A

Project Report
on
“Project Title”

Submitted in partial fulfillment of the requirements

for the award of the degree of

Bachelor of Technology (B.Tech.) in Mechanical of Engineering,

To

Punyashlok Ahilyadevi Holkar Solapur University, Solapur

By
1) Mr./Ms...................[PRN:…....]
2) Mr./Ms...................[PRN:…....]
3) Mr./Ms...................[PRN:…....]
4) Mr./Ms...................[PRN:…....]

Project Group No.: …....

Under the guidance of

Prof. D. T. Kashid

DEPARTMENT OF MECHANICAL ENGINEERING

SVERI’s COLLEGE OF ENGINEERING, PANDHARPUR

Academic Year: 2024-2025

 SVERI'S COLLEGE OF ENGINEERING, PANDHARPUR
CERTIFICATE
This is to certify that the dissertation entitled
“Project Title”
has been submitted by
1) Mr./Ms...................[PRN:…....]
2) Mr./Ms...................[PRN:…....]
3) Mr./Ms...................[PRN:…....]
4) Mr./Ms...................[PRN:…....]

in partial fulfillment of the requirements for the award of the degree of

Bachelor of Technology (B.Tech.) in Mechanical Engineering, as per the
curriculum prescribed by Punyashlok Ahilyadevi Holkar Solapur
University, Solapur, during the academic year 2024–2025.

(Prof. D. T. Kashid) (Dr. S. B. Bhosale)

Project Guide Head, Mech. Engg. Dept.

(Dr. B. P. Ronge)
Principal External Examiner
 DECLARATION

We hereby declare that the project work entitled “Project Title” submitted to
Punyashlok Ahilyadevi Holkar Solapur University, Solapur, in partial fulfillment of
the requirements for the award of the degree of Bachelor of Technology (B.Tech.) in
Mechanical Engineering, is a record of original work carried out by us under the
supervision of Prof. D. T. Kashid, Department of Mechanical Engineering, SVERI’s
College of Engineering, Pandharpur.

We further declare that:

● This project work has not been submitted, either in part or full, for the award of
any other degree or diploma in any university or institute.

● All sources of information and literature used in this report have been duly
acknowledged.

● We have strictly adhered to the guidelines prescribed by Punyashlok

Ahilyadevi Holkar Solapur University and the institute regarding academic
integrity, plagiarism, and ethical conduct.

Project Members:

Sr. No. Name of Student PRN Signature

1. Mr./Ms. _____________________ ___________ ___________

2. Mr./Ms. _____________________ ___________ ___________

3. Mr./Ms. _____________________ ___________ ___________

4. Mr./Ms. _____________________ ___________ ___________

 ACKNOWLEDGEMENT

This work is not merely the result of individual effort; it is the outcome of support and
collaboration from many people. We take this opportunity to express our sincere
gratitude to everyone who helped us bring this project to its successful completion.

First and foremost, we extend our heartfelt thanks to Dr. S. B. Bhosale, Head of the
Department of Mechanical Engineering, for accepting our project proposal,
continuously assessing our progress, and providing invaluable guidance through timely
suggestions and discussions at every stage.

We are especially grateful to our project guide, Prof. D. T. Kashid, Department of

Mechanical Engineering, for his expert guidance, inspiration, insightful suggestions,
and unwavering support throughout the duration of our project. His constructive
feedback and encouragement were instrumental in shaping this dissertation, and without
his mentorship, the successful completion of this work would not have been possible.
We thank him deeply and sincerely.

We also express our sincere gratitude to Dr. B. P. Ronge, Principal, SVERI’s College
of Engineering, Pandharpur, for the constant encouragement and support provided
during the course of this project.

Finally, we extend our thanks to our friends and all those who directly or indirectly
supported, encouraged, and motivated us throughout this project journey.

Project Members
1. Mr./Ms...................[PRN:…....]
2. Mr./Ms...................[PRN:…....]
3. Mr./Ms...................[PRN:…....]
4. Mr./Ms...................[PRN:…....]
 ABSTRACT

Mostly the micro channel parts are significant for lab on a chip device. Use of micro
channels is in biomedical devices and micro fluidic applications. The fabrication of
micro channel is quite tough by using conventional manufacturing. To characterize
technology, different methods are used for the fabrication of micro channel. By using
both conventional and non-conventional techniques, like micro milling, lithography,
embossing processes and laser ablation processing. In this paper, a study on the use of a
commercial CO2laser system for fabrication of micro-channel molds using Acrylic
material.
The accuracy of micro channel mainly depends on the fabricated molds. By using laser
power and scanning speed we can control the depth of micro channel. To analyze the
effect of Laser power and scanning speed on the depth of the Micro channel mold
primary experimentation is performed. According to analysis, it is observed that the
depth of micro channel mold increasing linearly with an increase in laser power and
decreasing with increasing speed. The micro channel with a straight configuration
having Y shaped inlet with circular, verticaland elliptical obstacles .By using the
CO2Laser machining on Acrylic material. In the present days, Acrylic comes in a wide
variety of standard colors (colorless sheet). The fact that some of them are bullet
resistant, it is now in highly demand.
Acrylics come in various shapes. There are many ways of processing them, and
the one discussed here is the process done by using laser cutter machines. The process
is called laser-cutting process.
Keywords: Micro channel, ……(minimum 5 keywords)
 LIST OF FIGURES

Sr. No Fig. No. Name of Figure Page No.

1 1.1 2
Classification of crash tests
2 1.2 3
Sled Test Set-up (schematic) at ARAI, Pune
3 1.3 Deceleration Pulse Specified in AIS 005 for 4
testing
Deceleration Pulse Specified in AIS 016 for
4 1.4 4
testing of seats, their anchorages and head
restraints for category M1category M1
5 1.5 5
Deceleration pulse specified for Frontal Impact
Deceleration Pulse Specified in ECE-44 for
6 1.63 5
child restraint system.(Deceleration pulse
specified For Rear Impact
 LIST OF TABLES

Sr. No Table No. Name of Table Page No.

