Numerical Investigation of Droplet Splitting in a Branched T-Shaped Microchannel with Varying Contact Angle

In the present work, droplet splitting behavior in a branched T-shape microchannel is investigated using a finite element method. The study employed the two-phase Level Set Method (LSM) to examine the process of droplet production and splitting in a branching T-junction microchannel with immiscible liquid–liquid two-phase flow. The impact of changing the contact angle of the outlet branches on droplet splitting behavior has been widely studied. Also, the effect of increasing the dispersed flow rate on the morphological evolution of the droplet is studied. The numerical results obtained were validated using experimental data from the literature, demonstrating a satisfactory level of agreement. According to our findings, effective droplet diameter increases as the dispersed flow rate increases. The study suggests that the behavior of droplet is affected by the contact angles of the outlet branches, resulting in various changes in shape in the splitting zone. Moreover, the division of the droplet can be seen until a specific threshold of dispersed phase flow rate is reached. Beyond that even at a high contact angle of the main channel filaments persist, passing through the upper outlet branch without splitting irrespective of the contact angle of the outlet branches.