Experimental and analytical investigation of liquid sheet breakup characteristics

The main objective of this research is to study analytically and experimentally the liquid sheet breakup of a flat fan jet nozzle resulting from pressure-swirling. In this study the effects of nozzle shape and spray pressure on the liquid sheet characteristics were investigated for four nozzles with different exit widths (1.0, 1.5, 2.0 and 2.5 mm). The length of liquid sheet breakup, liquid sheet velocity and the size of formed droplets were measured by a digital high speed camera. The breakup characteristics of plane liquid sheets in atmosphere are analytically investigated by means of linear and nonlinear hydrodynamic instability analyses. The liquid sheet breakup process was studied for initial sinuous and also varicose modes of disturbance. The results presented the effect of the nozzle width and the spray pressure on the breakup length and also on the size of the formed droplets. Comparing the experimental results with the theoretical ones for all the four types of nozzles, gives a good agreement with difference ranges from 4% to 12%. Also, the comparison between the obtained results and the results due to others shows a good agreement with difference ranged from 5% to 16%. Empirical correlations have been deduced describing the relation between the liquid sheet breakup characteristics and affecting parameters; liquid sheet Reynolds number, Weber number and the nozzle width.     

Effect of Nozzle Exit Turbulence on the Column Trajectory and Breakup Location of a Transverse Liquid Jet in a Gaseous Flow

This study examines the effect of fully developed turbulent flow at the exit of nozzle/injector on the trajectory and column breakup location of a liquid jet injected transverly into a gaseous crossflow. Liquid jet trajectory and column breakup for different nozzle geometries at different velocities of liquid jet and crossflow are analytically and experimentally Investigated. Shadowgraph imaging technique is used to determine the jet trajectory and breakup location of a transverse liquid jet in a uniform airflow. Particle image velocimetry (PIV) is used to measure the near-field velocity profile of a liquid jet discgarged into a quiescent atmosphere. The experimental results show a higher penetration and breakup height for the liquid jet ensuing from a nozzle with a smaller length to diameter ratio. This is due to the surface irregularities of the liquid column of a turbulent jet, which breaks up and consequently follows the cross airflow sooner. In order to capture the effect of turbulence, the analytical trajectory correlation developed in our previous studies is modified to account for the discharge coefficient of a nozzle. The discharge coefficient is estimated indirectly by comparing the liquid column trajectory predicted by the modified analytical correlation with that determined experimentally. The indirectly determined discharge coefficient is then used in the analytical correlation for predicting the breakup height of a transverse liquid jet. The results predicted using this approach are in good agreement with the experimental data of the present study at standard temperature and pressure (STP) test conditions.     

Numerical investigation of turbulent-jet primary breakup using one-dimensional turbulence

Primary breakup to form droplets at liquid surfaces is an important fundamental process to study as it determines the initial properties of the dispersed phase, which affect mixing rates, secondary breakup, droplet collisions, and flow separation within the dispersed flow region. Primary breakup can be regarded as one of the least developed model components for simulating and predicting liquid jet breakup. However, it is of paramount importance in many technical applications, e.g. fuel injection in engines and spray painting. This paper presents a numerical investigation of primary breakup of a turbulent liquid jet in still air at standard conditions using the one-dimensional turbulence (ODT) modeling framework. ODT is a stochastic model that simulates turbulent flow evolution along a notional 1D line of sight by applying instantaneous maps to represent the effect of individual turbulent eddies on property profiles. An important feature of ODT is the resolution of all relevant scales, both temporal and spatial. The restriction to one spatial dimension in ODT permits affordable high resolution of interfacial and single-phase property gradients, which is key to capturing the local behavior of the breakup process and allows simulations at high Reynolds and Weber numbers that are currently not accessible to direct numerical simulations (DNS).This paper summarizes our extensions of the ODT model to simulate geometrically simple jet breakup problems, including representations of Rayleigh wave breakup, turbulent breakup, and shear-driven breakup. Each jet breakup simulation consists of a short temporal channel section to initialize a turbulent velocity profile at the nozzle exit followed by an adjacent jet section. The simulations are carried out for jet exit Reynolds number of 11,500, 23,000, 46,000 and 92,000 while the Weber number is varied within the range 10²–10⁷. We present results on breakup statistics including spatial locations of droplet release, droplet sizes and liquid core length. The results on primary breakup are compared to experimental results and models.     