1 1.1 2
Classification of crash tests
2 1.2 3
Sled Test Set-up (schematic) at ARAI, Pune
3 1.3 Deceleration Pulse Specified in AIS 005 for 4
testing
Deceleration Pulse Specified in AIS 016 for
4 1.4 4
testing of seats, their anchorages and head
restraints for category M1category M1
5 1.5 5
Deceleration pulse specified for Frontal Impact
Deceleration Pulse Specified in ECE-44 for
6 1.63 5
child restraint system.(Deceleration pulse
specified For Rear Impact
 NOMENCLATURE

Psei Steady state inversion load

B Die fillet radius
Yo Yield stress of tube material
TR Theoretically obtained result
ER Experimental result
NR Numerical model Result
 TABLE OF CONTENTS

Chapter Title Page No.

Abstract i
List of Figures ii
List of Tables iii
Nomenclature iv
1 Introduction 1
1.1 What is smart farming 1
1.2 IoT in Smart Farming 2
1.3 Benefits of Smart Farming 3
1.4 IoT in Irrigation System 3
1.5 Need 4
1.6 Problem Statement 5
1.7 Objectives 5
2 Literature Review 6
3 Proposed System 8
3.1 ……… 8
3.2 …. …… 10
4 System Design and Analysis 11
4.1 …….. 11
4.2 …… 12
5 Methodology/ Devices Used 15
5.1 Experimental analysis of fluid flow 17
through Micro channels

6 Experimental Results / Outputs 20

6.1………… 22
7 Conclusions and Future Scope 28
 References 29
Annexure-I: Sponsored project 30
Approval &Completion letter
Appendix-II: Paper Publication 32
Certificate and Paper
Appendix-III: Photos related to 40
Experimental work

Note- Chapter No-1 and 2 are same for all students But Chapter No-03
onwards it will different as per title of your Project
CHAPTER 1

INTRODUCTION

Microfluidics deals with the behavior, precise control and manipulation of fluids
that are geometrically constrained to a small, typically sub-millimeter, and scale. It is a
multidisciplinary field at the intersection of engineering, physics, chemistry, biochemistry,
nanotechnology, and biotechnology, with practical applications in the design of systems in
which low volumes of fluids are processed to achieve multiplexing, automation, and high-
throughput screening. Microfluidics emerged in the beginning of the 1980s and is used in
the development of inkjet print heads, DNA chips, lab-on-a-chip technology, micro-
propulsion, and micro-thermal technologies. The devices used for Microfluidics are called
as micro channels.
In Microfluidics systems viscosity dominates flow and mixing is limited to
molecular diffusion due to laminar nature if micro flow and the flows tend to form a
laminate structure of micro flow instead of uniform mixture due to small Reynolds
Number. Hence the focus on this field of research is to propose a device itself and to
optimization of the geometry to enhance fluid mixing within the micro channels.
At the macroscopic level systems usually mix fluids using micro channels actuators
or turbulent 3D flow but at the micro scale level, neither of this approach is practical or
even possible. To characterize the fluid flow i.e. laminar or turbulent behavior, Reynolds
number is used which is as given below:

Re =
Where, ρ is fluid density, V is flow velocity, D is hydraulic diameter of channel, µ is
fluid’s dynamic velocity
Turbulent flow takes place when Re is high, typically when Re is greater than 2000.
The width of the micro channels usually is in the range of 100 to 500µm and the velocity is
approx. less than 1cm/sec. In this case, for water-like substances, Reynolds Number is
close to unity the fluid flow is thus clearly laminar so effective mixing if fluids in
microchannels is requires other means.
Nowadays micro total analysis systems (µTAS) plays significant role in many of
the applications and microchannel is one of the prominent parts of these systems. The
microchannels are having applications in various fields like medical, diagnostics, chemical,
biological, etc.
 The microchannels can be fabricated by using Acrylic material more economically
and efficiently as compared to commercial materials like Silicon, Glass and Polymers, etc.
Due to low cost and straight forward fabrication these microchannels are widely used in
Medical and Engineering fields.

1.1 The Physics of Micro-fluidics:

The work with the micro-fluidics, it is necessary first to understand the physical
phenomenon associated with the micro-fluidics and also the factors that dominate at the
micro-scale. Very few characters have given a comprehensive look at the physics of the
micro- scale. In this section, the physics of micro-fluidics are reviewed with references to
more complete treatment. The micro-fluidics id the handling and analyzing of fluids in the
structures of micro-scale dimensions. The creation of micro-fluidic devices began by using
technology originally developed for the micro-chip industry but has now grown into a field
of its own. New designs must be made to take advantage of forces that works on the micro-
scale. The effects that become dominant in micro-fluidics include laminar flow, fluidic
resistance, and surface area to volume ratio, diffusion, and surface tension.
1.1.1 Laminar Flow:
A common application of laminar flow is in the smooth flow of a viscous liquid
through a tube or pipe. In that case, the velocity of flow varies from zero at the walls to a
maximum along the cross-sectional centre of the vessel. The flow profile of laminar flow in
a tube can be calculated by dividing the flow into thin cylindrical elements and applying
the viscous force to them. For such systems, laminar flow occurs when the Reynolds
number is below a critical value of approximately 2,040, though the transition range is
typically between 1,800 and 2,100.
1.1.2 Surface area to volume ratio:
One characteristic of micro-scale and nano scale devices is the high surface area to
volume ratio (SAV), and this characteristic can lead to unconventional overriding forces.
For example, large SAVs typically make surface forces (such as surface tension) the
dominant force, while greatly reducing the influence of inertial and body forces. An
example of a micro-fluidic architecture that takes advantage of this feature involves
‘‘digital micro-fluidic technology’’ where droplets of water/oil are created and transported
in a controlled fashion to achieve functions such as storage, mixing, chemical reaction, or
analysis, in a 0discrete manner. The droplets are formed using the surface tension
properties of liquid, as well as by controlling the hydrophobicity of the substrate via
electrical fields and/or material coating .Digital micro-fluidics is gaining much attention
because of its ability to precisely control transport in the water/oil droplets. This
technology currently has the capability of being programmable, reconfigurable, and
reusable, towards the goal of creating a lab-on-a-chip.

