moreover, in case 7 that droplet diameter into cylinder dimension was 2, the maximum number of break-up into secondary droplets was 10 drops that occurred for 4 times.

     

Experimental study of the flow regimes resulting from the impact of an intermittent gasoline spray

The present paper reports a complete set of measurements made with a two-component phase Doppler anemometer of the two-phase flow generated at the impact of a transient gasoline spray onto a flat surface. The spray is generated by a pintle injector and the fuel used was gasoline. The measurements of droplet size–velocity were processed to provide time fluxes of number, mass, normal momentum, and energy of the poly-dispersion of droplets ejected at impact, and analyzed based on predictive tools available in the literature. The results show that splash is the dominant mechanism by which secondary droplets are ejected from the surface, either in the stagnation region or in the core region of the spray. In the stagnation region, a large fraction of each incident droplet adheres to the surface and the axial incident momentum contributes with a larger parcel than tangential momentum. As a result, the normal velocity of ejected droplets is much smaller than that of the original incident droplets, while tangential velocity is enhanced. The region near the stagnation point is immediately flooded upon impact of the leading front of the spray, forming a liquid film that is forced to move radially outwards as droplets continue to impinge during the steady period. Spray/wall interaction in the core region thus occurs in the presence of a moving thin liquid film, which enhances transfer of tangential momentum. As a result, film spreading and dynamics as a result of impingement forces are crucial to accurate model spray/wall interaction. The outer region of the spray is dominated by the vortical structure induced by shear forces, which entrains small responsive secondary droplets to re-impinge. Furthermore, prediction of the outcome of spray impact requires a precise knowledge of the two-phase flow in the presence of the target.     

Acetone Droplet Behavior in Reacting and Non Reacting Turbulent Flow

Acetone droplet characteristics in reacting and non-reacting turbulent flow are predicted and compared to experimental data. Investigations are conducted to study the effects of surrounding environment properties on the velocities, dispersion, and evaporation of a relatively volatile spray fuel that featured a wide range of Stokes numbers. The simulations are performed in the framework of Reynolds Averaged Navier Stokes equations along with the Eulerian-Lagrangian approach in which 12 different classes of the dispersed phase. The phase transition is modeled by the Langmuir-Knudsen law that accounts for non equilibrium effects based on a consistent determination of the molar mass fraction on the droplet surfaces. For the droplet dispersion, the Markov sequence model is improved by adding a correction drift term to the fluid fluctuation velocity at the parcel position along the droplet trajectory. This correction term aimed at accounting for the non-homogeneity effects in the turbulent flow. The combustion is captured using the Bray-Moss-Libby model that is extended to account for the partially premixed spray combustion. The chemistry is described with the flamelet model using a recent detailed reaction mechanism that involves 84 species and 409 reactions for which the Lewis number is not set to the unity. Mean droplet velocities for reacting and non-reacting test cases are compared with experimental data. Good agreement is observed. The spray is interacting with the nozzle edge developing new classes and relatively dense region. Hence the RMS-velocities close to the nozzle exit plan demonstrate discrepancies. The droplets group combustion effect is found to be important in the modeling of the burning velocity which influences the flame propagation. Reasonable agreements between the numerical and the experimental results are also observed in the spray flux and temperature profiles.     

Secondary atomization of water and isooctane drops impinging on tilted heated surfaces

The present paper reports an experimental study aimed at characterizing the effects of heat transfer on the secondary atomization, which occurs during droplet impact on hot surfaces at conditions reproducing those occurring at fuel injection in internal combustion engines. The experiments consider single isooctane and water droplets impacting at different angles on a stainless steel surface with known roughness and encompass a range of Weber numbers from 240 to 600 and heat transfer regimes from the film-vaporization up to the Leidenfrost regime. The mechanisms of secondary breakup are inferred from the temporal evolution of the morphology of the impact imaged with a CCD camera, together with instantaneous measurements of droplet size and velocity. The combination of a technique for image processing with a phase Doppler instrument allows evaluating extended size distributions from 5.5 μm up to a few millimetres and to cover the full range of secondary droplet sizes observed at all heat transfer regimes and impaction angles. Temporal evolution of the size and velocity distributions are then determined. The experiments are reported at impact conditions at which disintegration does not occur at ambient temperature. So, any alteration observed in droplet impact behavior is thermally induced. The analysis is relevant for port fuel injection systems, where droplets injected to impact on the back surface of the valves, behave differently depending on fuel properties, particularly when the use of alcohols is considered, even as an additive to gasoline.     

