Dynamics of jet breakup and the resultant drop size distribution-effect of nozzle size and impingement velocity

We conduct systematic experiments to investigate the dynamics of liquid jet breakup and the resulting droplet size distribution, emphasizing the influence of liquid jet velocity and needle exit diameter. We precisely control jet formation using a pressurized water tank equipped with needles of different sizes. Our study quantifies breakup dynamics through dimensionless parameters such as the liquid Weber number (We) and the needle exit area ratio (Ar). Our key findings identify three distinct breakup regimes—dripping, Rayleigh, and wind-induced—each dictated by the interplay of surface tension and aerodynamic forces for various combinations of liquid jet velocity and needle exit diameter. We construct a regime map to delineate different breakup behaviors in the We−Ar space. It is observed that lower jet velocities produce narrow probability density functions for jet breakup length due to stable jets, whereas higher velocities result in broader distributions. Increasing jet velocity extends breakup lengths for moderate flow rates due to enhanced stability in the Rayleigh regime, but higher velocities induce instability, leading to shorter breakup lengths. Additionally, we analyze the effects of the needle exit area ratio and liquid Weber number on droplet size distribution, highlighting the transition from mono-modal to bi-modal distribution under varying conditions.