Influence of inertia,topography and gravity on transient axisymmetric thin‐film flow

This study examines theoretically the development of early transients for axisymmetric flow of a thin film over a stationary cylindrical substrate of arbitrary shape. The fluid is assumed to emerge from an annular tube as it is driven by a pressure gradient maintained inside the annulus, and/or by gravity in the axial direction. The interplay between inertia, annulus aspect ratio, substrate topography and gravity is particularly emphasized. Initial conditions are found to have a drastic effect on the ensuing flow. The flow is governed by the thin‐film equations of the ‘boundary‐layer’ type, which are solved by expanding the flow field in terms of orthonormal modes in the radial direction. The formulation is validated upon comparison with the similarity solution of Watson (J. Fluid Mech 1964; 20 :481) leading to an excellent agreement when only 2–3 modes are included. The wave and flow structure are examined for high and low inertia. It is found that low‐inertia fluids tend to accumulate near the annulus exit, exhibiting a standing wave that grows with time. This behaviour clearly illustrates the difficulty faced with coating high‐viscosity fluids. The annulus aspect is found to be influential only when inertia is significant; there is less flow resistance for a film over a cylinder of smaller diameter. For high inertia, the free surface evolves similarly to two‐dimensional flow. The substrate topography is found to have a significant effect on transient behaviour, but this effect depends strongly on inertia. It is observed that the flow of a high‐inertia fluid over a step‐down exhibits the formation of a secondary wave that moves upstream of the primary wave. Gravity is found to help the film (coating) flow by halting or prohibiting the wave growth. The initial film profile and velocity distribution dictate whether the fluid will flow downstream or accumulate near the annulus exit. Copyright © 2004 John Wiley & Sons, Ltd.