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A passive micromixer based on the modified Tesla mixing unit was designed by embedding tip clearance above the wedge-shape divider, and its mixing performance was simulated over a wider range of the Reynolds numbers from 0.1 to 80. The mixing performance was evaluated in terms of the degree of mixing (DOM) at the outlet and the required pressure load between inlet and outlet. The height of tip clearance was varied from 40 μm to 80 μm, corresponding to 25% to 33% of the micromixer depth. The numerical results show that the mixing enhancement by the tip clearance is noticeable over a wide range of the Reynolds numbers Re &lt; 50. The height of tip clearance is optimized in terms of the DOM, and the optimum value is roughly h = 60 μm. It corresponds to 33% of the present micromixer depth. The mixing enhancement in the molecular diffusion regime of mixing, Re ≤ 1, is obtained by drag and connection of the interface in the two sub-streams of each Tesla mixing unit. It appears as a wider interface in the tip clearance zone. In the intermediate range of the Reynolds number, 1 &lt; Re ≤ 50, the mixing enhancement is attributed to the interaction of the flow through the tip clearance and the secondary flow in the vortex zone of each Tesla mixing unit. When the Reynolds number is larger than about 50, vortices are formed at various locations and drive the mixing in the modified Tesla micromixer. For the Reynolds number of Re = 80, a pair of vortices is formed around the inlet and outlet of each Tesla mixing unit, and it plays a role as a governing mechanism in the convection-dominant regime of mixing. This vortex pattern is little affected as long as the tip clearance remains smaller than about h = 70 μm. The DOM at the outlet is little enhanced by the presence of tip clearance for the Reynolds numbers Re ≥ 50. The tip clearance contributes to reducing the required pressure load for the same value of the DOM.

Mixing Performance of the Modified Tesla Micromixer with Tip Clearance