Numerical Study of Two-Phase Flows in Microchannels Using the Level Set Method

With increasing computer capabilities, numerical modeling of two-phase flows has developed significantly over the last few years. Although there are two main categories, namely 'one' fluid and 'two' fluid methods, the 'one' fluid methods are more commonly used for tracking or capturing the interface between two fluids. Level set (LS), volume-of-fluid (VOF), front tracking, marker-and-cell (MAC) and lattice Boltzmann (LB) methods are all 'one' fluid methods. It is clear that there is no perfect method; each method has advantages and disadvantages which make it more appropriate for one kind of problem than for others. For instance, a LS method will accurately compute the curvature and the normal to the interface, but tends to loss mass which is physically incorrect. On the other hand, a VOF method will conserve mass up to machine precision, but the computation of the curvature and normal to the interface is not as accurate. In order to minimize the disadvantages of these methods, several authors have used two or more methods together to model two-phase flows. This is the case for the CLSVOF (Couple Level Set Volume Of Fluid) method, where LS and VOF are coupled together in order to better capture the interface. In CLSVOF, the level set function is used to compute the interface curvature and normal to the interface, while the volume of fluid function is used to capture the interface. For two-phase flows in microchannels, surface tension forces play an important role in determining the dynamics of bubbles whereas gravitational forces are generally negligible. Also it is very important to consider the interaction between the boundaries and the fluids by prescribing or computing the correct contact angle between them. The commercial CFD code FLUENT allows the use of static constant angles, or the use of User Defined Functions (UDF) to compute the dynamic contact angles. It is inappropriate to use a static contact angle to model cases involving moving contact lines. For such cases a dynamic contact angle scheme should be implemented. In this study, FLUENT was used to model adiabatic and diabatic, time dependent two-phase flows. Since FLUENT already contains a VOF method, a LS method was implemented and coupled with VOF into FLUENT via UDFs. Furthermore, since the LS function, used to compute the surface tension force, ceases to be a signed distance to the interface even after one time step, a re-initialization equation was solved after each time step. This involved using a fifth order WENO (Weighted Essentially Non Oscillatory) scheme to discretize the space derivatives (otherwise oscillations of the interface occurred), and a first order Euler method for the time integration. In another part of the study, a 3D dynamic contact angle model based on volume fraction, interface reconstruction, and experimentally available advancing and receding static contact angles was also developed and implemented into FLUENT via UDFs. Several validations for the developed CLSVOF method and dynamic contact angle model are presented in this thesis, these includes a static bubble, a bubble rising in a stagnant liquid for Morton numbers ranging from 102 to 10-11, droplet deformation due to a vortex flow field, droplets spreading over a wall under the gravity effect and droplets sliding over a wall due to gravity. These validations demonstrated the high accuracy and the stability of our methods for modeling these phenomena. A heat and mass transfer model was also implemented into the commercial CFD code FLUENT for simulating of boiling (and condensation) heat transfer. Several simulations were presented with water and R134a as working fluids. The influence of the contact angle and the wall superheat was also studied.

We present a numerical simulation of two-phase flow in a three-dimensional cross-junction microchannel by using the lattice Boltzmann method (LBM). At first, we validated our LBM code with the velocity profile in a 3-dimensional rectangular channel. Then, we developed a lattice Boltzmann code based on the free energy model to simulate the immiscible binary fluid flow. The parallelization of the developed code is implemented on a PC cluster using the MPI program. The numerical results of two-phase flow in the microchannel reveal droplet formation process, which compares well with corresponding experimental results. The size of droplet decreases with increase of the flow-rate ratio and the capillary number. The movement of a droplet through the microchannel induces three-dimensional circulating flow inside the droplet. This complex flow is thought to enhance the mixing and reaction of reagents.

With the development of micro chemical and medical analysis in MEMS, micro-fluid-control chip becomes more and more popular. Based on discrete droplet control system, chemical and medical analysis is applied in the micro chip lab. The change of voltage between the dielectric layer of the electrode controls the wettability of a droplet on a dielectric solid surface and then makes it possible to create,transport,merge and cut the micro droplets. This paper presents a numerical method to simulate the droplet motion by electrowetting on dielectric (EWOD). The second-order projection method is carried out to solve N-S equations and level set function. The interface is captured as zero level set. Dynamic contact angle for fluid contacting a solid surface by the electric potential is used to evaluate the wettability of fluid by EWOD. The numerical scheme is based on staggered MAC grid. Numerical simulations are used to capture the interface between two kinds of fluids in micro channels, the shapes of micro droplets resting on the horizontal solid surface under different electric potential and the transportation of a micro droplet in a parallel-plate channel when electrodes are activated.

