The present study addresses the flow characteristics of a viscous, incompressible, steady, and Newtonian fluid flow through the undulating microchannel with a porous medium. The flow is governed by the Darcy–Brinkman model with no-slip boundary conditions at walls. The objective of this study is to develop theoretical and computational models for flow parameters that are independent of the permeability of the medium and to extend the scope of previous studies. The lubrication theory is used to determine key flow parameters, such as flow rate, velocity, and wall shear stress, in complex-shaped microchannels. To overcome the limitations of lubrication and boundary perturbation methods, the spectral method is applied to a sinusoidal microchannel. We observe that flow parameters are significantly affected by dimensionless quantities such as pattern amplitude, wavelength, and permeability (κ). The spectral model indicates non-linear flow rate behavior when the permeability is very high (κ1) and accurately captures the transition behavior of flow rate in the Darcian flow regime for various wavelengths, unlike other theories. Conversely, for small and large wavelengths with low permeability (κ1) at the Stokes flow limit, the flow rate behavior is monotonic. The spectral model demonstrates greater reliability compared to classical lubrication theory, extended lubrication theory, and boundary perturbation methods, especially for large values of the dependent variables. Predictions from the spectral approach closely align with numerical results over a broad range of parameters. A detailed analysis of the influence of various parameters on flow quantities is presented.

The Darcy–Brinkmann (DB) model advances the understanding of fluid flow through a porous medium by extending the foundational principles of Darcy's law1 to include viscous shear effects. This enhancement is crucial for accurately analyzing flows that are significantly influenced by both the porous characteristics (Darcy effect1) and the viscous shear (Brinkmann effect2). Integration of these effects makes the DB model a more comprehensive tool for studying complex flow dynamics. Exploring fluid flow in porous media is essential for the design and optimization of various engineering systems, including filtration devices,3 chemical reactors, and technologies for cooling microelectronics.4,5 The DB model represents a foundational tool for understanding porous media flow. However, it is limited in addressing the complexities of flows through microchannels with patterned surfaces. In practical applications at the microscale regime, the surface is not smooth due to its porosity. Therefore, investigating the impact of surface patterning on DB flow is essential for understanding fluid behavior.

To explore the wide range of applications involving fluid flow in wavy channels with a fluid-saturated porous medium, efforts have been made to investigate the hydrodynamic phenomena and heat transfer processes in these systems.6–8 Additionally, flow separation phenomena have also been observed due to nonlinear geometries, as these shapes are crucial for mass transportation.9 Flow separation occurs normally when the local adverse pressure gradient is strong enough to alter the wall shear stress (WSS) or vorticity. Outside of fluid dynamics, pattern surfaces are also useful in heat transfer,10–12 microfluidic mixing,13–15 geoscience,16,17 etc. For example, the effect of pattern on forced convection was studied by Wang and Chen.18 In microscale, the roughness effect on heat transfer and pressure drop was investigated using the finite-element-based codes.19 The shape of the peaks was selected to control the surface roughness. Recently, the flow circulation near the crests has driven attention to flow through wavy channels, which significantly enhances fluid mixing.15,20–22