1.1.3 Diffusion:
Diffusion is the process by which a concentrated group of particles in a volume
will, by Brownian motion, spread out over time so that the average concentration of
particles throughout the volume is constant (Figure 1.1). Diffusion can be modeled in one
dimension by the equation d2 =2Dt, where d is the distance a particle moves in a time t, and
D is the diffusion coefficient of the particle. Because distance varies to the square power,
diffusion becomes very important on the micro-scale.
While diffusion coefficients of the gases is of the order of 10 -5 m2/s, diffusion
coefficients in the liquids are of the order of 10-9 m2/s

Fig. 1.1 Two streams flowing in contact will not mix except by diffusion
1.2 Mixing:
Mixing in micro-fluidic devices presents a challenge due to laminar flows in
microchannels, which result from low Reynolds numbers determined by the channel’s
hydraulic diameter, flow velocity, and solution’s kinetic viscosity. To address this
challenge, novel methods of mixing enhancement within micro-fluidic devices have been
explored for a variety of applications. Passive mixing methods have been created, including
those using ridges or slanted wells within the microchannels, as well as their variations
with improved performance by varying geometry and patterns, by changing the properties
of channel surfaces, and by optimization via simulations. In addition, active mixing
methods including micro-stirrers, acoustic mixers, and flow pulsation have been
investigated and integrated into micro-fluidic devices to enhance mixing in a more
controllable manner. In general, passive mixers are easy to integrate, but difficult to control
externally by users after fabrication. Active mixers usually take efforts to integrate within a
device and they require external components (e.g. power sources) to operate. However,
they can be controlled by users to a certain degree for tuned mixing. In this article, we
provide a general overview of a number of passive and active mixers, discuss their
advantages and disadvantages, and make suggestions on choosing a mixing method for a
specific need as well as advocate possible integration of key elements of passive and active
mixers to harness the advantages of both types.

1.2.1 Need for Micro-Mixing:

Active development and improvement of micro-fluidic devices have
allowed making significant progress in biomedical diagnostics study, development of
miniaturized micro-fluidic and nano -fluidic biosensors, in DNA analysis, chemical
synthesis and genomics study, etc. The channel dimensions in micro-fluidic systems are
measured in micrometers and in nano-fluidics they go down to nanometers. This allowed to
noticeably reduce surface to volume ratios and thus, to decrease samples/reagents
consumption and obtain compact devices. However, sample flows in such miniaturized
channels are extremely laminar and not turbulent, which corresponds to small Reynolds
number values. Consequently, in such laminar flows, traditional turbulent mixing between
two liquids cannot occur. However, controllable and fast mixing is critical for subsequent
practical development of micro-fluidic and lab-on-chip devices often used for assays
involving many reagents and samples. That’s why different mixing techniques were
developed and studied by various research groups.

1.3 Micro- Mixers:

In mechanics, a micro-mixer is a device based on mechanical micro parts used to
mix fluids. This device represents a key technology to fields such as chemical industry,
pharmaceutical industry, analytical chemistry, biochemical analysis, and high-throughput
synthesis, since it makes use of the miniaturization of the fluids associated in the mixing to
reduce quantities involved in the chemical and/or biochemical processes.
There are two types of micro-mixers: passive and active. The active ones use an
external energy source, which can be electric or magnetic, to perform the mixing of the
fluids. In the passive ones, there is no power source employed and basically, pressure
guides the flow of fluids.
1.3.1 Passive Micro-mixers:
Passive micro-mixers rely on the mass transport phenomena provided by molecular
diffusion and chaotic advection. These devices are designed with a channel geometry that
increases the surface area between the different fluids and decreases the diffusion path. By
contrast, the enhancement of chaotic advection can be realized by modifying the design to
allow the manipulation of the laminar flow inside the channels. The modified flow pattern
is characterized by a shorter diffusion path that improves the mixing velocity. In this
section, an overview of the different types of passive micro-mixers is provided. Mixed
phase passive micro-mixers can be categorized as:
1. T- and Y-shaped micro-mixers
2. Parallel lamination micro-mixers
3. Sequential lamination micro-mixers
4. Focusing enhanced mixers
5. Chaotic advection micro-mixers
6. Droplet micro-mixers
1.3.2 Active Micro-mixers:
As described previously, active micro-mixers rely on an external energy input to
introduce perturbation within the fluid streamlines to achieve mixing. Therefore, they are
categorized with respect to the type of external perturbation energy:
1. Pressure Field
2. Electokinetic Micro-mixing Within Micro-fluidic Devices
3. Dielectrophoretic
4. Electro wetting