Breakup of Newtonian and non-Newtonian fluids in air jets

The breakup of droplets of non-Newtonian fluids has been investigated by high speed photography and impaction following preliminary results of Newtonian fluids, which confirmed the suitability of the measurement techniques. Single droplets with diameters from 2.4 to 3.3 mm, were arranged to fall under gravity into a jet of air with velocities up to 36o m/s. The droplets of Newtonian fluids, water and Diesel oil, were atomised in the expected manner within three main regimes characterised by the Weber number of the droplet and air jet conditions, while similar droplets of non-Newtonian fluids were found not to atomise but to develop under shear and stretching into ligaments of fluid separated from a local region of their surface; these ligaments were elongated until breakup occurred, though not into small droplets as with the Newtonian fluids. Some of the non-Newtonian fluids (TEP with 7.5% and lo% K125, with and without water) were found not to break up at the maximum speed of the tests and they will be re-examined at higher jet velocities. Increase in the concentration of K125 in TEP resulted in higher critical speed for a given droplet diameter.The authors would like to thank Prof. J. H. Whitelaw of Imperial College for many discussions and useful suggestions during the course of this work, and Dr. G. Cambray of CBDE for his valuable administrative support     

A unified spray model for engine spray simulation using dynamic mesh refinement

This study is based on dynamic mesh refinement and uses spray breakup models to simulate engine spray dynamics. It is known that the Lagrangian discrete particle technique for spray modeling is sensitive to gird resolution. An adequate spatial resolution in the spray region is necessary to account for the momentum and energy coupling between the gas and liquid phases. This study uses a dynamic mesh refinement algorithm that is adaptive to spray particles to increase the accuracy of spray modeling. On the other hand, the accurate prediction of the spray structure and drop vaporization requires accurate physical models to simulate fuel injection and spray breakup. The present primary jet breakup model predicts the initial breakup of the liquid jet due to the surface instability to generate droplets. A secondary breakup model is then responsible for further breakup of these droplets. The secondary breakup model considers the growth of the unstable waves that are formed on the droplet surface due to the aerodynamic force. The simulation results are compared with experimental data in gasoline spray structure and liquid penetration length. Validations are also performed by comparing the liquid length of a vaporizing diesel spray and its variations with different parameters including the orifice diameter, injection pressure, and ambient gas temperature and density. The model is also applied to simulate a direct-injection gasoline engine with a realistic geometry. The present spray model with dynamic mesh refinement algorithm is shown to predict the spray structure and liquid penetration accurately with reasonable computational cost.     

Bag breakup of nonturbulent liquid jets in crossflow

An experimental investigation of the bag breakup of round nonturbulent liquid jets in gaseous crossflow at room temperature and pressure is described. Pulsed photography, pulsed shadowgraphy, and high-speed imaging were used to observe the column and surface waves along the liquid jet and the formation and breakup of bags. Measurements included: wavelengths of column and surface waves, jet velocities, the number of bags along the liquid jet, the number of nodes per bag, droplets sizes and velocities, and trajectories of droplets. Present results show that the column waves of a nonturbulent liquid jet in crossflow within bag breakup regime can be explained based on Rayleigh–Taylor instability. The number of nodes per bag affected the breakup mechanism of the bags. Three distinctive sizes of droplets were produced due the breakup of the bag membrane, the ring strings and the ring nodes. The size of the droplets resulting from the breakup of the bag membrane was constant independent of the crossflow Weber number. Finally different trajectories were observed for the three groups of droplets.     

