Professional Documents
Culture Documents
I J C R E: Nternational Ournal of Hemical Eactor Ngineering
I J C R E: Nternational Ournal of Hemical Eactor Ngineering
INTERNATIONAL JOURNAL OF
CHEMICAL REACTOR ENGINEERING
Asymptotic analysis of ow processes at
drawing of single optical microbres
Giovanni Luzi
Philipp Epple
Michael Scharrer
Ken Fujimoto
Cornelia Rauh
Antonio Delgado
Max Planck Institute for the Science of Light and Institute of Optics, University of Erlan-
gen/Nuremberg, Michael.Scharrer@mpl.mpg.de
\
|
+ = + +
(3)
Herein, the derivatives are denoted by subscripts, and r represents the radial
coordinate, see also Fig. 1. The flow under consideration is assumed to be axis-
symmetric, therefore independent on the azimuthal angle . Furthermore, no
velocity in the latter direction occurs. Thus, the velocity q of the molten glass
is
r x
we ue q + = , where
x
e and
r
e are unit vectors in the x and r direction,
respectively. The other symbols , , , , p g denote the pressure, gravity, density,
dynamic viscosity and surface tension, respectively.
The exact dependence of the other material properties, such as density and surface
tension, on the temperature is not known, especially in the high temperature range
of interest. In practice, however, only the viscosity of the glass varies by several
orders of magnitude over a relative modest temperature range, while the other
parameters are only a weak function of the temperature, for more details see [13].
The molten glass can be treated as an incompressible fluid, so its behaviour can
be described by means of the Navier Stokes equations. Denoting the inner and the
outer radius of the capillary by ) , (
1
t x h r = and ) , (
2
t x h r = , the equations (1)-(3)
thus apply in this region. In order to solve them in a closed form, suitable
boundary and initial conditions must be provided. We consider the feed and the
draw speeds, respectively denoted by U
f
and U
d
, the ambient pressure by
a
p and
the pressure in the hole by
H
p .
Problem solution
The solution of the problem consists of three basic steps. The equations of motion
(1)-(3) are first transformed into a set of non-dimensional equations by applying a
suitable scaling and then the unknowns, i.e. velocities and pressure, are expanded
in power series of the so called slenderness parameter L h/ = . Herein h
denotes a typical drawn capillary size and L denotes the length of a typical hot
zone, as it will be specified later on.
The second step makes use of the small value of in order to simplify the
equations of motions. The third step deals with the solution of the latter for some
particular asymptotic cases. The problem is fully closed by specifying kinematic
and dynamic boundary conditions on the free boundaries.
4
For brevity, the first two steps will not be discussed here, since one can find them
described in details in [8]. The simplified equation of motion will be examined in
some asymptotic limits of interest.
The novel class of equations of motion found by Fitt & Alii in [8] is in the final
dimensional form
( ) ( )
( )
( )
2 2
0 1 2 1 2 1 2 2 2
1 1 0
2 2
2 1
( ( ))
t x
p h h h h h h
h h u
T x h h
+
+ =
(4)
( ) ( )
( )
( )
2 2
0 1 2 1 2 1 2 2 2
2 2 0
2 2
2 1
( ( ))
t x
p h h h h h h
h h u
T x h h
+
+ =
(5)
( )| |
( ) ( )
2 2
2 1 0 0 0
2 2
2 1 0 1 2
3 ( ( ))
t x
x
x
h h u u u g
T x h h u h h
+ =
(
+ +
(6)
where
a H
p p p =
0
.
Equation (6) represents an equation for the leading order velocity of the glass,
while equations (4) and (5) represent evolution equation for the radii
1
h and
2
h .
Appropriate initial and boundary conditions will be now specified.
1
h ,
2
h and
0
u
are all assumed known function of at the time 0 t = and the draw speed is
prescribed (
0
u at x L = ). Therefore we can write
( ) ( ) ( ) ( )
1 10, 2 20, 0 0
0 0 0 , ,
f d
h h h h u U u L U = = = =
(7)
These conditions hold for the specific leading order model but not for the full set
of the Navier-Stokes equations described by (1)-(3).
In comparison to the general equation of motion they offer the possibility to
reduce the enormous mathematical and numerical efforts often required for
solving the general equation model (1)(3). Additionally, basic physical features
of the flow become better accessible. In this context, studying asymptotic cases
offers unique possibilities for optimizing the control of the drawing process.