1.4 Micro-mixing:
Mixing in micro-fluidic devices presents a challenge due to laminar flows in
microchannels, which result from low Reynolds numbers determined by the channel
diameter, flow velocity, and solution’s kinetic viscosity. To address this challenge, novel
methods of mixing enhancement within micro fluidic devices have been explored for a
variety of applications. Passive mixing methods have been created, including those using
ridges or slanted wells within the micro channels, as well as their variations with improved
performance by varying geometry and patterns, by changing the properties of channel
surfaces, and by optimization via simulations. In addition, active mixing methods including
micro stirrers, acoustic mixers, and flow pulsation have been investigated and integrated
into micro fluidic devices to enhance mixing in a more controllable manner.However,
micro-fluidic devices also have limitations. One of the challenges is mixing, which is often
required for sample dilution, reagent homogenization, and chemical or biological reactions.
The difficulty in achieving sufficient mixing in a micro-fluidic device results from laminar
flows that can be explained by low Reynolds number. The characteristic length (L) of a
micro flow is typically on the order of 100 μm. The hydraulic diameter of the channel is
used as the characteristic length, and is defined as 4A/Pw where A is the cross sectional
area and Pw is the wetted perimeter of the channel. The low L values commonly found
in micro fluidic devices suggest a high surface-area-to-volume ratio, yielding enhanced
heat and mass transfer within these devices.1However, this low hydraulic diameter,
combined with typically small (~1 mm/s) flow velocities(V)due to extremely high back
pressures and with typical kinematic viscosities of on the order of 10-6m2/s, leads to
very small Reynolds numbers for flow in microchannels (~0.1). As a result, flows in
micro-fluidic devices are almost always laminar in nature. The low Reynolds number
implies that viscous forces are dominating over inertial forces within the flow, dampening
out any flow irregularities that might aid in fluid mixing.

1.5 Droplet Formation:

Fig. 1.2 (a) Co-Flowing System (b) Droplet formation in channel by
crossing

CHAPTER 2
LITERATURE REVIEW
A lot of research has been done on micro-channels with different configurations,
both experimentally and numerically. This chapter deals with the literature review of
analysis of fluid flow through micro-channel with different configurations. This chapter is
divided into the three sections:

2.1 Fluid Flow Analysis:

Wong et al. [2] fabricated micro T-mixers and tested to investigate their feasibility
as rapid mixing micro-mixers. The micro T mixers were fabricated out of a silicon
substrate and bonded to Pyrex glass plate to enable their mixing performances that
observed and characterized. The mixing was characterized using a blue dye and a colorless
liquid; the results were further verified by the hydrolysis reaction of dicloroacetyl phenol
red. Different pressures were applied on to the inlets of the micro T-mixers and their
corresponding mixing performances were observed with an optical microscope. Liquid
streams break up into striations at progressively higher Reynolds number of flow and there
exists a Reynolds number between 400 and 500 when these striations disappear into
uniform concentration across the mixing channel. The observations were further supported
by computer simulations, which enable the fast mixing to be explained by the asymmetrical
flow conditions at the inlets, in addition to the generation of vortices and secondary flow at
the junction. It was shown that for a micro T-mixer with a mixing channel having a
hydraulic diameter of 67 um, an applied pressure of 5.5 bars was sufficient to cause
complete mixing within less than a millisecond after the two liquids made contact.
Orsi et al. [4] has performed numerical simulations to study the mixing dynamics of
two miscible liquids within a T shaped micro-mixer, comparing the case where the two
inlet fluids are both water (W - W) At smaller Reynolds number, Re <100, there was no
vortex formation for either cases, therefore, mixing water and ethanol was Slightly easier
than mixing water with water because the residence time of the fluid occupying the
interfacial region in the W-E case was larger than that of the W-W case. On the other hand,
at larger Reynolds number, mixing water and ethanol may take considerably longer, as the
onset of engulfment was retarded and occurs at large Reynolds number. All these behaviors
were due to the fact that, as a W-E mixture has a viscosity that was almost three times
larger than that of water, at the confluence of the T-mixer. The two streams were separated
by a viscous layer of a W-E mixture that hampers vortex formation and retards mixing.
Tsai et al. [6] investigated the mixing phenomena between ferro-nano fluids (a
watersolution with suspended Fe3O4nano particles) and water in a Y-type semi-
activemicro-mixer. A permanent magnet with a magnetic strength of 2200G was
installeddirectly under the mixer at a location behind the junction of the Y-type micro-
mixer toimprove the mixing. The permanent magnet was 9.6 mm long, 9.6 mm wide and
1.6 mm thick. Equal volumetric flow rates for both ferro-nano fluid and water were testedin
two different channel widths, 300μm and 500μm. Three different volumetric flow rates of
3μLmin, 6μ Lmin, and 10μL/min were analyzed to determine the effect offlow rate on the
mixing of fluids in the micro-mixer. Since Fe 3O4nano particles in theferro-nano fluid were
strongly affected by a relatively uniform magnetic field from the permanent magnet. Result
shows that a rapid mixing between ferro-nano fluid andwater can be achieved immediately
downstream of the permanent magnet for allvolumetric flow rates and all channel widths
tested.

2.2 Mixing Principles:

Michael et al. [10] has investigated mixing in a cross shaped micro-mixer with
static mixing elements (SME) was carried out through the use of a computational fluid
dynamics software package. It was found that with the inclusion of these mixing elements
at the outlet channel of the cross shaped micro-mixer, rapid mixing of two liquids can be
achieved. Distinct improvements in the concentration uniformity were observed after static
mixing elements were used. The performances with and without static mixing elements
were compared. The enhancement in mixing performance was thought to be caused by the
generation of eddies and lateral velocity component when the mixture flows past these
element. The pressure requirement for rapid mixing was drastically reduced as a result of g
these static mixing elements in the micro-mixer. It was shown that the mixing time of less
than 1ms can be achieved with just 2 bar of applied pressure on each liquid. It finds
application in reaction kinetics studies and at the same time opens up many new
possibilities.
Yong et al. [13] described that small-scale mixing is of uttermost importance in bio
and chemical analysis using micro TAS (total analysis systems) or lab-on-chips. Many
micro-fluidic applications involve chemical reactions where, most often, the fluid
diffusivity was very low so that without the help of chaotic advection the reaction time can
be extremely long. They reviewed various kinds of mixers developed for use in micro-
fluidic devices. The review started by defining the terminology necessary to understand the
fundamental concept of mixing and by introducing quantities for evaluating the mixing
performance, such as mixing index and residence time. In particular, the concept of chaotic
advection and the mathematical terms. Since these concepts were developed from nonlinear
dynamical systems, they have important roles in devising micro-fluidic devices with
enhanced mixing performance. They classified the designs in terms of the driving forces,
including mechanical, electrical and magnetic forces, used to control fluid flow upon
mixing.