Atomized non-equilibrium two-phase flow in mesochannels: Momentum analysis

Two-phase pressure drop measurements are very difficult to make while the fluid is in non-equilibrium condition, i.e. while phase change is taking place. This is further complicated when an atomized liquid is introduced in the system at much higher velocity than other components such as liquid layer, vapor core, and entrained droplets. The purpose of this paper is to develop a model to predict the two-phase pressure characteristics in a mesochannel under various heat flux and liquid atomization conditions. This model includes the momentum effects of liquid droplets from entrainment and atomization. To verify the model, an in-house experimental setup consisting of a series of converging mesochannels, an atomization facility and a heat source was developed. The two-phase pressure of boiling PF5050 was measured along the wall of a mesochannel. The one-dimensional model shows good agreement with the experimental data. The effects of channel wall angle, droplet velocity and spray mass fraction on two-phase pressure characteristics are predicted. Numerical results show that an optimal spray cooling unit can be designed by optimizing channel wall angle and droplet velocity.     

A STUDY ON DROPLET VELOCITY OF ETHANOL DURING ELECTROSPRAYING PROCESS AT CONE-JET MODE

研究液滴在静电喷雾下的速度特性是理解喷雾形态的形成及演化的关键.结合锥射流模式下乙醇静电喷雾实验数据,建立了静电喷雾二维轴对称模型.基于离散相液滴运动方程、连续相空气运动方程、电场方程以及用户自定义函数,进行了数值求解,获得了锥射流模式下的乙醇静电喷雾形态、空间电场分布以及液滴速度场分布.考虑了不同空气入口流速的影响,得到了乙醇/空气同轴射流静电喷雾形态的变化规律.结果表明,喷雾外围液滴与空气流场有较强的相互作用,导致喷雾中轴线附近的液滴速度分布变化较小,而在喷雾外围处的液滴速度分布沿径向剧烈变化;随着空气入口速度的增大,乙醇/空气同轴射流静电喷雾形态先趋于发散,当空气入口速度大于喷雾外围液滴轴向速度时,喷雾形态则趋于聚拢.因此,除改变施加电压、液体流量和电极结构外,通过控制空气入口速度来影响喷雾液滴速度场,也可获得不同的静电喷雾效果.     

A two-dimensional splashing model for investigating impingement characteristics of supercooled large droplets

In this article, a two-dimensional (2D) splashing model is proposed to investigate the dynamics when supercooled large droplets (SLD) impinging on a wall surface in the aircraft-icing field. Energy conservation for droplet motion and impingement is used to capture the properties of the splashed droplets. A new statistical treatment of the droplet impinging energy and angle during the droplet-wall interaction is introduced in order to calculate the average dynamics of the SLD within a micro-control volume on wall surface. Based on the LEWICE predictions of droplet collection efficiencies and the available experimental ones, a new criterion for droplet splashing/deposition as well as a new formulation for the splashed mass is suggested. Lagrangian approach is adopted to describe the movement and impingement of SLD. The proposed model together with the previously developed droplet tracking method (DTM) for calculating droplet collection efficiency with the effect of droplet reimpingement constitute a relatively complete predicting approach of SLD impingement characteristics. Comparisons between the current predictions and the experimental observations, including SLD impingement over clean and contaminated airfoil surfaces as well as shapes of ice accretion in typical icing conditions, are carried out. Further, results obtained with the LEWICE splashing model are also plotted on the same graphs in order to assess the accuracy of the current splashing model in predicting SLD impingement. Results show that good agreement is achieved between the current predictions, including SLD impingement and ice accretion shapes, and the experimental ones. The predictions of the impingement distribution over contaminated surfaces obtained with the current splashing model show a much closer agreement with the experimental results than the ones obtained with LEWICE splashing model. For further investigation of SLD impingement, the properties of the droplet splashing and reimpingement during the ice accretion process are also addressed.     

