Effects of capillary number and flow rates on the hydrodynamics of droplet generation in two-phase cross-flow microfluidic systems

Background: The control and manipulation of the hydrodynamics droplets primarily relate to flow governing geometrical parameters. This study has explored influences capillary number (10−4≤Cac≤1) rate ratio (0.1≤Qr≤10) on droplet generation in two-phase through T-junction cross-flow microfluidic device. Methods: finite element method is used solve Eulerian framework a mathematical model based mass continuity, Navier-Stokes, conservative level set equations at fixed (Rec=0.1). Significant findings: Results are presented terms instantaneous phase field, size, detachment time, frequency as function parameters (Cac Qr). regimes namely squeezing, first transition, dripping, second parallel, jet marked. In contrast reported value threshold Cac≈10−2, squeezing regime exists for all Cac 2≤Qr≤10. also mapped into non-droplet zones by using Car which scales quadratically with Qr. length varies linearly Qr regime. Both size show power-law relations zone. Finally, predictive correlations guide engineering design microfluidics devices.