Numerical Investigation of Flow Patterns and Plug Hydrodynamics in a 3D T-junction Microchannel

A three-dimensional (3D) numerical simulation of a two-phase flow liquid/liquid is performed in rectangular microchannel with T-junction. The volume fluid (VOF) method was used under ANSYS Fluent to capture the interface between two phases. dynamic mesh adaptation technique together assumption symmetry plane helps us reduce computational cost. study focuses on patterns and hydrodynamics plugs. So, influence rate ratio $$q$$ , capillary number $$Ca$$ viscosity liquid film, plug/droplet shape, velocity are examined here. Particularly, lengths predicted by show good agreement experimental correlation available literature. results revealed six distinct dispersing water continuous phase silicone oil. By decreasing as well ratio, film thickness increases corners side planes. In turn, this greatly impacts plug velocity. Furthermore, (based velocity) also shown have greater impact than curvature radii tail always larger front one.