A study on flow through hydroentangling nozzles and their degradation

Abstract

Hydroentangling is a technique for mechanically bonding loose filaments or fibers arranged in a web. The efficiency with which the web is entangled depends on the peculiar properties of laminar high-speed waterjets used. The characteristics of such waterjets strongly depend on the operating pressure and the nozzle inlet sharpness which influence the dynamics of fluid flow. In this study, we report on experiments and CFD simulations aimed at improving our knowledge of such two-phase flows. In particular, we simulate the formation and growth of the cavitation cloud inside a sharp-edge hydroentangling nozzle at pressures ranging from 10 to 200 bars ( 5700 < Re < 25 600 ) . Our experimental results run at the same pressures, confirm that nozzle cavitation will cause “hydraulic flip”. Once hydraulic flip occurs, atomizing waterjets will turn into constricted laminar waterjets with long intact lengths—a necessary condition for hydroentangling. It has been observed that the nozzle inlet deteriorates under high pressures. Our CFD simulations show a striking similarity between the contours of shear stress at the nozzle inlet and the nozzle wear pattern. These findings together with the SEM elemental analysis at the nozzle inlet reveal the potential for metal oxidation around the inlet, implicating stress-induced corrosion as a major contributor to the nozzle wear. Cavitation might also be one of the mechanisms responsible for the above-mentioned wear at the inlet edge. Additionally, our water-borne solid particle tracking, confirms SEM experimental results that particle deposition can potentially play a considerable role in the deterioration of the nozzle inlet shape.