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Volume 10, Issue 03, March 2019, pp. 1326–1338, Article ID: IJMET_10_03_134
Available online at http://www.iaeme.com/ijmet/issues.asp?JType=IJMET&VType=10&IType=3
ISSN Print: 0976-6340 and ISSN Online: 0976-6359
ABSTRACT
A majority of the modern inkjet printers utilise drop on demand devices because of
its precision in terms of time and easy control. The time-dependent fluid interface
disruption renders the fluid dynamics process during droplet ejection complex. The
current work attempts to provide an idea of the drop ejection behaviour based on the
computation of energies required for droplet formation and splat formation. The
simulation results for various nozzle diameters with different polymer inks are examined
and it is validated with computational model. Further attempt is made to analyse the
effect of rheological properties like viscosity and surface tension in the droplet
formation.
Key words: Drop on demand; inkjet; droplet ejection; viscosity; surface tension.
Cite this Article: Rajesh.P.K. and Aravindraj.S, A Numerical Simulation and
Validation Study of the Mathematical Model of Droplet Formation in Drop on
Demand Inkjet Printer and the Effect of Rheological Properties of Polymerink for
Automobile Lighting Application, International Journal of Mechanical Engineering
and Technology 10(3), 2019, pp. 1326–1338.
http://www.iaeme.com/IJMET/issues.asp?JType=IJMET&VType=10&IType=3
1. INTRODUCTION
There is a tremendous efforts in the search for new means of further improving the quality and
reducing device cost of ink jet printing due to its rapid growth over manufacturing of
automotive electronics. Knowledge in fluid dynamic process of drop formation and drop
ejection takes precedence in research and development of new ink jet print heads. There are
two main types of ink jet devices, namely, continuous–jet type and drop-on demand type. [3 -
4]. In a continuous-jet device, there is a disintegration into a train of drops of the liquid,
emerging from the nozzle continually in the form of a jet. The amount of electric charge on
each individual drop and direction of motion of each drop from the continuous jet require
sophisticated electrical signals. A drop-on-demand device, on the other hand, uses electrical
signal to control the actuation at the instance of the ejection of an individual drop. Due to its
basic simplicity, the drop-on-demand type is common in the most modern ink jet printers. This
work focuses on the basic drop ejection process in drop-on-demand devices.
A drop-on-demand inkjet printer consists of a fluid chamber with a nozzle which is actuated
to eject the droplet. The actuation pushes a certain amount of the liquid out of the fluid chamber
through the nozzle. A drop is ejected when the liquid pushed out of the nozzle gains enough
forward momentum to overcome the surface tension restoring effect, [5]. The generation and
behaviour of liquid droplets [6] is effected by the Surface tension, inertia and viscosity. Surface
tension is a contractive tendency of the surface of a liquid that allows it to resist an external
force. Liquid atoms or molecules at a free surface have higher energy than those inside the
liquid body. Therefore, the shape of liquid with the lowest surface tension energy is sphere. For
the generation of a droplet, a liquid must necessarily have the tendency to form a shape with
lowest energy. The attraction of water molecules to each other is greater than the molecules in
the air, when the droplet is generated. As a result, an inward force at its surface makes water to
behave as if its surface was covered by a stretched elastic membrane. This is also the primary
cause of pinch‐off effect [7]. The surface tension of most of the liquids used in inkjet printing
have the order of tens of dyn/cm (or mN/m). The importance and influence of the above
parameters can characterized by three essential dimensionless numbers: 1. Reynolds number,
2.Weber number and 3.Ohnesorge number [8].
Friction loss (or skin friction) is the loss of pressure or “head” that occurs in nozzle flow due to
the effect of the fluid's viscosity near the surface of the orifice [23]. The fictional loss is given
by the Hagen-poissoulle equation (i.e.)
32μu0 l
hf = (9)
ρgd20
Frictional energy[E2] is given by
E2 = ρ x g x hf (10)
The forces on the control volume are advection +ρπR2 u2 , Laplace pressure +σπR, and the
direct effect of surface tension−σπR, should sum up to zero if the velocity is constant.