Effects of gas and droplet characteristics on drop-drop collision outcome regimes

Droplet-droplet collisions occur in many spray systems. The collision of two spherical droplets in a gas is considered in terms of the five primary phenomenological outcomes: slow coalescence (SC), bounce (B), fast coalescence (FC), reflexive separation (RS), and stretching separation (SS). The boundaries that separate these outcomes were investigated herein in terms of droplet viscosity and surface tension as well as gas pressure and density. Gas effects are not accounted for previous models, but can be important for hydrocarbon drops in pressurized sprays associated with many fuel systems. Based on a comprehensive review of available drop-drop collision data, phenomenological models were proposed herein for a wide variety of test conditions. For slow coalescence/bouncing (SC/B), increasing droplet viscosity and gas pressure were found to increase the probability of a bouncing outcome of the collision. For the B/FC boundary, increasing droplet viscosity and gas density were also found to increase bouncing probability. In both cases, the variations can be explained in terms of the stability of the gas layer that develops between the droplets. Additionally, the Brazier-Smith model for the FC/SS boundary was modified to increase robustness for a wide range of droplet viscosities. In general, the present models reasonably predicted collision outcomes for a large variety of gas pressures and densities as well as droplet viscosities and surface tensions. These are also the first models to include gas effects and the first models of the SC/B boundary. However, the droplet diameters of the data set were limited in range from 200 to 400 microns. Significantly larger droplet collisions may include effects on initial non-sphericity while significantly smaller drop collisions may include effects on non-continuum flow and gas viscosity.     

Modelling impingement of hollow metal droplets onto a flat surface

Despite many theoretical and experimental works dealing with the impact of dense melt droplets on the substrate during the process of thermal spray coating, the dynamics of the impingement of hollow melt droplet and the subsequent splat formation are not well addressed. In this paper a model study for the dynamic impingement of hollow droplet is presented. The hollow droplet is modelled such that it consists of a liquid shell enclosing a gas cavity. The impingement model considers the transient flow dynamics during impact, spreading and solidification of the droplet using the volume of fluid surface tracking method (VOF) coupled with a solidification model within a one-domain continuum formulation. The results for spreading, solidification and formation of splats clearly show that the impingement process of hollow droplet is distinctly different from the dense droplet. Study with different droplet void fractions and void distribution indicates that void fraction and void distribution have a significant influence on the flow dynamics during impact and on the final splat shape. The results are likely to provide insights for the less-explored behaviour of hollow melt droplets in thermal spray coating processes.     

用格子Boltzmann方法模拟液滴撞击固壁动力学行为

首次用格子Boltzmann方法中的伪势模型对液滴撞击固壁的动力学行为进行了数值模拟.详细研究了液滴在壁面上的流动状态以及各种因素对撞击过程的影响.通过数值模拟得到:壁面的可润湿性越小,液滴越容易发生反弹,液滴的回缩速度越快;液滴的撞击速度越大,所得到的相对直径越大,回缩速度越快;液滴的粘性越小,所得到的相对直径越大;液滴的表面张力越大,液滴越容易发生反弹现象.另外,液滴的最大相对直径与We数满足一定的线性关系,这些结果与前人的理论预测和实验结果完全吻合.     

Modelling spray impingement using linear stability theories for droplet shattering

This paper compares several linear‐theory‐based models for droplet shattering employed for simulations of spray impingement on flat wall surface or a circular cylinder. Numerical simulations are conducted using a stochastic separated flow (SSF) technique that includes sub‐models for droplet dynamics and impact. Results for spray impingement over a flat wall indicate that the linear theory applicable for a single droplet impact over‐predicts the number of satellite (or secondary) droplets upon shattering when compared to experimental data. The causes for the observed discrepancies are discussed. Numerical simulation results for spray impingement over a circular cylinder in cross flow are obtained and discussed. Copyright © 2005 John Wiley & Sons, Ltd.     

Experimental study of water droplet boiling on hot, non-porous surfaces

In this paper, the results of a series of experimental tests on single- and multi-droplet boiling systems are presented and discussed. The main objectives of the present study are: a) to investigate experimentally the effect of the boiling onset on the evaporation rate of water droplets; b) to measure the evolution of the solid surface temperature during evaporation; c) to examine the possibility of improving spray cooling efficiencies. The behavior of small water droplets (from 10 to 50 μl) gently deposited on hot, non-porous surfaces is observed. The evaporation of multi-droplet arrays (50 and 100 μl) under the same conditions of the single-droplet tests is analyzed. In particular, the conditions which determine the onset of nucleate and film boiling are stressed out. In the experimental tests, the interaction of different materials with several multi-droplet systems is monitored by infrared thermography. The spray cooling efficiency is related to the solid temperature decrease as a function of the water mass flux. In the present study, the effect of varying the droplet volume and the mass flux is also analyzed and discussed. The results on the droplets evaporation time and on the solid surface transient temperature distribution are also compared with the data obtained by the same authors during the analysis of droplet evaporation in total absence of nucleate and film boiling. In order to analyze the different behavior of the evaporating droplet as a function of the solid surface thermal conductivity, evaporative transients on aluminum, stainless steel and macor (a glass-like, low-conductivity material) are considered. Received on 20 February 1998     

