Experimental and numerical study on the performance index of mixing for low aspect ratio serpentine microchannels

Abstract In this work, the effect of a range of Dean numbers (De) varying from 0.01–70 on low aspect ratio (AR = 0.05–0.2) serpentine microfluidic devices was studied experimentally and numerically. It was observed that the AR, the number of circular bumps, and the angular positions of bumps transverse to the flow have a significant influence on the pressure drop and flow features (i.e., the position and shape of flow separation zones). Mixing was exclusively driven by diffusive mechanisms at low De values and at high De values, it was primarily induced by Dean vortices. The lowest mixing index (MI) was observed for De = 1 in all channel types, highlighting the transition region between the diffusion and Dean vortices-dominant mixing regimes. The MI was generally increased by increasing the AR of the channels. However, at high De, Dean vortices became strong enough to induce rapid mixing that was largely independent of the AR and bump placement. A dimensional performance index (PI) was defined as a function of the MI and the pressure drop per unit length. Distinct flow patterns arising from various positioning of bumps resulted in significant variations in the MI and PI values, with different dependencies on De. This underscored the importance of bump positioning based on the operational De range to optimize the mixing performance. Despite minor deviations between the designed and fabricated channels, the use of 3D-printed molds proved effective even at scales close to the resolution of the printer, resulting in mixing patterns consistent with the designed channels. These findings provide valuable insights into optimizing serpentine microchannels for efficient mixing while considering the trade-offs between enhanced mixing and increased pressure drop.