In the literature, the DB flow with micropatterning has been studied from different perspectives, such as different shapes of channel,23–27 no-slip,8,25,26 slip boundary conditions,28,29 Newtonian8,25,30 and non-Newtonian31,32 fluids, isotropic8,26,30 and anisotropic porosity25,33 of porous material, and flow direction. The investigation has been focused on the impact of wall corrugation on pressure drop, velocity distribution, and flow resistance in microchannels. Researchers have studied porous media flow in ducts and considered the DB model for the investigation, such as parallel plate channels,34 circular,35 rectangular ducts,23,24 and sinusoidal.8,30 The flow behavior has also been examined for two-dimensional8,30 and three-dimensional36,37 geometries. For all geometries, it is observed that initially, the velocity profile is flat, and it becomes parabolic when the porous media parameter is small. The DB equation was examined for a three-dimensional curved channel using the domain perturbation methods (DPMs), and it observed that the flow resistance strongly depends on the porous media factor and bumps of geometry.8 Furthermore, the flow of porous media was examined for a tube with a three-dimensional bumpy surface using the boundary perturbation method. It was assumed that the amplitude of the surface bumps is small compared to the mean tube radius.37 In this study, they found that flow resistance is minimized with permeability parameters and wave numbers. The aforementioned literature models assumed a no-slip boundary, and the permeability is considered to be isotropic porous media used to examine DB flow. These models are accurate up to small values of perturbation parameters (amplitude-to-pitch ratio). The porous media flow for two-dimensional channels with different orientations has also been studied by several researchers.8,26,30,38,39 The DB model is used to examine the non-Newtonian fluid flow through anisotropic porous media. Recently, Gupta and Vajravelu31 investigated non-Newtonian flow in an anisotropic rotating porous channel with an inclined magnetic field. They found that the maximum volumetric flow rate was obtained with higher values of the Jeffrey parameter. Bhargavi et al.32 studied the Darcy–Brinkman–Forchheimer model for a non-Newtonian fluid through anisotropic porous media. The study revealed that as the anisotropic parameter increases, the velocity profile transitions from a parabolic to a flatter shape at the center of the channel.

Several theoretical models have been proposed based on the flow direction8,25,30,38–40 such as longitudinal and transverse to study the porous media flow for different topographies. The eigenfunction expansion was used, and it was found that the flow resistance was lowest in the longitudinal flow.38 The boundary perturbation method was employed to examine DB flow through the grooved channel, and a mathematical model was developed for a flow rate for small pattern amplitude in longitudinal flow.8 In this study, they found that the effect of corrugation is greater in the Stokes limit than in the Darcian limit at a small wavelength. The flow orientation along the length has also been explored in the context of a rough, curved channel filled with a porous medium.26 This study examines the effects of channel curvature, wall corrugations, and medium permeability using the boundary perturbation method for small corrugation amplitudes. The porous medium significantly affects flow compared to a clear conduit, especially at low permeability. In porous media flow, the porosity of the channel plays a significant role in flow parameters. In the literature, the transverse flow8,37–39,41 has been given more attention than the longitudinal flow. The effect of the anisotropic permeability ratio for DB flow along the transverse direction has been examined, and the lubrication theory was employed to develop a theoretical model of an arbitrary channel.25 In this study, it was determined that the anisotropic permeability ratio causes flow separation near the wall crests, where viscous forces are significant.

A number of theoretical models were proposed using boundary perturbation method,8,26,30,38 lubrication theory,25,42,43 and Fourier methods44–49 to investigate the effect of micropatterning for Stokes flow and Darcy–Brinkmann flow. The aforementioned literature makes it clear that several studies have been conducted to understand the effect of micropatterning on DB flow. However, these studies are limited by small pattern amplitude, long channel wavelength, and a small permeability parameter. There is no study that examines this flow without restricting the dependent variables, such as permeability parameter, pattern amplitude, and wavelength. In the past, the domain perturbation method was applied to examine the effect of pattern surface on the Darcy–Brinkmann model, which is accurate at small values of perturbation parameter. The main purpose of the current work is to expand previous studies by Ng and Wang8 and Karmakar and Sekhar.25 Additionally, we found that the flow across the grooves has attracted considerably more attention than the flow along the grooves. To fill these gaps, we employed the lubrication theory for longitudinal flow to explore Darcy–Brinkmann flow for any arbitrary geometries. Later, this study is extended to a sinusoidal surface. Overall, the aim of the present research will be to develop mathematical and computational modeling for flow parameters, such as flow rate, velocity and wall shear stress, without the restriction of dependent variables. Therefore, a spectral approach is employed to conduct the present study. Additionally, a finite-element-based numerical simulation (NM) is also performed to understand the usefulness of the present models and the limitations of the existing models.