Flow characteristics of spray impingement in PFI injection systems

The present paper addresses an experimental study of the dynamic exchanges between the impact of an intermittent spray and the liquid film formed over the target, based on detailed phase Doppler anemometry (PDA) measurements of droplet size, velocity and volume flux in the vicinity of the impact. The flow configuration is that of a pulsed injector spraying gasoline onto a flat disc to simulate the port fuel injection (PFI) of an internal combustion engine operating at cold-start conditions. The measurements evidence that the outcome of impact cannot be accurately predicted based on the characteristics of the free spray, but requires precise knowledge of the flow structure, induced by the target. The implications for spray–wall interaction modelling are then discussed based on the application of conservation equations to the mass, momentum and energy exchanged between the impinging droplets and the liquid film. The results show that the liquid film starts to form in the vicinity of the stagnation region at early stages of injection and a non-negligible proportion of droplets impinging at outer regions splash after interaction with the film. Film disruption is mainly driven by the intermittent axial momentum of impinging droplets, which enhances the vertical oscillations. The radial momentum imparted to the liquid film at the stagnation region is fed back onto secondary droplets emerging later during the injection cycle at outwards locations, where momentum of impacting droplets is much smaller. As a consequence, although the number of splashed droplets is enhanced by normal momentum, their size and ejection velocity depends more on the radial spread induced onto the liquid film and, hence, on the radial momentum at impact. The analysis further shows that existing spray–wall interaction models can be improved if the dynamic exchanges between the impacting spray and the liquid film are accounted.     

Transient fuel spray impingement at atmospheric and elevated ambient conditions

This study analyses detailed temporally resolved full flow field data for pre- and post-impingement fuel sprays under atmospheric and elevated ambient conditions. A comprehensive suite of diagnostic techniques is utilised comprising of phase-resolved Phase Doppler Interferometry—employing a very fine grid and velocity signature to differentiate between pre- and post-impingement droplets—high-speed imaging (utilising Mie-scattering), high-magnification shadowgraphy and an adapted instantaneous mass-rate tube. Raised ambient conditions are achieved in a high-temperature, high-pressure constant volume rig affording large optical access. Temporal data for the free and impinging sprays is compared and analysed within three phases—early, mid and late injection—defined by the mass-rate tube data. All experimental techniques employed present consistent temporal and spatial trends at atmospheric and elevated ambient conditions, and global trends are consistent with the phenomenological flow structure originally proposed by Ozdemir and Whitelaw. Detailed analysis close to the piston surface reveals approximately a threefold increase in the D₅₀ mean spray diameter for the post-impingement droplet size distribution at the wall spray tip. It is suggested that this is due to droplet coalescence, with some supporting evidence from high-speed imaging. Comparison of transient mass deposited on the surface with model predictions show reasonable agreement with the ‘Wet’ model assumption.     

A moment method for splashing and evaporation processes of polydisperse sprays

A new moment method for the modelling of polydisperse sprays is proposed that simultaneously takes into account the dispersion in droplet size and droplet velocity. For the derivation of this Eulerian method the kinetic spray equation is used which constitutes a partial differential equation for the probability density function of droplets. To reduce the complex kinetic spray equation to a form that can be managed with the available numerical procedures, moment transforms with respect to the droplet velocity and the droplet size are conducted. The resulting moment equations are closed by choosing an approximate probability density function which applies to polydisperse sprays. The method is successfully tested for configurations in which a polydisperse spray is either splashed, evaporated or effected by a Stokes drag force. The tests are organised in such a way that crossing of two spray distributions is always included. The new method is able to capture the polydisperse nature of sprays as well as the bi-(or multi-) modal character of the droplet velocity distribution function, for example, when droplets cross each other.     