Development of an efficient statistical volumes of fluid–Lagrangian particle tracking coupling method

The breakup of a liquid jet into irregular liquid structures and droplets leading to the formation of a dilute spray has been simulated numerically. To overcome the shortcomings of certain numerical methods in specific flow regimes, a combined approach has been chosen. The intact liquid core, its primary breakup and the dense spray regime are simulated using the volumes of fluid (VOF) method in combination with LES, whereas the Lagrangian particle tracking (LPT) approach in the LES context is applied to the dilute spray regime and the secondary breakup of droplets. A method has been developed to couple both simulation types on a statistical basis. This statistical coupling approach (SCA) reflects the dominating physical mechanisms of the two‐phase flow in each regime to a high degree. The main benefit of the SCA is computational efficiency as compared with the more straightforward approach where one follows each structure, denoted here as the direct coupling approach. The computational benefits stem from the reduction of computational time since the VOF simulation is run only until statistical convergence and not during the whole spray development. A second benefit using the SCA is the possibility to use the stochastic parcel method in the LPT simulation whereby a large number of droplets may be handled. The coupling approach is applied to the atomization of a fuel jet in a high pressure chamber, demonstrating the gain of efficiency of the SCA as compared with direct coupling approach. Copyright © 2014 The Authors. International Journal for Numerical Methods in Fluids published by John Wiley & Sons Ltd.     

Thermal modulation and breakup of liquid jets

In this paper, we study the breakup behavior of Newtonian liquid and non‐Newtonian liquid jets with an arbitrary variation surface tension imposed along its length. The effect of duty cycle, fluid properties, and the various profiles of the surface tension is investigated. It is shown that the breakup behavior of a jet can be constructed by using the Fourier expansion of the surface tension profile. When the dimensionless wavenumber k is larger than 0.5, the jet breakup behavior is determined by the lowest frequency of the Fourier series expansion of the surface tension profile. As k decreases, higher frequency Fourier modes come to play. In general, for k between, 1∕(n+ 1) and 1∕n,n Fourier modes are needed to determine the jet breakup behavior. The current nonlinear model differs from the existing linear slender jet model in the literature in several ways. While the principle of superposition is valid for the linear model, it is not generally valid for the current nonlinear model. For the linear model, the jet will never break up when the wavenumber is larger than 1. The current model, however, shows clearly that the jet can indeed break up when the wavenumber is larger than 1. Furthermore, the current nonlinear model predicts a breakup time substantially higher than that from the linear model.Copyright © 2011 John Wiley & Sons, Ltd.     

Jet and drops formation in electrohydrodynamic spraying of liquids. A systematic approach

 The surface of the liquid issuing from a capillary subjected to the electric stresses deforms to an elongated jet which disrupts to a series of droplets. In the paper the detailed experimental studies of jet and drop formation from liquid issuing from a capillary maintained at high voltage of positive or negative polarity have been reported. The forms of the jet and the way it disrupts into droplets have been classified into the modes of spraying. A definition of the mode of spraying and the criteria for the mode classification, based on the geometrical form of the meniscus, jet or drop formation are given. Received: 16 September 1997/Accepted: 15 November 1998     

Application of maximum entropy method for droplet size distribution prediction using instability analysis of liquid sheet

This paper describes the implementation of the instability analysis of wave growth on liquid jet surface, and maximum entropy principle (MEP) for prediction of droplet diameter distribution in primary breakup region. The early stage of the primary breakup, which contains the growth of wave on liquid–gas interface, is deterministic; whereas the droplet formation stage at the end of primary breakup is random and stochastic. The stage of droplet formation after the liquid bulk breakup can be modeled by statistical means based on the maximum entropy principle. The MEP provides a formulation that predicts the atomization process while satisfying constraint equations based on conservations of mass, momentum and energy. The deterministic aspect considers the instability of wave motion on jet surface before the liquid bulk breakup using the linear instability analysis, which provides information of the maximum growth rate and corresponding wavelength of instabilities in breakup zone. The two sub-models are coupled together using momentum source term and mean diameter of droplets. This model is also capable of considering drag force on droplets through gas–liquid interaction. The predicted results compared favorably with the experimentally measured droplet size distributions for hollow-cone sprays.     