ρπR2 u2 + σπR − σ2πR = 0 (16)
From this equation, we get the tail droplet velocity as
σ
u = √ρR
generation. For Z<1, viscous dissipation prevents drop ejection. For Z>10, the ink is freely
ejected from the nozzle without significant viscous dissipation. The kinetic energy of the drop,
however, increases leading to rupture of filament and formation of satellites [36]. A typical
inkjet printer nozzle diameter ranges from 20 μm to 50 μm . For PEDOT: PSS and PEGDA,
the suitable nozzle diameter is selected based on the inverse ohnerorge number (Z) obtained
from the Table [5.1, 5.2] as shown in Table [4]
PEDOT:PSS PEGDA
Suitable Diameter 30 40
t=0 𝛍𝐬 t=18𝛍𝐬 t=37𝛍𝐬 t=56𝛍𝐬 t=76𝛍𝐬 t=114𝛍𝐬 t=133𝛍𝐬 t=130𝛍𝐬 t=152𝛍𝐬 t=171𝛍𝐬
Figure 4 Droplet formation of PEDOT: PSS ink for the nozzle diameter 40μm
In figure 4, at frame 1, the valve is open and pressure pulse is active but the total energy is
not enough to form the droplet. At 15μs, in frame 2 the valve is closed, the negative pressure is
created on top of liquid inside reservoir which ejects the droplet from the nozzle [39]. At this
stage, the ink neck is sufficiently thin to be broken while the rest is sucked into reservoir. At
30μs, the detached volume of liquid outside the nozzle forms a spherical shape. At
30μs, the tail formation takes place and pinch off occurs at 115μs. The diameter of the PEDOT:
PSS ink observed from the simulated results is 1.255 cm.
t=0 𝛍𝐬 t=19𝛍𝐬 t=38𝛍𝐬 t=57𝛍𝐬 t=76𝛍𝐬 t=95𝛍𝐬 t=114𝛍𝐬 t=133𝛍𝐬 t=152𝛍𝐬 t=190𝛍𝐬
Figure 5 Droplet formation of PEGDA ink for the nozzle diameter 40μm
In figure 5, at frame 1, the valve is open and pressure pulse was active but total energy is
not enough to form the droplet. At 19μs, in frame 2 the valve is closed,a negative pressure is
created on top of the liquid inside the reservoir which ejects the droplet from the nozzle [40].
At this stage, the ink neck is sufficiently thin to be broken while the rest is sucked into the
reservoir. At 57μs, the detached volume of liquid outside the nozzle forms a spherical shape
and pinch off occurs at 152μs and when compared to PEDOT:PSS ink, the pinch off time in
PEGDA ink is more due to high viscosity.
Table 5 Parameters for Force profile used in printing PEDOT: PSS [41]
NOMENCLATURE
S No Symbols Description
1 E1 Energy required for deflecting diaphragm
2 E2 Frictional energy in orifice
3 E3 Kinetic energy of the droplet at the outlet of the print head
4 E4 Surface tension energy of the droplet at the outlet
5 E Total Energy to eject the droplet
6 r Local radius of the membrane from its centre
7 D Diameter of the chamber
8 E Young's modulus of the membrane
9 I Flexural rigidity of the membrane
10 ∈ Poisson's ratio of the membrane (assumed as 0.3)
11 t Thickness of the membrane
12 δ Maximum deflection of the membrane
13 d Diameter of the droplet
14 μ Apparent viscosity
15 uo Average velocity of the fluid inside orifice
16 do Diameter of the orifice
17 ρ Density of the ink
18 hf Frictional head
19 V Volume of the droplet
20 ub Velocity of the droplet at the beginning of its ejection
21 p Pressure inside the droplet
22 θ Contact angle
23 d1 Diameter of the spread
24 Re Reynold’s number
25 Vi Droplet impact velocity
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