Modeling of binary droplet collisions for application to inter-impingement sprays

In this paper, we focused on modeling the collision phenomenon between two liquid droplets for application in spray simulations. It has been known that the existing O’Rourke collision model widely used in CFD codes is inaccurate in determining collision outcomes and droplet behavior. In addition, since the collision probability of the model follows a statistical approach involving computational cell geometry, the prediction results should be strongly dependent on the cell size. As a result, to more accurately calculate droplet collisions, the technique for predicting the droplet velocity and its direction after collision must be extended for use in spray modeling. Further, it is also necessary to consider all the possible collision outcomes, such as bouncing, stretching separation, reflexive separation and coalescence. Therefore, this paper describes the appropriateness of a composite concept for modeling collision outcomes and the implementation of deterministic collision algorithms into a multidimensional CFD code for the calculation of post-collisional droplet movements. Furthermore, the existing model does not consider the formation of satellite droplets. For this reason, our present modeling concept includes a fragmenting droplet collision model. Using the present model, we have validated the collision interactions between liquid droplets under high Weber number conditions by comparing our calculations with experimental results from a binary droplet collision. This paper also deals with the application of the model to inter-impingement sprays by analyzing the atomization characteristics, such as mean droplet size and velocity, spray tip penetrations and spray-shapes of the impinging spray using the suggested collision algorithms and then comparing the results with available experimental data.     

Computational study of bouncing and non-bouncing droplets impacting on superhydrophobic surfaces

We numerically investigate bouncing and non-bouncing of droplets during isothermal impact on superhydrophobic surfaces. An in-house, experimentally validated, finite element method-based computational model is employed to simulate the droplet impact dynamics and transient fluid flow within the droplet. The liquid–gas interface is tracked accurately in Lagrangian framework with dynamic wetting boundary condition at three-phase contact line. The interplay of kinetic, surface and gravitational energies is investigated via systematic variation of impact velocity and equilibrium contact angle. The numerical simulations demonstrate that the droplet bounces off the surface if the total droplet energy at the instance of maximum recoiling exceeds the initial surface and gravitational energy, otherwise not. The non-bouncing droplet is characterized by the oscillations on the free surface due to competition between the kinetic and surface energy. The droplet dimensions and shapes obtained at different times by the simulations are compared with the respective measurements available in the literature. Comparisons show good agreement of numerical data with measurements, and the computational model is able to reconstruct the bouncing and non-bouncing of the droplet as seen in the measurements. The simulated internal flow helps to understand the impact dynamics as well as the interplay of the associated energies during the bouncing and non-bouncing. A regime map is proposed to predict the bouncing and non-bouncing on a superhydrophobic surface with an equilibrium contact angle of 155°, using data of 86 simulations and the measurements available in the literature. We discuss the validity of the computational model for the wetting transition from Cassie to Wenzel state on micro- and nanostructured superhydrophobic surfaces. We demonstrate that the numerical simulation can serve as an important tool to quantify the internal flow, if the simulated droplet shapes match the respective measurements utilizing high-speed photography.     

Retraction and Adhesion of a Single Droplet Normal Impact on the Solid Surface

The impact behavior of individual biomass oil droplets was investigated on solid surfaces having different structures (flat, cylindrical, and spherical) using the high-speed video technique. This makes it possible to compare the evolution of the droplet impact on various surface structures. The impact behaviors of retraction–oscillation and adhesion are analyzed for different hydrophobic surfaces. The influence of the Weber number (We), the surface structure, and the surface curvature is further examined by focusing on the retraction and stable adhesion (thickness, adhesion, and contact angle) for different biomass oil droplets. The results show that the retraction factor gradually increases as We increases to some critical value, beyond which the increase rate slows down or the retraction factor begins to decrease. The largest retraction factor is observed on the flat surface and the smallest one appears on the spherical surface. The adhesion thickness of the liquid film oscillates periodically over time, and its oscillation amplitude gradually decreases with a constant frequency, which is smaller for the more hydrophobic surfaces. The curvatures of the cylinder and sphere have little influence on the stable adhesion behavior. For the different droplet types, the adhesion diameter on the flat surface gradually increases as We rises, whereas the adhesion thickness gradually decreases with increase in We. These results are helpful for understanding the impact behaviors of biomass oil droplets with high viscosity and small surface tension on solid surfaces.

     

Spray impact onto flat and rigid walls: Empirical characterization and modelling

An experimental study of spray impact onto horizontal flat and rigid surfaces is presented and used as input data for a new empirical model. A phase Doppler instrument has been used to measure drop size and two components of velocity directly above the target. The average film thickness formed due to spray impact has been measured using a high-speed CCD camera. The spray–wall interaction has been characterized in terms of correlations for the velocity and trajectory of secondary droplets and the mass and number ratio of the secondary spray. The novel aspect of the model is that the correlations are based on mean statistics over many events and not on the outcome of single drop impact experiments. Furthermore a rather large range of oblique impact angles have been studied and incorporated into the empirical models as an influencing factor.