An Eulerian–Lagrangian hybrid model for the coarse-grid simulation of turbulent liquid jet breakup

In this paper we present a numerical model for the coarse-grid simulation of turbulent liquid jet breakup using an Eulerian–Lagrangian coupling. To picture the unresolved droplet formation near the liquid jet interface in the case of coarse grids we considered a theoretical model to describe the unresolved flow instabilities leading to turbulent breakup. These entrained droplets are then represented by an Eulerian–Lagrangian hybrid concept. On the one hand, we used a volume of fluid method (VOF) to characterize the global spreading and the initiation of droplet formation; one the other hand, Lagrangian droplets are released at the liquid–gas interface according to the theoretical model balancing consolidating and disruptive energies. Here, a numerical coupling was required between Eulerian liquid core and Lagrangian droplets using mass and momentum source terms. The presented methodology was tested for different liquid jets in Rayleigh, wind-induced and atomization regimes and validated against literature data. This comparison reveals fairly good qualitative agreement in the cases of jet spreading, jet instability and jet breakup as well as relatively accurate size distribution and Sauter mean diameter (SMD) of the droplets. Furthermore, the model was able to capture the regime transitions from Rayleigh instability to atomization appropriately. Finally, the presented sub-grid model predicts the effect of the gas-phase pressure on the droplet sizes very well.     

Nonlinear analysis of the deformation and breakup of viscous microjets using the method of lines

We present a numerical model for predicting the instability and breakup of viscous microjets of Newtonian fluid. We adopt a one‐dimensional slender‐jet approximation and obtain the equations of motion in the form of a pair of coupled nonlinear partial differential equations (PDEs). We solve these equations using the method of lines, wherein the PDEs are transformed to a system of ordinary differential equations for the nodal values of the jet variables on a uniform staggered grid. We use the model to predict the instability and satellite formation in infinite microthreads of fluid and continuous microjets that emanate from an orifice. For the microthread analysis, we take into account arbitrary initial perturbations of the free‐surface and jet velocity, as well as Marangoni instability that is due to an arbitrary variation in the surface tension. For the continuous nozzle‐driven jet analysis, we take into account arbitrary time‐dependent perturbations of the free‐surface, velocity and/or surface tension as boundary conditions at the nozzle orifice. We validate the model using established computational data, as well as axisymmetric, volume of fluid (VOF) computational fluid dynamic (CFD) simulations. The key advantages of the model are its ease of implementation and speed of computation, which is several orders of magnitude faster than the VOF CFD simulations. The model enables rapid parametric analysis of jet breakup and satellite formation as a function of jet dimensions, modulation parameters, and fluid rheology. Copyright © 2010 John Wiley & Sons, Ltd.     

Multiscale simulations and experiments on water jet atomization

Numerical simulation of primary atomization at high Reynolds number is still a challenging problem. In this work a multiscale approach for the numerical simulation of liquid jet primary atomization is applied, using an Eulerian-Lagrangian coupling. In this approach, an Eulerian volume of fluid (VOF) method, where the Reynolds stresses are closed by a Reynolds stress model is applied to model the global spreading of the liquid jet. The formation of the micro-scale droplets, which are usually smaller than the grid spacing in the computational domain, is modelled by an energy-based sub-grid model. Where the disruptive forces (turbulence and surface pressure) of turbulent eddies near the surface of the jet overcome the capillary forces, droplets are released with the local properties of the corresponding eddies. The dynamics of the generated droplets are modelled using Lagrangian particle tracking (LPT). A numerical coupling between the Eulerian and Lagrangian frames is then established via source terms in conservation equations. As a follow-up study to our investigation in Saeedipour et al. (2016a), the present paper aims at modelling drop formation from liquid jets at high Reynolds numbers in the atomization regime and validating the simulation results against in-house experiments. For this purpose, phase-Doppler anemometry (PDA) was used to measure the droplet size and velocity distributions in sprays produced by water jet breakup at different Reynolds numbers in the atomization regime. The spray properties, such as droplet size spectra, local and global Sauter-mean drop sizes and velocity distributions obtained from the simulations are compared with experiment at various locations with very good agreement.     