The present paper is structured as follows. In Sec. II, the key governing equations and boundary conditions are discussed. Mathematical modeling using lubrication and grid-free spectral approaches are thoroughly explained in Secs. III and IV, respectively. At the end of this section, an asymptotic model is calculated for a periodic sinusoidal surface. In Sec. V, we also briefly remark on special cases of spectral method such as Darcian flow limit, Stokes flow limit, and asymptotic solution. Section VI focuses on a relation of porous permeability between the lubrication and spectral model (SM). The behavior of flow rate, wall shear stress, and velocity profile with reference to dependent variables are represented graphically in Sec. VII. At the end of the paper, we discussed key conclusions, future work, and the application of the present work. Some key supporting equations and numerical simulations are discussed in Appendixes A and B, respectively.

The orientation of the channel is defined by a flat top wall and a grooved bottom wall, as shown in panels (a) and (b) of Fig. 1. The flat wall is located at y=h, while the grooved bottom wall is represented by y=ah(x), where h denotes the mean height of the channel and a represents the amplitude of the topographic pattern. The flow is assumed to be fully developed, and a pressure gradient along the z axis (longitudinal direction) is denoted by pz. The velocity components along the rectangular Cartesian coordinates x, y, and z are represented by u, v, and w, respectively, as shown in Fig. 1. For a sparse porous medium, the DB model2,34,50 can be applied,
(1)
Here, u represents the superficial velocity, p is the pressure, μ is the viscosity of the fluid, K is the permeability, and μeff is the effective viscosity of the porous matrix. Porous media with high porosity, such as fiberglass wool, are generally well represented by Eq. (1). The inertial nonlinear Forchheimer term is not included in this study because it is typically negligible in low-speed applications such as filters, heat exchangers, and catalytic convertrs.51 Additionally, the focus is on modeling the effects of micropatterning, which are amplified by the small dimensions of the channel. In such microfluidic systems, the Reynolds number is very small [ O(103) or lower], rendering inertial effects insignificant. References, such as Tam,52 Lundgren,53 and Howells,54 provide the theoretical framework for the Brinkman term used in low solid fraction media. When K0, the Darcy–Brinkman model becomes the Darcy equation. However, when K, it reduces to the Navier–Stokes equations. A no-slip boundary condition is imposed at both walls,
(2a)
(2b)
Recently, several researchers have employed similar geometries to investigate the influence of the grooved surface.8,25,42,55,56 Ng and Wang8 used a domain perturbation approach to develop a mathematical model for flow quantities that is accurate for small values of the perturbation parameters. Their work inspires further investigation into DB flow within complex geometries and solutions for large values of dependent variables. To address this, we employed the lubrication theory for arbitrary topographies, as shown in panel (a) of Fig. 1. A spectral method is used to develop a mathematical model for a sinusoidal surface [y =  ah(x) =  acos(2πxL)] with significantly large amplitude, wavelength, and permeability of the porous medium as demonstrated in panel (b) of Fig. 1.
FIG. 1.

The schematic illustrates a periodic grooved microchannel used for Darcy–Brinkman flow analysis. The flow direction is along the z axis (longitudinal flow). L, a, and h are defined as pattern wavelength, amplitude, and mean channel height, respectively. The top wall is considered flat for both approaches. (a) In the lubrication theory, the lower boundary is defined by an arbitrary shape, represented as y=ah(x). (b) In the spectral method, the lower boundary follows a sinusoidal profile, expressed as y=acos(2πxL). In both approaches, the analysis assumes one periodic cell.

FIG. 1.

The schematic illustrates a periodic grooved microchannel used for Darcy–Brinkman flow analysis. The flow direction is along the z axis (longitudinal flow). L, a, and h are defined as pattern wavelength, amplitude, and mean channel height, respectively. The top wall is considered flat for both approaches. (a) In the lubrication theory, the lower boundary is defined by an arbitrary shape, represented as y=ah(x). (b) In the spectral method, the lower boundary follows a sinusoidal profile, expressed as y=acos(2πxL). In both approaches, the analysis assumes one periodic cell.