SummaryThe parametric level set approach is an extension of the conventional level set methods for topology optimization. By parameterizing the level set function, level set methods can be directly coupled with mathematical programming to achieve better numerical robustness and computational efficiency. Moreover, the parametric level set scheme can not only inherit the primary advantages of the conventional level set methods, such as clear boundary representation and the flexibility in handling topological changes, but also alleviate some undesired features from the conventional level set methods, such as the need for reinitialization. However, in the existing radial basis function–based parametric level set method, it is difficult to identify the range of the design variables. Besides, the parametric level set evolution often struggles with large fluctuations during the optimization process. Those issues cause difficulties both in numerical stability and in material property mapping. In this paper, a cardinal basis function is constructed based on the radial basis function partition of unity collocation method to parameterize the level set function. The benefit of using cardinal basis function is that the range of the design variables can now be clearly specified as the value of the level set function. A distance regularization energy functional is also introduced, aiming to maintain the desired signed distance property during the level set evolution. With this desired feature, the level set evolution is stabilized against large fluctuations. In addition, the material properties mapped from the level set function to the finite element model can be more accurate.

Today there is a great interest in micro-scale multiphase fluid flow. In the paper, the numerical simulation of two-phase flow inside 3 mm minichannel was carried out. The liquid- gas interface was captured using the level-set method. During the calculation, the stabilization and reinitialization of level set function was performed in order to obtain the proper accuracy of the simulation. Incompressible Navier-Stokes equations were solved using the COMSOL Multiphysics® on a two-dimensional mesh. The process of formation of different two-phase flow patterns in the minichannel has been investigated. During the simulation it has been analysed three flow patterns: the bubbly flow and two kinds of slug flow with short and long slugs. It has been shown that unsteady flow at the inlet of the minichannel is responsible for the chaotic character of changes of the slug and bubble sizes. Such unsteady flow modifies the distance between the bubbles and slugs. It has been shown that for the low water inlet velocity the two-phase flow pattern becomes more stable.

Level set methods have been widely used in image processing and computer vision. In conventional level set formulations, the level set function typically develops irregularities during its evolution, which may cause numerical errors and eventually destroy the stability of the evolution. Therefore, a numerical remedy, called reinitialization, is typically applied to periodically replace the degraded level set function with a signed distance function. However, the practice of reinitialization not only raises serious problems as when and how it should be performed, but also affects numerical accuracy in an undesirable way. This paper proposes a new variational level set formulation in which the regularity of the level set function is intrinsically maintained during the level set evolution. The level set evolution is derived as the gradient flow that minimizes an energy functional with a distance regularization term and an external energy that drives the motion of the zero level set toward desired locations. The distance regularization term is defined with a potential function such that the derived level set evolution has a unique forward-and-backward (FAB) diffusion effect, which is able to maintain a desired shape of the level set function, particularly a signed distance profile near the zero level set. This yields a new type of level set evolution called distance regularized level set evolution (DRLSE). The distance regularization effect eliminates the need for reinitialization and thereby avoids its induced numerical errors. In contrast to complicated implementations of conventional level set formulations, a simpler and more efficient finite difference scheme can be used to implement the DRLSE formulation. DRLSE also allows the use of more general and efficient initialization of the level set function. In its numerical implementation, relatively large time steps can be used in the finite difference scheme to reduce the number of iterations, while ensuring sufficient numerical accuracy. To demonstrate the effectiveness of the DRLSE formulation, we apply it to an edge-based active contour model for image segmentation, and provide a simple narrowband implementation to greatly reduce computational cost.

The level set method is a mathematical and computational, technique for tracking a moving interface over time. It can naturally handle topological changes such as merging or breaking interfaces. Intrinsic geometric properties of the interface, such as curvature and normal direction, are easily determined from the level set function p. There are many applications of the level set method, including kinetic crystal growth, epitaxial growth of thin films, image restoration, vortex dominated flows, and so forth. Most applications described in the growing literature on the applications of level sets advance the level set equation with explicit time integration. Hence, small CFL-respecting time steps are needed to maintain stability. In this thesis, an implicit level set method is introduced and applied to wildland firespread models, removing vulnerability to instability.

In conventional level set methods, the slope of the level set function needs to be well controlled to maintain the numerical stability during the topology optimization process. One common solution is to regularize the level set function to be a signed distance function, which is usually achieved by periodically implementing the so called re-initialization scheme to force the level set function to gain the desired signed distance property. However, the re-initialization scheme will bring some unwanted drawbacks to the optimization process, such as zero level set drifting, time consuming etc. In addition, re-initialization is usually implemented outside the optimization loop, which will cause convergence issues. In this paper, a distance regularization functional is introduced to the structural topology optimization objective functional to ensure the signed distance property of the level set function near the structure boundaries. This functional can also keep the level set function to be constant-value at positions far away from the structural boundaries. The radial basis function (RBF) based parameterization technique together with the mathematical programming are utilized to improve the potential capability of handling multiple constraints for the topology optimization. The combination of these two techniques makes the level set based topology optimization be capable of handling complicated multi-constrained problems with higher numerical efficiency, leaving no compromise to multiple drawbacks. To demonstrate the validity of the proposed scheme, benchmark examples on minimum compliance structural optimization are employed. This type of problem is computed by the conventional level set method with the introduced distance regularization functional, the RBF based parametric level set and at last, the distance regularized RBF based parametric level set separately to demonstrate their differences.