Temporal analysis of breakup for a power law liquid jet in a swirling gas

The breakup mechanism and instability of a power law liquid jet are investigated in this study. The power law model is used to account for the non-Newtonian behavior of the liquid fluid. A new theoretical model is established to explain the breakup of a power law liquid jet with axisymmetric and asymmetric disturbances, which moves in a swirling gas. The corresponding dispersion relation is derived by a linear approximation, and it is applicable for both shear-thinning and shear-thickening liquid jets. Analysis results are calculated based on the temporal mode. The analysis includes the effects of the generalized Reynolds number, the Weber number, the power law exponent, and the air swirl strength on the breakup of the jet. Results show that the shear-thickening liquid jet is more unstable than its Newtonian and shear-thinning counterparts when the effect of the air swirl is taken into account. The axisymmetric mode can be the dominant mode on the power law jet breakup when the air swirl strength is strong enough, while the non-axisymmetric mode is the domination on the instability of the power liquid jet with a high We and a low Re _n . It is also found that the air swirl is a stabilizing factor on the breakup of the power law liquid jet. Furthermore, the instability characteristics are different for different power law exponents. The amplitude of the power law liquid jet surface on the temporal mode is also discussed under different air swirl strengths.     

Viscoelasticity in inkjet printing

We investigate the effects of viscoelasticity on drop generation in inkjet printing. In drop-on-demand printing, individual ink ‘drops’ are ejected from a nozzle by imposed pressure pulses. Upon exiting the nozzle, the shape of each ‘drop’ is that of a nearly spherical bead with a long thin trailing ligament. This ligament subsequently breaks up under the Rayleigh instability, typically into several small droplets (known as satellite drops). These satellite drops can create unwanted splash on the target substrate and a reduction in printing quality. Satellite drops can potentially be eliminated by adding polymer to the ink; elastic stresses can act to contract the trailing ligament into the main drop before capillary breakup occurs. However, elasticity can also reduce the drop velocity and can delay or even prevent the break-off of the drop from the ink reservoir within the nozzle. To achieve optimal drop shape and speed, non-Newtonian parameters such as the polymer concentration and molecular weight must be chosen correctly. We explore this parameter space via numerical simulations, using the Lagrangian–Eulerian finite-element method of Harlen et al. (J Non-Newtonian Fluid Mech 60:81–104, 1995). Results are compared with experimental observations taken from real printheads.     

Evaluation of FFT-based cross-correlation algorithms for PIV in a periodic grooved channel

The design of a pneumatic droplet generator to produce small (~0.2 mm diameter) water droplets on demand is described. It consists of a cylindrical, liquid-filled chamber with a small nozzle set into its bottom surface, connected to a gas cylinder through a solenoid valve. Rapidly opening and closing the valve sends a pressure pulse to the liquid, ejecting a single droplet through the nozzle. Gas in the chamber escapes through a vent hole so that the pressure drops rapidly and more droplets do not emerge. We photographed droplets as they emerged from the nozzle, and recorded pressure fluctuations in the chamber. We determined the duration of the pressure pulse required to generate a single drop; longer pulses produced satellite drops. The length of the water jet when its tip detached and the diameter of the droplet that formed could be predicted using results from linear stability analysis. The peak pressure in the cavity could be increased by raising the supply pressure, increasing the width of the pressure pulse, or by reducing the size of the pressure relief vent.     

Experimental investigation of liquid jet injection into Mach 6 hypersonic crossflow