Close modal
The lubrication theory is an approximation of the Navier–Stokes and continuity equations at low Reynolds numbers for narrow geometries with slow changes in curvature.57–59 We assumed that the flow occurs along the z axis, while velocities in the x and y directions are negligible. Therefore, the function w depends on x and y. We introduce the non-dimensional variables as follows: x=LX, y=hY, and w=pzhLWμeff. Accordingly, the governing equations in terms of the non-dimensional variables can be expressed as
(3)
The aspect ratio of the channel is denoted as δ=h/L. The non-dimensional parameter κl =  hμμeffK appears in Eq. (3) and that characterizes the porous medium within lubrication framework. The Stokes and Darcian flow limits are given by κl0 and κl1, respectively. Boundary conditions at both walls are
(4a)
(4b)
where ω=ah is a ratio between the pattern amplitude and the mean channel height of the pattern. Here, H(X) is a normalized shape function. Section III A applies the perturbation method to calculate the flow quantities.
A perturbation method can be employed to obtain an approximate solution for problems involving a wavy channel. The objective of this section is to improve the solution by adding extra terms in the perturbation solution. Correspondingly, we assume that the ratio δ=h/L=1/λ is small or δ1, and this allows for the use of δ as a perturbation parameter. Therefore, the following expression is used for velocity,
(5)
Before proceeding further, the non-dimensional governing equation and boundary conditions need to be determined at different orders of δ. Therefore, substituting the above-mentioned expansion in Eq. (3) and collecting terms in powers of δ, the coefficients of δ2 and δ4 are set to zero. The governing equations and boundary conditions of the problem at leading and second orders will be discussed in Secs. III A 1 and III A 2.

1. The leading order problem: O(δ0)

The first step involves a standard discussion found in textbook.58 Since the problem statement only incorporates δ2, which is assumed to be small, the analysis at the leading order O(δ0) reduces to the well-known classical lubrication theory (CLT) problem. In this context, the primary flow characteristics are governed by the principles of standard lubrication theory. Consequently, the governing equation becomes
(6)
Boundary conditions are Wl0(X,Y=1)=0 and Wl0(X,Y=ωH(X))=0. Utilizing these two boundary conditions and solving Eq. (6) for an arbitrary surface,
(7)
Equation (7) gives the velocity profile for the classical lubrication theory (CLT) for any complex geometries. Additionally, we also focused on a periodically grooved sinusoidal surface, and the shape function is assumed H(X)=cos(2πX), which yields
(8)
Equations (7) and (8) are independent of the perturbation parameter (δ). It depends on ω, κl, X, and Y.

