Droplet step emulsification has been proven to possess
the unique
advantage of decoupling the flow parameters, which obviously contributes
to the realization of the mass production of monodisperse droplets.
However, a complete understanding of the dynamic characteristics underlying
droplet spontaneous formation in step emulsification has not been
fully revealed and remains a challenge because the channel confinement
effect always results in the complexity in interface spatiotemporal
evolution under various conditions. In this work, the spontaneous
formation mechanisms of droplets in step emulsification are numerically
investigated via a VOF–CSF model. The physics behind the two
distinct flow patterns regarding dripping and jetting are deeply revealed
based on the local flow field structures and pressure distribution,
and it was found that in dripping, before final pinch-off of the neck,
a finite time singularity usually exists, thus leading to infinite
velocity and pressure inside the neck. However, in jetting, as the
droplet steadily expands, the velocity and pressure inside the neck
finally reach an equilibrium state. Besides, by taking multiple variables
with a wide range into account, the flow pattern diagram and the prediction
correlation of droplet size are established with several dimensionless
numbers, exhibiting excellent universality. In particular, the force
field characteristics previously undocumented for droplet step emulsification
are also quantitatively clarified from a new perspective of momentum
conservation. The results obtained in this study reveal the spontaneous
formation mechanisms of droplets in step emulsification, thus providing
theoretical guidance for precisely regulating the emulsification process.