The injection of a liquid jet into a crossing Mach 6 air flow is investigated. Experiments were conducted on a sharp leading edge flat plate with flush mounted injectors. Water jets were introduced through different nozzle shapes at relevant jet-to-air momentum–flux ratios. Sufficient temporal resolution to capture small scale effects was obtained by high-speed recording, while directional illumination allowed variation in field of view. Shock pattern and flow topology were visualized by Schlieren-technique. Correlations are proposed on relating water jet penetration height and lateral extension with the injection ratio and orifice diameter for circular injector jets. Penetration height and lateral extension are compared for different injector shapes at relevant jet-to-air momentum–flux ratios showing that penetration height and lateral extension decrease and increase, respectively, with injector’s aspect ratio. Probability density function analysis has shown that the mixing of the jet with the crossflow is completed at a distance of x/d _j  ~ 40, independent of the momentum–flux ratio. Mean velocity profiles related with the liquid jet have been extracted by means of an ensemble correlation PIV algorithm. Finally, frequency analyses of the jet breakup and fluctuating shock pattern are performed using a Fast Fourier algorithm and characteristic Strouhal numbers of St = 0.18 for the liquid jet breakup and of St = 0.011 for the separation shock fluctuation are obtained.     

Ballistic imaging in the near-field of an effervescent spray

We have investigated liquid breakup mechanisms in the near nozzle region of a high-pressure effervescent atomizer using ballistic imaging. This technique has revealed various breakup regimes depending upon total flow rate and the gas-to-liquid ratio (GLR). At low total speeds, the jet does not exhibit the wide spread angle and rapid breakup for which effervescent sprays are known, even at high GLR. Above a distinct threshold value for total flow rate, the jet passes through several recognizable flow regimes depending on GLR and it does achieve the expected wide spread angle and rapid breakup. Intermediate GLR’s produce interesting flow patterns that seem to be generated by surging at the nozzle exit, and this surging can probably be attributed to the flow pattern just at the nozzle exit. Indeed, specific interior flows seem to generate the most rapid breakup and should be investigated further.     

Simulation of the primary breakup of a high-viscosity liquid jet by a coaxial annular gas flow

The conversion of low-grade fossil and biogenic energy resources (petcoke, biomass) to a synthesis gas in a high pressure entrained flow gasification process opens a wide spectrum for high efficient energy conversion processes. The synthesis gas can be used for production of methane (SNG), liquid fuels (BtL, CtL) or as fuel for operation of a gas turbine in a combined cycle power plant (IGCC). The production of a tar free high quality syngas is a challenging objective especially due to the fact that typical liquid or suspension fuels for entrained flow gasifiers feature viscosities up to 1000 mPas. Fuel droplet conversion at typical entrained flow gasification conditions is characterized by heat up, evaporation and subsequent degradation of the vapour phase. To guarantee a high fuel conversion rate in the gasifier an efficient atomization of the fuel is required. Mainly twin-fluid burner nozzles are used for atomization of those typically high viscous fuels. The present study is focused on the assessment of the accuracy of CFD computations for the primary breakup of high-viscosity liquids using an external mixing twin fluid nozzle. In a first step experiments were performed with a Newtonian glycerol-water-mixture featuring a liquid viscosity of 400 mPas. Jet breakup was investigated using a high speed camera as well as PIV and LDA-System for a detailed investigation of the flow field. In a second step the experimental results serve as reference data to assess the accuracy of CFD computations. Compressible large eddy simulations (LES) were performed to capture the morphology of the primary breakup as well as the important flow field characteristics. A Volume of Fluid (VOF) approach was used to track the unsteady evolution and breakup of the liquid jet. Comparison of experimental and numerical results showed good agreement with respect to breakup frequency, velocity fields and morphology.     

A pneumatic droplet-on-demand generator

The design of a pneumatic droplet generator to produce small (~0.2 mm diameter) water droplets on demand is described. It consists of a cylindrical, liquid-filled chamber with a small nozzle set into its bottom surface, connected to a gas cylinder through a solenoid valve. Rapidly opening and closing the valve sends a pressure pulse to the liquid, ejecting a single droplet through the nozzle. Gas in the chamber escapes through a vent hole so that the pressure drops rapidly and more droplets do not emerge. We photographed droplets as they emerged from the nozzle, and recorded pressure fluctuations in the chamber. We determined the duration of the pressure pulse required to generate a single drop; longer pulses produced satellite drops. The length of the water jet when its tip detached and the diameter of the droplet that formed could be predicted using results from linear stability analysis. The peak pressure in the cavity could be increased by raising the supply pressure, increasing the width of the pressure pulse, or by reducing the size of the pressure relief vent.