2. The second order problem: O(δ2)

In the past, many researchers have employed the lubrication approach to examine the effects of micropatterning, typically truncating the analysis at the leading-order solution [ O(δ0)]. The objective of this section is to refine the solution of CLT by incorporating additional terms into the perturbation solution, with the next order being O(δ2). This solution is considered an extended lubrication theory (ELT). At the next order, O(δ2), the governing equation and boundary condition become
(9)
(10a)
(10b)
Here, we determine Wl0XX using Eq. (8), as outlined in  Appendix B. O(δ2)-solution for complex surfaces is provided by
(11)
If a shape function is H(X)=cos(2πX),
(12)
The expressions of χ1, T11, T22, T8, and T9 are given in  Appendix B. The total flow-field is obtained by Wl=Wl0+δ2Wl2+O(δ4), where Wl0 and Wl2 can be obtained from Eqs. (8) and (12), respectively.
Equation (5) is utilized to evaluate the flow rate for a single periodic cell of the channel. Based on the current scaling parameters, X varies from 1/2 to 1/2, while Y ranges from ωH(X) to 1. By solving Eq. (5) along the X and Y axes, we obtain the dimensionless flow rate for one periodic cell of the channel, denoted as Ql,
(13)
By substituting Eq. (5) in Eq. (13) and separating the velocities according to different orders of δ, the flow rate can be calculated up to O(δ2) for H(X) =  cos(2πX), as follows:
(14)
The O(δ0) solution is
(15)
If the bottom wall is smooth or straight (with no topographical patterns, ω=0), then the dimensional flow rate (Qls) is
(16)
The O(δ2) solution is
(17)
The expression of R1 is defined in  Appendix B. In order to study confined flow, a key parameter is scaled flow rate or effective hydraulic permeability, which is denoted by Ql/Qls. Here, Ql denotes the dimensionless flow rate for a channel with a wavy bottom wall, whereas Qls denotes the dimensionless flow rate for a straight channel of identical width and average thickness (h). The scaled flow rates for both classical lubrication theory (CLT) and extended lubrication theory (ELT) are given by
(18)
(19)
The final integration for scaled flow rate is accomplished using MATHEMATICA software. To assess the impact of a wavy bottom wall on a channel's hydraulic conductance relative to a straight channel, we use the dimensionless flow rate ratio Ql/Qls in the present paper.
The objective of this section is to develop a model for flow parameters that are accurate for significantly large dependent variables (permeability parameters, wavelengths, and amplitudes). Therefore, the spectral method is applied to investigate the impact of micropatterning on porous media flow as illustrated in panel (b) of Fig. 1. According to the current approach, we introduce the non-dimensional variables as follows: x=L2πX, y=L2πY, and w=pzhLW2πμeff. Note that these dimensionless parameters differ from those used in the lubrication approach (Sec. III). By applying this non-dimensionalization scheme to the governing equation and boundary conditions, i.e., Eqs. (1), (2a), and (2b), the revised dimensionless governing equation and boundary conditions are as follows:
(20)
(21a)
(21b)
Here, H=2πhL=2πλ, where λ=L/h represents the relationship between pattern wavelength and the mean channel height. The parameter ε=2πaL defines the ratio of pattern amplitude to wavelength. Meanwhile, κf =  L2πμμeK characterizes the porous media in the governing Eq. (20).
The velocity field is assumed in the form of a Fourier series. Due to the channel's periodic nature, the analysis is conducted within a single periodic cell to capture the repeating flow dynamics throughout the channel,
(22)
Substituting Eq. (22) in Eq. (20) and collecting the coefficients of cos(nX) (n0), we equate them to zero to derive ordinary differential equations for F0(Y) and Fn(Y). No-slip boundary condition at Y=H given by Eq. (21a) necessitates that F0(H)=0 and Fn(H)=0. The resulting equations are
(23)
where η=n2+κf2. Upon substituting Eq. (23) in Eq. (22), the velocity profile can be expressed as follows:
(24)
Equation (24) is required to adhere to the no-slip boundary condition on the undulating surface [Eq. (21b)], leading to the following form after trigonometric simplification:
(25)
Equation (25) is integrated between π and π. Using the property of a modified Bessel function that In(z)=1π0πezcos(θ)cos(nθ)dθ, the resultant equation after integration can be rewritten as
(26)
In the above-mentioned equation, cos(mX) is multiplied on both sides. Here, m is an element of the set of non-negative integers that will provide a different set of equations with reference to m (m>0). The resultant expressions are integrated from π and π [Eq. (25)]. Equation (26) is considered for m=0, and for m>0, equation is outline as follows:
(27)
By truncating each summation occurring in Eqs. (26) and (27) to n terms, we obtained a numerical solution for the equation system governing the n+1 constants {C02,C1n,C2n}. We achieved this by truncating the number of equations to n+1 and performing matrix inversion.
Equation (22) is used to evaluate the dimensionless flow rate (Q) for one periodic cell of the channel. As per the current scaling parameter, X varies from π to π and Y varies from εcos(X) to H,
(28)
which evaluates to
(29)
When the pattern amplitude is zero (ε = 0), the dimensionless flow rate in a straight channel is given by
(30)
The ratio of the dimensionless flow rate in the patterned channel to that of the straight channel is denoted as QQ* and is referred to as the scaled flow rate,
(31)
Equation (31) shows that the scaled flow rate depends on the dimensionless pattern amplitude (ε), wavelength (λ), and porous parameter (κf). Notably, the expression for the scaled permeability of a channel does not impose any limitations on the values of ε, λ, and κf. However, to accurately determine the coefficients Cn, Eq. (26) must be solved numerically. In certain cases, closed-form asymptotic approximations for the coefficients, as given by Eqs. (26) and (27), can be derived. These cases will be discussed in Secs. V A and V B.

