Simulation and Analysis of

Equally Distributed Flow for Use

in Ultrasonic Atomization

Lindsay Rogers
University of Wisconsin, Platteville
Mechanical Engineering

Dr. Chen S. Tsai

University of California, Irvine
Department of Electrical Engineering and Computer Science

Dr. Shirley C. Tsai

California State University, Long Beach
Department of Chemical Engineering

Background

Applications

Medical: Pulmonary Drug Delivery

Thin, Even Spray Coating
Material Science
MEMS Fabrication (photoresist coating)
Nanoelectronics (deposition of conductor material)

History

Bulk Metal-based Ultrasonic Nebulizer

Ink-Jet Printer Nozzles (drop-on-demand)

Overview

The Nozzle

Fourier Horn: half-wavelength design and

vibration amplitude magnification of two
Constant cross-sectional area of inner
channel permits cascading horns
Nozzle Holders placed at nodes allowing
proper vibration

Transducer Drive Section

Nodal Bar

3-Fourier Horns

Nozzle
Holder

Ultrasonic Atomization
Mechanism

Piezoelectric plate excited,

causing the formation of a
standing longitudinal
wave throughout fluid
Liquid issues from nozzle,
creating thin film at tip
with capillary wave
generated on liquid
surface
Operation at resonance
causes wave instability
and breaks liquid into
drops upon ejection
Drop size uniform

Advantages
Can operate at higher frequencies than
conventional ultrasonic nozzles while
requiring less electric drive power
Smaller, more uniform drops
Reduction in overall size
Integration

Arrays of multiple nozzles

Combine piezoelectric plate application with
nozzle fabrication process

Array of Nozzles
Increase Production of Monodisperse Droplets

Manifold
Supply equally distributed
fluid flow to each nozzle
Manufactured on same
wafer as nozzle array
Optimize parameters
including:

Junction Angles
Length of straight sections
and overall length

Simulation

ANSYS, finite element software

Utilized program code instead of graphically
drawing profile for ease of controlling parameters

Analysis

Procedure

Model a range of channel profiles by varying

optimization parameters
Acquire FEM solutions (velocity, pressure drop)

Vector Plot of Velocity

Contour Plot of Pressure

Analysis

How results interpreted

Visually study plots (velocity, pressure)

Minimize overall pressure-drop

Results
Max Pressure in 4 Channel Array
alpha
beta
45
65
75
90
100
110

20
104.279
95.167
92.745
90.702
90.258
90.524

35
87.824
78.676
76.254
74.211
73.767
74.032

45
83.509
74.383
71.962
69.919
69.476
69.74

50
73.062
73.084
70.663
68.62
68.177
68.441

60
80.702
71.553
69.15
67.109
66.666
66.93

75
80.443
74.942
68.893
66.85
66.407
66.671

85
81.495
72.366
69.943
67.902
67.459
67.723

90
82.42
73.291
70.868
68.829
68.385
68.648

115
94.362
85.238
82.816
80.774
80.331
80.595

Pressure vs Y-Junction Angles of 4 Channel Array

120

100

100-120

80

80-100
60-80
40-60

Pressure (Pa)

60

20-40
0-20

40

20
45
0

90
20

35

45

50
alpha (degrees)

60

75

85

90

115

beta (degrees)

Closing Thoughts
Silicon-based nozzle
created which produces
monodisperse drops
Manifold of microfluidic
channels simulated and
optimized
Further work being
conducted on channels
with more than two
branch angles and
arrays which dont follow
2n pattern (2, 4, 8, 16)

Acknowledgements
Professors Chen and Shirley Tsai
Graduate Students

Ning Wang
Eugene Huang

National Science Foundation

IM-SURE Program

Said Shokair (major props)

G.P. Li
Goran Matijasevic
IM-SURE participants