Some asymptotic solutions
Starting with the simplest possible scenario, considering the steady case when
internal hole pressure, surface tension, inertial and gravity effects are neglected
and the viscosity is assumed constant with the temperature, one obtains from (4)
(5) and (6) after introducing the initial and the final conditions (7)
5 Luzi et al.: Asymptotic analysis of fibre drawing process
Published by The Berkeley Electronic Press, 2011
0
10 1
u
U
h h
f
= (8)
0
20 2
u
U
h h
f
= (9)
(
\
|
=
L
x
U u
f
exp
0
(10)
where ) / log(
f d
U U = , for more details see [8].
In Fig. 2 the behaviour of a preform is shown, when the above assumptions apply
Figure 2: Evolution of the internal and external radius of a preform for the simplest case, when
internal hole pressure, surface tension, inertial and gravity effects are neglected and the viscosity
is assumed constant with the temperature
Taking into account the viscosity dependence on the temperature, one obtains a
slightly different equation for the axial velocity, i.e.
(
(
(
(
L
x
d
T
d
T
d
U u
0
0
0
)) ( (
)) ( (
exp
(11)
while the evolution equations for the radii
1
h and
2
h are the same as (8) and (9),
for more details, see [8].
6
Figure 3: Evolution of the internal and external radius of a preform for the simplest case, when
the viscosity dependence on the temperature (and therefore on the position) is considered.
The shape of the two radii is determined by the viscosity profile, see Fig.3, where
the viscosity profile used here is given in [2]. The absence of surface tension and
internal hole pressurization means that the initial fibre geometry is always
preserved throughout the pull. This is a consequence of the fact that no force act
in the plane of the fibre cross section.
Surface tension effects
One can easily notice that in the asymptotic limit considered in the previous
section the initial shape of the radius is preserved. In contrast to that, it will be
shown here how the effects of surface tension can lead to dramatic changes in the
shape of the radius, when fibres are drawn. Considering the steady isothermal
case, taking into account only the surface tension effects and neglecting gravity,
inertia and internal pressure the following equations are obtained
( ) ( )
2 2
2 1 0 1 2
3 0
x
x
h h u h h
(
+ + =
(12)
( )
( )
( )
1 2 1 2 2
1 0
2 2
2 1
x
h h h h
h u
h h
+
=
(13)
( )
( )
( )
1 2 1 2 2
2 0
2 2
2 1
x
h h h h
h u
h h
+
=
(14)
Integrating the first equation and rearranging, one obtains
( )
( )
1 2
0
2 2
2 1
3
x
C h h
u
h h
+
=
(15)
7 Luzi et al.: Asymptotic analysis of fibre drawing process
Published by The Berkeley Electronic Press, 2011
where C is an arbitrary constant which arise from the integration. The
quantity
( )
2 2
2 1 0
h h u , which can be regarded as the mass flux of the draw, can be
obtained subtracting (14) from (13), and when the boundary conditions (7) apply
( )
2 2
20 10
2 2
2 1
0
f
h h U
h h
u
= (16)
Inserting it in the expression for the derivative of the velocity, i.e. (15), one gets
( )
( ) ( )
1 2
0 0 0
2 2 2 2
20 10 20 10
3 3
x
f f
h h C
u u u
h h U h h U
+
= +
(17)
Expanding the derivatives in the equation for the radii (13) and (14) one obtains
( )
( )
2 1 2 0 1
1
2 2
0 20 10
2 2
x
x
f
h h h u h
h
u h h U
+ | |
=
|
\
(18)
( )
( )
1 1 2 0 2
2
2 2
0 20 10
2 2
x
x
f
h h h u h
h
u h h U
+ | |
=
|
\
(19)
where an expression for
0
0
x
u
u
can be obtained by (17).
