We consider the role of heating and cooling in the steady drawing of a long and thin viscous thread with an arbitrary number of internal holes of arbitrary shape. The internal holes and the external boundary evolve as a result of the axial drawing and surface-tension effects. The heating and cooling affects the evolution of the thread because both the viscosity and surface tension of the thread are assumed to be functions of the temperature. We use asymptotic techniques to show that, under a suitable transformation, this complicated three-dimensional free boundary problem can be formulated in such a way that the transverse aspect of the flow can be reduced to the solution of a standard Stokes flow problem in the absence of axial stretching. The solution of this standard problem can then be substituted into a system of three ordinary differential equations that completely determine the flow. We use this approach to develop a very simple numerical method that can determine the way that thermal effects impact on the drawing of threads by devices that either specify the fibre tension or the draw ratio. We also develop a numerical method to solve the inverse problem of determining the initial cross-sectional geometry, draw tension and, importantly, heater temperature to obtain a desired cross-sectional shape and change in cross-sectional area at the device exit. This precisely allows one to determine the pattern of air holes in the preform that will achieve the desired hole pattern in the stretched fibre.
Mathematical modelling is used to examine the unsteady problem of heating and pulling an axisymmetric cylindrical glass tube with an over-pressure applied within the tube to form tapers with a near uniform bore and small wall thickness at the tip. To allow for the dependence of viscosity on temperature, a prescribed axially varying viscosity is assumed. Our motivation is the manufacture of emitter tips for mass spectrometry which provide a continuous fluid flow and do not become blocked. We demonstrate, for the first time, the feasibility of producing such emitters by this process and examine the influence of the process parameters, in particular the pulling force and over-pressure, on the geometry. There is not a unique force and over-pressure combination to achieve the desired geometry at the tip but smaller over-pressure (hence force) yields a more uniform bore over the entire length of the emitter than does a larger over-pressure (and force). However, the sensitivity of the geometry to small fluctuations in the parameters increases as the over-pressure decreases. The best parameters depend on the accuracy of the puller used to manufacture the tapers and the permissible tolerances on the geometry. The model has wider application to the manufacture of other devices.
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