Topology optimization of compliant mechanism and its support through a level set method

Even though numerical simulation of two-phase flows in microchannels has been attempted by many investigators, most efforts seem to have failed in correctly capturing the flow physics, especially the slug-flow regime characteristics. The presence of a thin liquid film in the order of 10 μm around the bubble (sometimes called gas pocket or gas slug) may be a contributing factor to the above difficulty. Typically, liquid films have a significant effect on the flow field. Thus, there is a strong motivation to employ numerical simulation methods to avoid some of the experimental difficulties. In this paper, the characteristics of two-phase slug flows in microchannels are calculated with the help of the volume-of-fluid (VOF) method. Formation of the slugs for different superficial velocities, capillary numbers, and gas volume fractions are investigated. The minimum mesh resolution required to capture the liquid film surrounding the gas bubble is reported employing a dynamic mesh adaptation methodology with interface tracking. Results are shown to be in good agreement with experimental data and empirical correlations.

A numerical investigation is carried out to study hydrodynamic behavior and thermal performance of slug flow in serpentine microchannel with different curvature ratio and wall properties. By using coupled Level Set and Volume of Fluid (CLSVOF) method implemented in Fluent, gas-liquid interface shows good consistency with experimental results especially for slug flow. Distribution of sectional velocity profile in curved microchannel with various curvature ratios was investigated. On the basis of fluid flow in microchannel with non-slip boundary condition, by means of user defined function (UDF), influence of slip velocity on hydrodynamic characteristics was performed numerically. For a better prediction on thermal performance, further analysis of combined effect of wall properties and curvature ratio on fluid flow characteristics was also conducted. As a consequence, the increasing slip velocity on channel wall can reduce hydraulic resistance. Both the contact angle and the curvature ratio have an appreciable influence on thermal performance of gas-liquid two-phase flow in serpentine microchannel.

The aim of this research is to construct a structural optimization method based on a level set method, the so-called convected level set method. The basic idea of this method is that the level set function is defined as a truncated smooth function obtained using a sinus filter based on a hyperbolic tangent function. The local property of the hyperbolic tangent level set function stabilizes the computation of the advection equation used for evolving the level set function and reduces the computational cost of the reinitialization that maintains the profile of the level set function. Additionally, the low computational cost characteristic enables the use of convective reinitialization, whose basic idea is that the reinitialization is incorporated in the advection equation, avoiding the need for a separate computation. Consequently, the convected level set method can avoid the need for additional computations when conducting reinitialization. The validity of our proposed method is tested with standard structural optimization problems.

An efficient lithographic source and mask optimization approach is developed based on localized level set methods, which is reformulated as an inverse problem by tracking the evolution of level-set functions (LSFs) embedding the level-set representation of source and mask patterns. A distance regularized level-set (DRLS) term is incorporated into the level-set formulation enabling not only stable LSF evolution and accurate computation by maintaining a signed-distance property, but also a simple and efficient narrow-band implementation. Consequently, optimization dimensionality is significantly reduced by updating the pixels in the vicinity of zero level set (narrow band) instead of all the level sets, effectively reducing computation complexity, resulting in significantly improvements in pattern fidelity convergence in terms of runtime, computation load, Euler time step and caching memory requirement which are merited by numerical simulations.

A boundary element method is developed for the topology optimization problem. The topological change is captured using the level set method. The level set function which is defined by signed distance from the boundary contour is assigned to fixed grid points. Boundary elements are developed along the zero contour of the level set function. The design sensitivity analysis is performed for the boundary element equation, and then the boundary velocity is obtained. The velocity field which leads the level set function to optimal material distribution is obtained by the extension of the boundary velocity. Numerical examples show that the proposed method is valid for the topology optimization problems. Copyright © 2006 John Wiley & Sons, Ltd.

In Sussman, Smereka, and Osher [ J. Comp. Phys., 94 (1994), pp. 146--159], a numerical was presented for computing incompressible air--water flows using the level set method. Crucial to the above method was a new iteration method for maintaining the level set function as the signed from the zero level set. In this paper we implement a along with higher order difference schemes in order to make the iteration method more accurate and efficient. Accuracy is measured in terms of the new computed signed function and the original level set function having the same zero level set. We apply our redistancing to incompressible flows with noticeably better resolved results at reduced cost. We validate our results with experiment and theory. We show that our distance level set scheme with the added constraint competes well with available interface tracking schemes for basic advection of an interface. We perform basic accuracy checks and more stringent tests involving complicated interfacial structures. As with all level set schemes, our method is easy to implement.