The evolution equations for the internal and the external radii therefore read
( )
( )
( )
( ) ( )
2 1 2 1 2 1
1
2 2 2 2 2 2
20 10 20 10 20 10
2 2 3 3
x
f f f
h h h h h h C
h
h h U h h U h h U
| |
+ +
| = +
|
\
(20)
( )
( )
( )
( ) ( )
1 1 2 1 2 2
2
2 2 2 2 2 2
20 10 20 10 20 10
2 2 3 3
x
f f f
h h h h h h C
h
h h U h h U h h U
| |
+ +
| = +
|
\
(21)
Now, a system of three equations in three unknowns has been obtained, which can
be easily solved numerically, but first the value of the constant C arising in the
equations has to be fixed. The solution strategy used in order to solve the problem
is to guess a velocity profile in the following form
0
exp
f
u U x
L
| |
=
|
\
(22)
where is the ratio log
d f
U U and is a convergence parameter,. The derivative
of (22) reads
0
exp
x f
u U x
L L
| |
=
|
\
(23)
Now an expression for the constant C can be obtained, when the equation (17) is
evaluated at x=0,
8
( ) ( )
20 10
2
10
2
20
3 h h
L
U h h C
f
+ + |
\
|
=
(24)
Inserting now (24) in (17) a compete system of equations for the asymptotic
velocity and the radii can be obtained,
( )
( )
0 0 2
10
2
20
2 1
0
3
u
L
u
U h h
h h
u
f
x
+
=
(25)
( )
( )
( )
( )
(
(
+
=
L U h h
h h h
U h h
h h h
h
f f
x
2
10
2
20
2 1 1
2
10
2
20
2 1 2
1
3 2 2
(26)
( )
( )
( )
( )
(
(
+
=
L U h h
h h h
U h h
h h h
h
f f
x
2
10
2
20
2 1 2
2
10
2
20
2 1 1
2
3 2 2
(27)
In order to solve numerically the system of equations (25)-(27) a fourth order
Runge-Kutta Merson method is recommended. Choosing a good initial guess of
the parameter and a sufficient fine grid size, the numerical integration is
performed and the mass conservation equation
in out
m m = & & is checked; if the latter is
not satisfied, then is increased by a certain small amount and the integration is
repeated. The process repeats until the condition
11
10
in out
m m
< & & is satisfied. A
results for such a case, only when surface tension is considered is presented below
Figure 4: Evolution of the internal and external radius of a preform, when only the effects of
surface tension are taken into account and the viscosity is assumed constant with the temperature
As expected, the diameters undergo a contraction, since the effects of surface
tension tend to close the internal hole. In some cases the surface tension can
lead to hole collapse and this must be prevented.
In order to provide a better insight into the surface tension effects, some examples
regarding the evolution of the internal radius of preforms is presented, when
9 Luzi et al.: Asymptotic analysis of fibre drawing process
Published by The Berkeley Electronic Press, 2011
different ratios
10 20
/
a
r h h = are tested.
20
20 h = cm will be kept constant and
10
h will be varied.
In the figures below, the value of surface tension is varied between 0.01 [N/m]
and 0.3 [N/m]. The first of the two values has practically no influence on the
diameter, while the situation changes dramatically if the latter one is used. The
value of 0.3 [N/m] almost produces the collapses of the structure, in particular for
very small values of r
a
(i.e. r
a
=0.2 mm).
Figure 5: Influence of different values of surface tension on the internal diameter for different r
a
:
a) r
a
=0.2, b) r
a
=0.3, c) r
a
=0.4, d)= r
a
=0.6
The case with non constant viscosity is also considered. Following the same
strategy, one begins to assume an expression for the velocity as in (22), now
taking into account that the viscosity is not anymore a constant parameter.
Performing the necessary derivations and substituting it into (17) one gets a new
expression for the constant C, that is
( ) ( )( ) ( )
20 10
2
10
2
20
0 3 h h
L
U h h T C
f
+ + |
\
|
=
(28)
The equation for the velocity become
10
( )
( )
0 0 2
10
2
20
2 1
0
3
u
L
D u
U h h
h h
u
f
x
+
=
(29)
where D is
( ) ( )
( ) ( ) x T
T
D
0
=
(30)
The evolution equations (18)-(19) for the two radii remain the same, but now the
expression for
0 0
/ u u
x
has to be calculated from (29).
In Fig. 6 the effects of the variable viscosity are shown when a preform is drawn,
where the viscosity profile used here is again given in [2].
Figure 6: Evolution of the internal and external radius of a preform for the case taking into
account only the effects of
surface tension. In this case the viscosity varies with the temperature
Influence of the internal pressure
During the process of capillary drawing, the closure of a capillary can often be
avoided by the introduction of a pressure difference between the air inside and
outside the capillary. As suggested by Fitt and Alii [8] the steady isothermal draw
from the equations (4), (5) and (6) is considered, ignoring the effects of inertia,
gravity and surface tension. This leads to the following problem
11 Luzi et al.: Asymptotic analysis of fibre drawing process
Published by The Berkeley Electronic Press, 2011
( )
2 2
2 1 0
3 0
x
x
h h u
(
=
(31)
( )
( )
2 2
2 0 1 2
1 0
2 2
2 1
x
p h h
h u
h h
=
(32)
( )
( )
2 2
2 0 1 2
2 0
2 2
2 1
x
p h h
h u
h h
=
(33)
The system of equation (31)-(33) can be solved analytically by applying the initial
and the final conditions (7)
0
exp
f
u U x
L
| |
=
|
\
(34)
( )
( )
1
2
2 2 2
10 20 10
1
2 2
20 10
exp 1
x L
x L o
f
h h h e
h
p L
h e h
U
| |
|
|
=
|
(
|
(
|
(
\
(35)
( )
( )
1
2
2 2 2
20 20 10
2
2 2
10 20
exp 1
x L
x L o
f
h h h e
h
p L
h e h
U
| |
|
|
=
|
(
|
+ +
(
|
(
\
(36)
for more details see [8]. The shape of the two radii, in case of increasing applied
pressure, is shown below if Fig. 7
12
Figure 7: Evolution of the initial preform as different values of internal pressure are applied.