2.3 Micro-mixer configuration:

Nguyen et at.[16] demonstrated a Y-junction type micro-mixer with a circular
obstacle on the circular-wave, vertical in vertical elliptical and horizontal in horizontal
elliptical flow channel for enhancing the mixing ability by using the chaotic advection
principle was designed and the mixing efficiency was measured.The micro-mixer was
fabricated on quartz material by SF6/Ar inductively coupledplasma (ICP) etching. The
mixing capability of the mixer was tested by mixing NaOH and phenolphthalein solutions
and analyzing the colourdensity from the image takenby a charge coupled device (CCD)
camera at a given position. The mixing characteristics were measured by varying the flow
rate from the micro pumps and the channel width of the mixer. The mixing percentage
increased slowly with increasing flow rate, but rapidly with decreasing microchannel
width.
Shou-Shing et al. [17] described the angle effect (a= +30°, ±60°, ±90° and ±120°)
ofY-type micro-mixers using micro Laser Induced Fluorescence (µLIF) and microParticle
Image Velocimetry (µPIV) optical techniques to visualize and quantify concentration and
velocity fields in order to examine mixing performance. An optimal α was obtained based
upon mixing efficiency and mixing length
Yang et al. [20] described micro-mixers which were commonly utilized in the areas
ofbiotechnical engineering, analytical chemistry, medical industry and high-
throughputsynthesis because biological processes generally involve complicated
chemicalreactions that require useful reactant mixing for initiation. In this, the
design,simulation, fabrication and test of a new high performance micro-mixer via
threedimensional (3D) Tesla structures to realize the effective mixing process in themicro-
fluidic devices for bio-applications has explained. Both computational fluiddynamics
(CFD) calculations and experiments were conducted to study the flow andmixing
characteristics in the development of 3D Tesla micro-mixers. The predictedand measured
results of the proposed micro-mixer have illustrated excellent mixingperformance for
Reynolds numbers (Re) ranging from 0.1 to 100 (0.015 to 15 µL/s)with its pressure drop
less than 1054 Pa at Re 100. It also showed the successfulapplication of the proposed mixer
to the immuno fluorescence analysis of the EGI
Research Gap:

⮚ The Microfluidics has variety of application like DNA sequencing, drugdelivery,

Lab on chip device,micro-reactors etc. Micro-mixer is one of theimportant parts for

lab on chip devices.

⮚ The majority of the literature explains about the vast micro mixer study, butthere is

Few researches related to comparative experimental study of differenttypes of

micro-mixers.

⮚ Very less research observed on experimental analysis of micro mixers.

⮚ The combined computational and experimental study for different types of micro

Mixers were carried out by few researchers. The experimental study for different
types of micro mixer is not reported yet.So there is huge scope for use of micro
mixer for mixing micro fluids.

Summary:
This chapter gives literature about various micro-mixer configurations. Further it
elaborates literature about mixing principles and literature about fluid flow analysis. Based
on the vigorous literature review, research gaps have found out.
CHAPTER 3
OBJECTIVES & METHODOLOGY
3.1 Objectives:

Objectives of the study and brief methodology to achieve these objectives are
summarized below:

1. To fabricate different Micro Mixers geometry with various geometrical

configuration:
Micro-mixers were developed using CO2 LASER Machining, PDMS
(Polydimethyl-siloxane) i.e. soft lithography technique

2. To study the mixing performance and pressure drop of micro mixers using
different approaches:

Micro-mixer channels of different cross section were analyzed for mixing

performance, a USB digital microscope was used for fluid flow visualization during
experimentation. In that different design variables such as viscosity of fluid,
velocity, flow rate, hydraulic discharge, diffusion coefficient and two dimensionless
factors as the Reynolds number (Re) and the Dean number (Dn) were studied. The
different parameters of importance were mixing time required for fluid, mixing
length, width and cross sectional area of micro-mixer and mixing index.

An open loop syringe pump system was designed for the work. Syringe pump
provides constant flow rate with ±0.5% accuracy range of Reynolds number
was covered by the changing the volumetric flow rate (i.e. by changing the inlet
velocities). To measure the pressure drop a Micro Electro Mechanical System
(MEMS) based sensors will be fixed at the two inlets of the channel, cole –
parmertubing will be used to connect the MEMS sensors to the syringe pump
and micro channel, measured pressure will be monitored and recorded with
the computerized data acquisition system. The flow will be considered to be
reached steady state. To optimize the mixing length of the micro channels for
chemical analysis:

3. To optimize the mixing length of the micro channels for chemical analysis:
In order to optimize the mixing length of the channel, Optimization of micro
mixerwas performed for different design and performance parameters such as
mixing time, mixing length, cross sectional area etc.
3.2 METHODOLOGY:

Following steps are followed while making microchannel Molds:

1. Prepare 2D-CAD Drawing:

We have design the Microchannel molds in CAD software. We prepared the

2D CAD drawings in AutoCAD software 2018 version. We prepared 2D drawings with
different configuration like 0.3mm, 0.4mm, 0.5mm, with different obstacles. We used
obstacles like circular, vertical elliptical and horizontal elliptical.

2. Input to CO2 LASER Machining:

The CO2 laser machining takes input as a 2D CAD drawings and it analyze
the path of channel which is given in CAD drawing. The drawings of the Y microchannel
with different configurations and different obstacles are shown in Figure 3.1-3.2-3.3.These
drawings are given to CO2 LASER machining by saving these drawing in, .dxf format.

3. Material Feeding:

After given input to CO2LASER machining we have to feed the material.

