In silico evaluation of manufacturing concepts for non-Newtonian products

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The main aim of the work is to establish the optimal geometric configuration for a particular configuration of process mixer(a Controlled Deformation Dynamic Mixer (CDDM)). The project will seek to understand the unique flow dynamics foundinside the mixer itself and, through that understanding, improve the quality of the mixture that the device produces. At thesame time, the work will establish changes to the mixer geometry such that the overall mixture is improved, whilesimultaneously reducing the power required. The analysis of the mixer is made more complex because the flow within istypically non-Newtonian, and demonstrates a viscosity that is dependent (in the first instance) on the shear rate and (in thesecond instance) on the processing history of the fluid itself. The physics of the process material, coupled with thecompeting influences of high angular velocities (the mixer typically runs at approximately 50000rpm), high pressure dropsand extremely small flow geometries preclude easy characterisation of the flow. In addition, the channels through the mixerare sinuous and change with the mixer rotor position. In the light of these, the flow will be studied initially in the laminarflow mode and static configuration; as understanding develops, increasingly complex dynamics will be introduced---eitherthrough the mixer motion itself, through the action of the viscosity, through turbulent flow physics or some combination of allthree. The work is of considerable interest to the academic partner, as the evolving rheology represents an application ofmultiphysics; it couples together CFD, rheology and (in the longer term) meso-scale modelling. The wider goal of theproject is to accelerate the introduction of new & better products into the market by the simulation of manufacturingprocesses for complex multiphase liquid products for fast moving consumer goods (FMCG), and unifies computational fluiddynamics (CFD), rapid prototyping (RP) and experimental evaluation.