Here the surface tension effects are not taken into account: a) p
o
=60 [Pa], b) p
o
=80 [Pa], c)
p
o
=100 [Pa] and d) p
o
=137[Pa]
Dividing now
1
h by
2
h
( )
2 2
20 1
2 2
2 10
exp 1
x L o
f
h p L h
e
h h U
(
=
(
(
(37)
The higher the pressure, the more the ratio
1 2
h h increases till certain point at
which the fiber may finally explode and the expression above became unbounded.
To clarify this, consider the mass conservation of the fluid flow taken between
two different points A and B i.e.
( ) ( )
2
2 2 2 2 2 1
2 1 2 1 2 2
2
1
B
A A B B B
B
h
h h h h h
h
| |
= =
|
\
.
One easily sees that if
1
h approaches
2
h the mass is not conserved anymore. If one
considers
1 2
h h = in (37) then an expression for which (35) and (36) become
unbounded is worked out
13 Luzi et al.: Asymptotic analysis of fibre drawing process
Published by The Berkeley Electronic Press, 2011
10
20
2
log 1 log
f
o
U
h L
x
p L h
(
= +
(
(38)
Since the drawing takes place between 0<x<L one may claim that at x=L the fiber
structure has the weakest part and so it is there that the explosion begins to occur.
Setting x=L in (38) and solving for the pressure, one has
( )
10 20
max
2 log
1
f
o
U h h
p
L e
(39)
where
max 0
p is the maximum pressure the fibre can tolerate. For more details
about equations (37), (38) and (39) see [8].
If now the value of the internal pressure is increased till the fibre explodes, one
can see that the coordinate value along the furnace, at which the explosion occurs,
decreases as the pressure increases, see, as instance, Fig.8 below
Figure 8: Coordinate values at which the explosion occurs for different values of internal
pressure: a) p
o
=150 [Pa], b) p
o
=158 [Pa], c) p
o
=164 [Pa], d) p
o
=190 [Pa]
The value of the pressure necessary to decrease the x-coordinate at which the
explosion occurs does not increase linearly. This happens because the amount of
14
material to blow up increases as one moves toward the beginning of the hot
zone, and the thickness of the fibre does not decrease linearly along the furnace
as long as the draw takes place.
The interplay between internal pressure and surface tension
In the real case, during the drawing, one may have to take into account the
combined effects of internal pressure and surface tension. The internal pressure is
sometimes necessary in order to prevent hole collapse. Again, starting from
equations (4), (5) and (6) and considering both internal pressure and surface
tension, one gets
( ) ( )
2 2
2 1 0 2 1
3 0
x
x
h h u h h
(
+ + =
(40)
( )
( )
( )
2 2
1 2 1 2 1 2 2
1 0
2 2
2 1
o
x
p h h h h h h
h u
h h
+
=
(41)
( )
( )
( )
2 2
1 2 1 2 1 2 2
2 0
2 2
2 1
o
x
p h h h h h h
h u
h h
+
=
(42)
The equations (40)-(42) may now be manipulated as (12)-(14), arriving at the
following final system of equations for the steady isothermal case
( )
( )
0 0 2
10
2
20
2 1
0
3
u
L
u
U h h
h h
u
f
x
+
=
(43)
( )
( )
( )
( )
(
(
+
=
L U h h
h h h
U h h
h h h h h p
h
f f
x
2
10
2
20
2 1 1
2
10
2
20
2 1 2
2
2 1 0
1
3 2 2
(44)
( )
( )
( )
( )
(
(
+
=
L U h h
h h h
U h h
h h h h h p
h
f f
x
2
10
2
20
2 1 2
2
10
2
20
2 1 1 2
2
1 0
2
3 2 2
(45)
Note that if the surface tension coefficient is set equal to zero in (43)-(45) one
immediately obtains (34)-(36) (N.B. when the boundary conditions (7) apply one
finds = ), while if the pressure term is set equal to zero in (44) and (45) one
readily obtains (25)-(27). This means that all the formulas derived are consistent
to each other. Another interesting point is that if the derivatives of the
diameters
x
h and that of the velocity
x
u tend to zero, which means that the
diameters
1
h and
2
h , and the velocity
0
u become constants.