Here we feed the acrylic material to the CO2LASER machining.

4. Dry run:

After this process, we have to check the process is going correctly or wrong
for that purpose we can go for first dry run process then actual.

5. Machining Process:

After dry run process, the actual process is start. We get the desired
Microchannels by varying speed and number of passes. Here we kept the speed and number
of pass constant to achieve the 0.5 mm depth approximately. The material is removed by
vaporization and ablation.

6. Final product:

After these all process we get actual microchannelmolds which are

fabricated on CO2 LASER cut machining.
Microchannel Mold-1

Width - 0.3 mm Width - 0.4mm Width- 0.5mm

Fig. 3.1 Microchannel Mold-1(With Circular Obstacles)

-2
Width - 0.3 mm Width - 0.4mm Width- 0.5mm

Fig. 3.2 Microchannel Mold -2(With Vertical Elliptical Obstacles

Microchannel Mold-3

Width - 0.3 mm Width - 0.4mm Width-0.5mm

Fig. 3.3 Microchannel Mold -3(With Horizontal Elliptical Obstacles)

CHAPTER 4
FABRICATION OF MOLDS
4.1 Methods to fabricate Microchannel molds:
Microchannels can be generally fabricated by two different techniques given by
1. Miniaturized traditional technique
2. Modern technique
Traditional technique consists of conventional machining which are miniaturized to
use them in micro regime e.g. Micro EDM, Stereo Lithographic Fabrication,
Electroforming, Molding, Ultrasonic and Water Jet Machining, etc. Modern techniques
mainly contain Focused Ion Beam, LASER Machining, Isotropic and Anisotropic Wet
Chemical etchings are some examples of fabrication based on silicon. CO 2 LASER Cut
Machining having high ablation and vaporization rate which is used for microstructures
fabrications of high aspect ratio with compromising to the surface finish and quality.

Following are the various methods to fabricate microchannels molds-

⮚ Hot-embossing

⮚ Injection molding

⮚ Micro milling

⮚ Infrared laser ablation

⮚ Photochemical machining

⮚ CO2 laser machining

4.2 Selection of manufacturing method for Microchannel mold:

The use of CO2 laser machining not only speeds up the fabrication process but also
the high flexibility of changing the design. Thus, the CO 2 laser systems are very much
useful for micromachining. The YMicrochannel with straight and Different configuration
has been fabricated using the CO 2 laser machining with three different widths. The input
parameters are also varied in order to achieve the different depths for the Microchannel
molds.

4.3 Selection of Material for molds

Acrylic is widely known for its importance to the industry. It is used to make
various products, such as shower doors, bath enclosures, windows and skylights. It is
chosen over glass for many reasons. It is many times stronger than glass, making it much
more impact resistant and therefore safer. Falling against an acrylic shower door will not
likely break it. Acrylic also insulates better than glass, potentially saving on heating bills.
Another great advantage of acrylic is that it is only half as heavy as glass. This makes
working with acrylic much easier. It can also be sawed, whereas glass must be scored.

Fig. 4.1 Acrylic Material

In the present days, the applications include inspection windows, sight
gauges,windshields, meter faces, protective covers, safety shields, tanks, desk tops,
displays,trays, and chair pads. Acrylic comes in a wide variety of standard colors
(colorlesssheet). The fact that some of them are bullet resistant, it is now in highly demand.
Acrylics come in various shapes. There are many ways of processing them, andthe
one discussed here is the process done by using laser cutter machines. The process iscalled
laser-cutting process.

ADVANTAGES:

⮚ Excellent optical clarity

⮚ Excellent weather ability and resistance to sunlight

 ⮚ Rigid, with good impact strength

⮚ Excellent dimensional stability and low mould shrinkage

⮚ Stretch forming increases bi-axial toughness

4.4 Fabrication of Microchannel Molds using CO2 Laser Machining:

Laser cutting is a technology that uses a laser to cut materials and is usually used in
industrial manufacturing. Laser cutting works by directing the output of a high-power laser,
by computer, at the material to be cut. The material then melts, burns, vaporizes away, or is
blown away by a jet of gas, leaving an edge with a high-quality surface finish. Industrial
laser cutters are used to cut flat-sheet material as well as structural and piping materials.
Industrial laser cutters are used to cut flat sheet material as well as structural and piping
materials.
Laser cutting machine allows you to create intricate designs and highly detailed
inlays with a low-cost, highly profitable tool. Attached to the computer just like a printer,
the system will cut designs we create in most graphic software programs.
The carbon dioxide laser (CO2 laser) was one of the earliest gas lasers to be
developed (invented by Kumar Patel of Bell Labs in 1964) and is still one of the most
useful materials ever created. Carbon dioxide lasers are the highest-power continuous wave
lasers that are currently available.
They are also quite efficient: the ratio of output power to pump power can be as
large as 20%. This machine can cut through wood, acrylic, plastic, cloth, leather, matte
board, melamine, paper, pressboard, rubber, wood veneer, fiberglass, cork and many other
materials.
 Fig. 4.2 CO2 Laser Machining Setup

❖ Specification of machine:

Model- TIL6090

⮚ (wave length: 10.6 um)

⮚ Laser Type Sealed Hermetic CO2 Laser Tube

⮚ Laser Power 60W/80W/100W

⮚ Engraving Area 600 x 900 mm

⮚ Accuracy± 0.025 mm

⮚ Power Supply220 V±10%/50HZ.

⮚ Gross Power1800 watt. aprox.

⮚ Cutting Speed 500 mm/S (Max)

⮚ Engraving Speed 500 mm/S (Max)

General block diagram of CO2 Laser Machining as shown below:

Fig. 4.3 Block diagram of CO2 Laser Machining

4.5 Advantages of CO2 Laser Machining:

⮚ The laser creates a beam of light that is used to cut through the material, so there is

no part of the laser system in contact with the material.

