Assessment of 3D CFD Modeling of W/O Emulsification in Microfluidic Cross-Junctions

This study investigates water-in-oil emulsification in an asymmetric cross-slot microchannel using 3D CFD simulations. Two inlet streams with different cross-sections generate a head-on impinging flow that enhances droplet breakup via recirculation. Simulations are performed using the Volume of Fluid method in ANSYS Fluent, with URANS modeling and Adaptive Mesh Refinement and turbulence closure. Two experimental cases from literature are reproduced to analyze early-phase interface dynamics, velocity fields, and shear rates. Results offer high-resolution insight into emulsion formation mechanisms, supporting experimental design and optimization for high-throughput microfluidic applications.