One immediately notes the effects of the interplay between internal pressure and
surface tension, which leads to a higher value of the internal applied pressure
which can be tolerated by the fibre. While the internal pressure, roughly speaking,
tends to open the hole, the surface tension tries to close it, see as instance Fig. 9
15 Luzi et al.: Asymptotic analysis of fibre drawing process
Published by The Berkeley Electronic Press, 2011
Figure 9: Evolution of the initial preform as internal pressure and surface tension effects are
considered. The viscosity is here considered constant with the temperature: a) po=120 [Pa], b)
po=140 [Pa], c) po=160 [Pa], d) po=175 [Pa]
To improve the quality of the results one may use a finer grid space, but this does
not change the results. The non isothermal case, in which the viscosity is let to
vary with the temperature, has also been analyzed and it represents the real case
of fibre drawing. The system of the governing equations of the process reads
( )
( ) ( )( )
0 0 2
10
2
20
2 1
0
3
u
L
D u
U h h x T
h h
u
f
x
+
=
(46)
( )
( ) ( )( )
( )
( ) ( )( )
(
(
+
=
L
D
U h h x T
h h h
U h h x T
h h h h h p
h
f f
x
2
10
2
20
2 1 1
2
10
2
20
2 1 2
2
2 1 0
1
3 2 2
(47)
( )
( ) ( )( )
( )
( ) ( )( )
(
(
+
=
L
D
U h h x T
h h h
U h h x T
h h h h h p
h
f f
x
2
10
2
20
2 1 2
2
10
2
20
2 1 1 2
2
1 0
2
3 2 2
(49)
where the constant D is given by (30). The shape of the two radii is thus modified
by the viscosity profile, which is again given in [2].
16
Figure 10: Evolution of the initial preform as internal pressure and surface tension effects are
considered. The viscosity is here considered non constant with the temperature, which reaches its
peak (1950 [C])at the center of the furnace: a) p
o
=0 [mbars], b) p
o
=10 [mbars], c) p
o
=20
[mbars], d) p
o
=25 [mbars]
Conclusion and Outlook
The present paper aims at optimizing and controlling drawing processes on the
basis of a suitable mathematical model, which provides a better access to the basic
feature of the flow process and greatly reduces the simulation time. The
mathematical model proposed in [8], which couples the effects of surface tension
and internal pressure in the process of fibre drawing, has been analysed and
revisited.
For very simple cases the solution can be treated completely on an analytical
manner, and it provides basic insights into the velocity profile and the fibre shape.
Successively, the effects of internal hole pressurization and surface tension have
been included in the model, first separately and then together. Even for these
more complex situations the simplified equations are solved with less numerical
cost.
17 Luzi et al.: Asymptotic analysis of fibre drawing process
Published by The Berkeley Electronic Press, 2011
The results obtained elucidate how the surface tension acts in such a way that the
radii undergo a contraction and in some cases, when the internal radius of a
preform is very small, it may lead to the complete collapse of the structure. On the
other hand, when internal pressure is applied, an enlargement of the internal hole
occurs. If the applied pressure exceeds certain values, it may lead to the explosion
of the structure. Finally, if both effects are considered, it can be seen how internal
pressure acts as a stabilizing mechanism, maintaining holes opened and vice-versa
how surface tension increases the value of the explosion pressure.
Comparisons of the results obtained here with experimental data shows very good
agreement, for more details see [6], where, for convenience, this topic is presented
and discussed in detail.
TABLE I
NOTATION
Symbol Definition
t
time
x distance along capillary axis
r
distance perpendicular to axis
q
velocity of the molten glass
0
u leading order axial fluid velocity
H
p hole pressure
g
acceleration due to gravity
density
0
dynamic viscosity
surface tension
L furnace length
1
h inner diameter
2
h outer diameter
a
p ambient pressure
o
p hole overpressure
U typical draw speed
20
h outer diameter preform
10
h inner diameter preform
18
h difference between the outer diameter preform and the inner diameter preform
f
U
feed velocity
d
U draw velocity
convergence parameter
log(Ud/Uf)
Re Reynolds Number
slenderness parameter
h difference between the outer diameter preform and the inner diameter preform
i
t