An experimental investigation of meniscus roll coating

A two-roll apparatus is used to explore experimentally the detailed fluid mechanics of meniscus roll coating in which inlets are starved and flow rates are small. Both forward and reverse modes of operation (with contra- and co-rotating rolls) are investigated using optical sectioning combined with dye injection and particle imaging techniques. That part of parameter space where meniscus coating occurs is identified by varying the roll separation and roll speeds and hence flow rate and capillary number. Key features of the flow structures identified in the forward mode include two large eddies (each with saddle point, separatrix and sub-eddies), a primary fluid transfer jet and the existence of two critical flow rates associated with the switching-on of a second fluid transfer jet and the switching-off of the primary transfer jet followed by a change in the flow structure. In the reverse mode, the key features are a single large eddy consisting of two sub-eddies, a saddle point and separatrix, a primary fluid transfer jet and once again two critical flow rates. These correspond to (i) the switching-on of a secondary transfer jet and (ii) the disappearance of a saddle point at the nip resulting in the merger of the primary and secondary transfer jets. Measurements of film thickness and meniscus location made over a range of speed ratios and capillary numbers are compared with theoretical predictions. A plate-roll apparatus is used to confirm the presence, for very small flow rates, of a sub-ambient, almost linear, pressure profile across the bead. Investigated also is the transition from inlet-starved to fully flooded roll coating as flow rate is increased and the changes in flow structure and pressure profile are observed

Nested separatrices in simple shear flows: the effect of localized disturbances on stagnation lines

The effects of localized two-dimensional disturbances on the structure of shear flows featuring a stagnation line are investigated. A simple superposition of a planar Couette flow and Moffatt's [J. Fluid Mech. 18, 1--18 (1964)] streamfunction for the decay of a disturbance between infinite stationary parallel plates shows that in general the stagnation line is replaced by a chain of alternating elliptic and hyperbolic stagnation points with a separation equal to 2.78 times the half-gap between the plates. The flow structure associated with each saddle point consists of a homoclinic separatrix and two other separatrices which locally diverge but become parallel far from the disturbance. This basic structure repeats to give a sequence of nested separatrices permitting the streamfunction to approach that of simple shear flow far from the disturbance. Using the finite element method, the specific disturbance caused by a stationary cylinder placed on the stagnation line is considered, and results confirm the existence of the stagnation point chain, with computed separations and velocity damping ratios in very good agreement with those obtained from the Couette-Moffatt superposition. Numerical solutions also illustrate that while Reynolds number greatly affects the stagnation point separation and velocity damping ratio, these two quantities are the same for any pair of adjacent stagnation points in a given chain. Insight gained from the analysis of planar shear flows is applied to the flow in a half-filled horizontal annulus between rotating coaxial cylinders, and is used to explain why only certain flow patterns from the range of mathematically possible structures arise in previous numerical solutions. By way of contrast, the concentric annulus solution is then perturbed to allow for a small eccentricity. The non-uniformity of the inter-cylinder gap is shown to destroy the chain of stagnation points, but also to unfold additional flow structures not realizable when the gap is uniform

Flow in a double-film-fed fluid bead between contra-rotating rolls, Part 1: equilibrium flow structure

In multiple-roll coaters thin liquid films are transferred from roll to roll by means of liquid ‘beads’ which occupy the small gaps between adjacent rolls. Double-Film-Fed (DFF) beads are those which feature two ingoing films instead of the usual one, and arise in the intermediate stages of certain types of roll coater. One of the ingoing films, h1, is supplied from the previous inter-roll gap while the other, h2, ‘returns’ from the subsequent gap. Such a flow is investigated here under the conditions of low flow rate, small capillary number and negligible gravity and inertia, using lubrication theory and finite element analysis. The thickness of film h1 is fixed independently, while that of h2 is specified as a fraction, [zeta], of the film output on the same roll. This simple approach allows a degree of feedback between the output and input of the bead, and enables one to simulate different conditions in the subsequent gap. Predictions of outgoing film thicknesses made using the two models agree extremely well and show that, for each value of [zeta] < 1, one outgoing film thickness decreases monotonically with speed ratio, S, while the other features a maximum. Good agreement is also seen in the pressure profiles, which are entirely sub-ambient in keeping with the small capillary number conditions. The finite element solutions reveal that in the ‘zero-flux’ case (when [zeta] = 1) the flow structures are very similar to those seen in an idealized cavity problem. In the more general ([zeta] < 1) situation, as in single-film-fed meniscus roll coating, several liquid transfer-jets occur by which liquid is conveyed through the bead from one roll to the other. The lubrication model is used to calculate several critical flow rates at which the flow is transformed, and it is shown that when the total dimensionless flow rate through the bead exceeds 1/3, the downstream flow structure is independent of the relative sizes of the ingoing films