⮚ For thinner materials, all Epilog laser systems include an Integrated Vacuum

Table to hold down papers, fabrics, and thin plastics as you cut through the
Material.

⮚ It is amazingly precise, following the pattern you've drawn on screen.

⮚ Cut several patterns from the same piece of material.

4.6 Inspection of Microchannels molds:
After CO2 Machining process, prepared molds are inspected under Rapid-I Vision
inspection System Table 2.2 Shows technical specification of Rapid-I Vision.
Measuring instrument which is shown in fig.4.4 Rapid-I Vision Inspection System
is operated with Rapid-I 5.0 Software and readings are being taken and snap shot
also captured which are shown in following figures.

Table 4.1 Technical Specification of Rapid-I Vision Measuring Instrument

Model Rapid-I V2015J LX
Cool Zonal solid-state LEDs with control through S/W
Lighting 1.Quadra-zone surface lighting
2.Collimated Profile Lighting
Measuring Travels 200 X 150 X 150 (X x Y x Z)
Job Weight 5/25 Kg
Linear Scale 0.5 µm non-contact tape encoders
Accuracy Within (3+L/100) µm (L in mm)
1.Continuously variable analog joystick for 3+1 (free) axis
Motion Control control
2.Fully- automated CNC with Auto-Focus
Graphics CAD (import/edit/export .dxf)
Reports Direct Reports in MS excel

4.7 Fabricated MicrochannelsMolds:

Microchannel Mold-1(With Circular Obstacles)

Width-0.3mm Width-0.4mm Width-0.5mm

Fig. 4.5FabricatedMicrochannelMolds with circular obstacles

Microchannel

Microchannel Mold-2 (With Vertical Elliptical Obstacle)

Width-0.3mm Width-0.4mm Width-0.5mm

Fig. 4.6FabricatedMicrochannelMolds with vertical elliptical obstacles

Microchannel

Mold-3 (With Vertical Elliptical Obstacles)

 Width- 0.3mm Width- 0.4mm Width- 0.5mm

Fig. 4.7FabricatedMicrochannelMolds with horizontal elliptical obstacles

4.8 Performance Parameters of LASER CO2 Machine:

Microchannel Mold-1

Table 4.2– Performance parameter readings for MicrochannelMold- 1 Trial Readings

Depth
Width Speed No. of Pass Power
Achieved

100 1 60
0.3 0.505
100 1 40

100 1 60
0.4 0.519
100 1 40

100 1 60
0.5 0.516
100 1 40

Table 4.3 – Performance parameter readings for MicrochannelMold- 1 Final

Readings
 Depth
Width Speed No. of Pass Power
Achieved
100 1 60
0.3 0.505
100 1 40

100 1 60
0.4 0.519
100 1 40

100 1 60
0.5 0.516
100 1 40

Microchannel Mold-2

Table 4.4– Performance parameter readings for MicrochannelMold- 2 TrialReadings

Depth
Width Speed No. of Pass Power
Achieved
100 1 60
0.3 0.523
100 1 30

100 1 60
0.4 0.710
100 1 20

100 1 60
0.5 0.893
100 1 20

Table 4.5 – Performance parameter readings for MicrochannelMold- 2 Final

Readings
Depth
Width Speed No. of Pass Power
Achieved

100 1 60
0.3 0.495
100 1 40
 100 1 60
0.4 0.490
100 1 40

100 1 60
0.5 0.5
100 1 40

Microchannel Mold-3

Table 4.6– Performance parameter readings for MicrochannelMold- 3 TrialReadings

Depth
Width Speed No. of Pass Power
Achieved
100 1 60
0.3 0.730
100 1 20

100 1 60
0.4 0.668
100 1 20

100 1 60
0.5 0.559
100 1 30

Table 4.7 – Performance parameter readings for MicrochannelMold- 3 Final

Readings
Depth
Width Speed No. of Pass Power
Achieved

100 1 60
0.3 0.495
100 1 40

0.4 100 1 60 0.520

 100 1 40

100 1 60
0.5 0.508
100 1 40

CHAPTER 6
EXPERIMENTATION

6.1 Overview
This chapter deals with the detailed experimentation of fluid flow through micro-
channel of various geometries. This section will present Experimental results obtained in
micro fluidic laboratory at different Inlet velocities in all mentioned micro-mixers. After
that the experimental results will be compared for flow pattern with simulation results

6.2 Experimental Setup

6.2.1 Equipments
Following are the equipments used for Experiment:

⮚ Twin Syringe Pump

⮚ Silicon Tubing

⮚ Fittings(Connectors)

⮚ Glass ware or beaker

⮚ Samples

⮚ USB Digital Microscope integrated with Computer

Twin Syringe Pump (Manufacturer: Yashtech India Pvt. Ltd.Nashik) was used
forcontinuous fluid flow through the inlets of micro channel at various flow rates. Inthis
case, the pump do not directly gives the flow rate rather it gives the speed orrpm and
depending on that rpm the required flow rate can be adjusted. The TwinSyringe pump has a
speed range from 0.1ml/Hr to 199ml/Hr. Depending on therpm of the pump particular flow
rate can be selected. The flow rate was checkedby measuring the volume of fluid flow
through the pipe at a particular time. Fig.6.1 shows the schematic of Syringe pump used for
the experimentation
 Fig. 6.1 Twin Syringe Pump

Silicon Tubing of 0.8mm inner diameter were used in Syringe pump for continuous fluid
flow to the channel. Its one end was immersed into sample using PP Barbed fittings (Cole -
Parmer Product) and other end connected to the Syringe outlet.

Glass ware or beakers were used for keeping the samples which were used for
theexperimentations. Samples used for my experiment was Ink and Water. Ink was passed
through one inlet and Water was passed through the other inlet.
Fig. 6.2 Below shows the complete schematic diagram of experimental setup for
fluidflow through micro-channel.