Stokes flow in a half-filled annulus between rotating coaxial cylinders

A model is presented for viscous flow in a cylindrical cavity (a half-filled annulus lying between horizontal, infinitely long concentric cylinders of radii R-i,R-0 rotating with peripheral speeds U-i,U-0). Stokes' approximation is used to formulate a boundary value problem which is solved for the streamfunction, phi, as a function of radius ratio (R) over bar = R-i/R-0 and speed ratio S = U-i/U-0. Results show that for S > 0 (S 1, a sequence of 'flow bifurcations' leads to a flow structure consisting of a set of nested separatrices, and provides the means by which the two-dimensional cavity flow approaches quasi-unidirectional flow in the small gap limit. Control-space diagrams reveal that speed ratio has little effect on the flow structure when S 0 and aspect ratios are small (except near S = 1). For S > 0 and moderate to large aspect ratios the bifurcation characteristics of the two large eddies are quite different and depend on both (R) over bar and S

Stagnation–saddle points and flow patterns in Stokes flow between contra-rotating cylinders

The steady flow is considered of a Newtonian fluid, of viscosity mu, between contra-rotating cylinders with peripheral speeds U-1 and U-2 The two-dimensional velocity field is determined correct to O(H-0/2R)(1/2), where 2H(0) is the minimum separation of the cylinders and R an 'averaged' cylinder radius. For flooded/moderately starved inlets there are two stagnation-saddle points, located symmetrically about the nip, and separated by quasi-unidirectional flow. These stagnation-saddle points are shown to divide the gap in the ratio U-1 : U-2 and arise at \X\ = A where the semi-gap thickness is H(A) and the streamwise pressure gradient is given by dP/dX = mu(Ulf U-2)/H-2(A). Several additional results then follow. (i) The effect of non-dimensional flow rate, lambda: A(2) = 2RH(0)(3 lambda - 1) and so the stagnation-saddle points are absent for lambda 1/3. (ii) The effect of speed ratio, S = U-1/U-2: stagnation-saddle points are located on the boundary of recirculating flow and are coincident with its leading edge only for symmetric flows (S = i). The effect of unequal cylinder speeds is to introduce a displacement that increases to a maximum of O(RH0)(1/2) as S --> 0. Five distinct flow patterns are identified between the nip and the downstream meniscus. Three are asymmetric flows with a transfer jet conveying fluid across the recirculation region and arising due to unequal cylinder speeds, unequal cylinder radii, gravity or a combination of these. Two others exhibit no transfer jet and correspond to symmetric (S = 1) or asymmetric (S not equal 1) flow with two asymmetric effects in balance. Film splitting at the downstream stagnation-saddle point produces uniform films, attached to the cylinders, of thickness H-1 and H-2, where H-1/H-2 = S(S + 3)/3S + 1, provided the flux in the transfer jet is assumed to be negligible. (iii) The effect of capillary number, Ca: as Ca is increased the downstream meniscus advances towards the nip and the stagnation-saddle point either attaches itself to the meniscus or disappears via a saddle-node annihilation according to the flow topology. Theoretical predictions are supported by experimental data and finite element computations

Efficient and accurate time adaptive multigrid simulations of droplet spreading

An efficient full approximation storage (FAS) Multigrid algorithm is used to solve a range of droplet spreading flows modelled as a coupled set of non-linear lubrication equations. The algorithm is fully implicit and has embedded within it an adaptive time-stepping scheme that enables the same to be optimized in a controlled manner subject to a specific error tolerance. The method is first validated against a range of analytical and existing numerical predictions commensurate with droplet spreading and then used to simulate a series of new, three-dimensional flows consisting of droplet motion on substrates containing topographic and wetting heterogeneities. The latter are of particular interest and reveal how droplets can be made to spread preferentially on substrates owing to an interplay between different topographic and surface wetting characteristics

A model for deformable roll coating with negative gaps and incompressible compliant layers