Fig. 6.2 Schematic of Experimental Setup

6.3 Experimental Analysis of Fluid flow through Microchannels
To conduct the experiment, Blue Ink and Water was taken as the sample. So the
property of the fluid was nothing but the property of the ink only. Generally the density of
water is 1000 kg/m3, viscosity 0.0091 poise at 25°C.

6.3.1 Results Obtained after Experiment in Y- Shape micro-mixer

Case I: Results of the experimental investigation in Y-shaped micro-channel with circular
obstacles for inlet velocity 5 mm/s are presented below.

Fig. 6.3Y- Shaped Microchannelwith Circular obstacles during test at V=5ml/hr

Case II: Results of the experimental investigation in Y-shaped micro-channel with vertical
elliptical obstacles for inlet velocity 5 mm/s are presented below.

Fig. 6.4Y- Shaped Microchannel with Vertical Elliptical obstacles during test at
V=5ml/hr
Case III: Results of the experimental investigation in Y-shaped micro-channel with vertical
elliptical obstacles for inlet velocity 5 mm/s are presented below.

Fig. 6.5Y- Shaped Microchannel with Horizontal Elliptical obstacles during test V=
5ml/hr
 6.4 Measurement of Pressure drop for different Microchannel Configurations
6.4.1 Microchannel with Circular Obstacles (0.3mm)
Table 6.1 Experimentation Result for Pressure drop
Sr.No Avg. Pressure Atmospheric Pressure
Velocity(ml/hr) Error (%)
. (Mpa) (Mpa)
1 5 1825 1523 16.54
2 10 1815 1505 17.07
3 15 1800 1468 18.44
4 20 1790 1442 19.44
5 25 1790 1428 20.22
6 30 1765 1414 19.88

Fig. 6.6 Velocity vs Pressure drop (Circular Obstacles-0.3mm)

 6.4.2 Microchannel with Vertical Elliptical Obstacles (0.4mm)

Table 6.2 Experimentation Result for Pressure drop

Atmospheric Pressure
Sr.No. Velocity(ml/hr) Avg. Pressure (Mpa) Error (%)
(Mpa)
1 5 1695 1523 10.14
2 10 1635 1505 7.95
3 15 1615 1468 9.1
4 20 1540 1442 6.36
5 25 1540 1428 7.27
6 30 1515 1414 6.66

Fig. 6.7 Velocity vs Pressure drop (Vertical Elliptical-0.4mm)

6.4.3Microchannel with Horizontal Elliptical Obstacles (0.5mm)

 Table 6.3 Experimentation Result for Pressure drop
Atmospheric Pressure
Sr.No. Velocity(ml/hr) Avg. Pressure (Mpa) Error (%)
(Mpa)
1 5 1800 1523 15.38
2 10 1780 1505 15.44
3 15 1770 1468 17.06
4 20 1760 1442 18.06
5 25 1745 1428 18.16
6 30 1735 1414 18.50

Fig. 6.8 Velocity vs Pressure drop (Horizontal Elliptical Obstacles-0.5mm)

Summary: Y Shape Micromixer with elliptical obstacles give better mixing

length but slightly lesser pressure drop compared to Y shape micro mixer with
circular obstacles. As the channel width decreases, mixing time and mixing length
of Micromixer decreases.

CHAPTER 7
CONCLUSION AND FUTURE SCOPE
7.1 Conclusion
Micromixer is one of the essential components in integrated microfluidic systems
for chemical, biological and medical applications. Among the differentfeatures of fluid at
the microscale, one of the most relevant to mixing applications laminar flow where mixing
can be dominantly accomplished by molecular diffusion. COMSOL Multiphysics software
package isused for simulation of fluid flow and mixing through channels of
differentconfigurations.The microchannels are major components required in Lab on a chip
device. The fabrications of Y-shaped microchannels with different configurations like
straight with circular obstacles have been carried out using Laser cut machining. The molds
are fabricated for three different widths and using two different parametric conditions. The
depths recorded are as 0.5 mm and 0.52 mm. The fabricated molds can be employed for
thefabrication of PDMS microchannels using soft lithography process. The study further
can be extended for the parametric optimization of laser cut machining for fabrication of
microchannels with different widths.
Y shape micro mixers with two different geometries such as circular and elliptical
have designed. CO2Laser Machining is used for mold making of micromixer. The Y
shapechannel with circular and elliptical obstacles is fabricated by PDMS material
forexperiment analysis. The use of PDMS as a material reduces the time, complexityand
cost of prototyping.
The effect of obstacles on the mixing length and pressure drop is studied. Theeffect of
different parameter on micro mixer performance is concluded as:

● Decrease in the inlet velocities of the incoming fluids gives minimummixing

length of Micromixer.

● Decrease in the inlet velocities of the incoming fluids gives minimum pressure

drop.

● Y Shape Micromixer with elliptical obstacles give better mixing length but slightly

lesser pressure drop compared to Y shape micro mixer with circular obstacles.

● As the channel width decreases, mixing time and mixing length of Micromixer

decreases.
7.2 Future work:
Future work can be focus on,
1. The optimization of design including bends (curve) and geometrical effect to the
specific mixing fluid.
2. The effect of angle between two inlet channels on rate of mixing.
3. Mixing performance can be enhanced by either different shapes and/or size of
obstacles along the channel which acts as a barrier, splitting the fluid flow for
mixing.
4. The effect of wall protrusion and wall surface roughness for which in the case of
micro channels flow without mixing may cause chaotic advection depending on
the Reynolds number and shapes.
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 Annexures

Annexures (If applicable — in order)

○ Annexure I: Sponsored Project Approval & Completion Letter

○ Annexure II: Paper Publication Certificate and Paper

○ Annexure III: Photos related to Experimental Work

○ Annexure IV: Supplementary Material (if any)