A soft elastohydrodynamic lubrication model is formulated for deformable roll coating involving two contra-rotating rolls, one rigid and the other covered with a compliant layer. Included is a finite-strip model (FSM) for the deformation of the layer and a lubrication model with suitable boundary conditions for the motion of the fluid. The scope of the analysis is restricted to Newtonian fluids, linear elasticity/viscoelasticity and equal roll speeds, with application to the industrially relevant highly loaded or 'negative gap' regime. Predictions are presented for coated film thickness, interroll thickness, meniscus location, pressure and layer deformation as the control parameters - load (gap), elasticity, layer thickness and capillary number, Ca - are varied. There are four main results: \ud (i) Hookean spring models are shown to be unable to model effectively the deformation of a compliant layer when Poisson's ratio nu --> 0.5. In particular, they fall to predict the swelling of the layer at the edge of the contact region which increases as v - 0.5; they also fail to locate accurately the position of the meniscus, X-M, and to identify the presence, close to the meniscus, of a 'nib' (constriction in gap thickness) and associated magnification of the sub-ambient pressure loop. (ii) Scaling arguments suggest that layer thickness and elasticity may have similar effects on the field variables. It is shown that for positive gaps this is true, whereas for negative gaps they have similar effects on the pressure profile and flow rate yet quite different effects on layer swelling (deformation at the edge of the contact region) and different effects on X-M. (iii) For negative gaps and Ca similar to O(1), the effect of varying either viscosity or speed and hence Ca is to significantly alter both the coating thickness and X-M. This is contrary to the case of fixed-gap rigid roll coating. (iv) Comparison between theoretical predictions and experimental data shows quantitive agreement in the case of X-M and qualitive agreement for flow rate. It is shown that this difference in the latter case may be due to viscoelastic effects in the compliant layer

Stirring and transport enhancement in a continuously modulated free-surface flow

The transport of fluid from a recirculation region adjacent to a free surface is studied using a numerical method validated with experimental flow visualization. The flow is an example of a liquid film coating process, and consists of two counter-rotating rolls placed side-by-side and half-submerged in a bath of fluid. In the gap between the rolls a recirculation zone exists just below the free surface, around which the flow splits into two films. Fluid recirculating for long periods has been identified as a source of coating defects, so this paper considers a possible method of inducing stirring. The flow is modulated by driving one of the rolls through a Hooke's joint, which delivers a well-characterized periodic perturbation to the roll speed. In response to this speed modulation, the free surface undergoes a periodic change in position and shape which drives an exchange of fluid between the recirculation region and the surrounding flow. The amplitude of the free-surface motion is strongly dependent on modulation frequency. The dynamics of the free surface preclude a quasi-steady approach, even in the small-frequency limit, and so a fully time-dependent analysis based on the finite element method is employed. Trigonometric temporal interpolation of the finite element data is used to make passive tracer advection calculations more efficient, and excellent agreement is seen between simulation and experiment. Computations of the stable and unstable invariant manifolds associated with periodic points on the free surface reveal that the exchange of fluid is governed by a self-intersecting turnstile mechanism, by which most fluid entrained during a modulation cycle is ejected later in the same cycle. Transport over several cycles is explored by observation of the evacuation of passive tracers initially distributed uniformly in the recirculation zone. Results demonstrate the persistence of unmixed cores whose size is dependent on the modulation frequency. By considering the percentage of tracers remaining after a fixed number of cycles, contours in frequency-amplitude space show that for each modulation amplitude there is a frequency which produces the most effective transport, with up to 80 % of tracers removed by a modulation which produces only a 5 % change in film thickness. Finally it is shown how modulation of both rolls at slightly different phases can reduce the film thickness variation to about 1 % while maintaining the level of transport

Droplet migration: quantitative comparisons with experiment

An important practical feature of simulating droplet migration computationally, using the lubrication approach coupled to a disjoining pressure term, is the need to specify the thickness, H, of a thin energetically stable wetting layer, or precursor lm, over the entire substrate. The necessity that H be small in order to improve the accuracy of predicted droplet migration speeds, allied to the need for mesh resolution of the same order as H near wetting lines, increases the computational demands signicantly. To date no systematic investigation of these requirements on the quantitative agreement between prediction and experimental observation has been reported. Accordingly, this paper combines highly ecient Multigrid methods for solving the associated lubrication equations with a parallel computing framework, to explore the eect of H and mesh resolution. The solutions generated are compared with recent experimentally determined migration speeds for droplet ows down an inclined plane

Adaptive finite element simulation of three-dimensional surface tension dominated free-surface flow problems

An arbitrary Lagrangian--Eulerian finite element method is described for the solution of time-dependent, three-dimensional, free-surface flow problems. Many flows of practical significance involve contact lines, where the free surface meets a solid boundary. This contact line may be pinned to a particular part of the solid but is more typically free to slide in a manner that is characterised by the dynamic contact angle formed by the fluid. We focus on the latter case and use a model that admits spatial variation of the contact angle: thus permitting variable wetting properties to be simulated. The problems are driven by the motion of the fluid free surface (under the action of surface tension and external forces such as gravity) hence the geometry evolves as part of the solution, and mesh adaptivity is required to maintain the quality of the computational mesh for the physical domain. Continuous mesh adaptivity, in the form of a pseudo-elastic mesh movement scheme, is used to move the interior mesh nodes in response to the motion of the fluid's free surface. Periodic, discrete remeshing stages are also used for cases in which the fluid volume has grown, or is sufficiently distorted, by the free-surface motion. Examples are given of a droplet sliding on an inclined uniform plane and of a droplet spreading on a surface with variable wetting properties