The present study explored several novel features of the spectral method, including second-order solutions [ O(ε2)] for the DB flow8 and Stokes flow limit.55 Equations (26), (27), and (31) are used to calculate an asymptotic solution for the scaled flow rate.

In the past, Ng and Wang8 employed the boundary perturbation method to study the DB flow through a sinusoidal grooved wall and developed a mathematical model for flow rate, which is an O(ε2)-accurate. Here, we assumed the top wall is flat. An alternate form of representing the pattern amplitude is α, which is utilized in the literature model. α and ε are defined as α =  a/h =  ε/H. A key novel of the spectral method is that we can obtain the literature model using the two terms (n=2) in the Fourier series. Equation (22) is essential for calculating the dimensionless flow rate and also aids in determining the flow rate through a straight channel (ε=0). When we truncate Eqs. (26) and (27) to a 2×2 form, the resulting set of equations provides an O(α2) accurate solution for the scaled flow rate. Similarly, truncating the series to include additional terms yields an accuracy of O(αn). For a 2×2 truncation, the resulting constants are as follows:
(32)
The expressions of χ2 and η2 are defined in  Appendix B. Here, η1=κf2+1 and ε =  α×H,
(33)
Equations (32) and (33) signify the order of perturbation parameter (α). For example, the first term in Eq. (32) is an order of O(α0), whereas the second term is an order of O(α2). The next term will contribute up to O(α4). For C1, the first term contribution in a series is on O(ε), and the next term will be O(α3). The final expression for the scaled flow rate is
(34)
The second key novel contribution of the spectral method is to obtain the scaled flow rate for the Stokes limit (κf0). Stroock et al.55 employed the boundary perturbation method to develop a mathematical model for flow rate at Stokes limit, which was accurate at a small amplitude-to-pitch ratio. The extension of this work was carried out by Dewangan and Datta47 using the spectral method, which is accurate at a significant amplitude-to-pitch ratio. To obtain the literature model, two terms are considered in Eq. (31) at κf0. The final expression of the scaled flow rate is
(35)
Equation (35) is similar to Eq. (6) of the literature model55 as per the current notation.
The present study employs two methodologies to investigate the effect of micropatterning on DB flow. The first approach utilizes lubrication theory (discussed in Sec. III), while the second employs the spectral method (discussed in Sec. IV). Both theories involve distinct scaling parameters. The height of the channel keenly influences the dimensionless parameters in the lubrication theory, whereas, in the spectral method, the wavelength of the patterned surface plays a critical role. κl=hμμeK is a parameter characterizing the porous medium for the lubrication method, whereas, as per the spectral model, κf is equal to L2πμμeK. In this section, we demonstrated a relation for the permeability of porous media between both mathematical approaches, which is defined as
(36)
In Sec. II, δ =  1λ is defined as a perturbation parameter (δ) as per the lubrication theory. The key findings of the present mathematical modeling are demonstrated graphically in Sec. VII.

The present study examines fluid flow through a channel with one grooved and one flat, impermeable wall, with porous material present in the channel. The fluid movement in the porous area is governed by the DB equation, considering only viscous forces. Lubrication equations are thoroughly validated by comparison with numerical simulations (NS) of the DB equation, as discussed in Sec. VII A. A finite-element-based numerical study is also conducted using COMSOL Multiphysics® software, as discussed in  Appendix A. The present NS is validated with the existing literature models8,55 and the current theoretical models (lubrication approach and grid-free spectral approach). In this paper, numerical values are represented symbolically. This section effectively illustrates the influence of dependent variables on scaled flow rate through graphical representation.

The variation of the scaled flow rate ratio is shown against the non-dimensional pattern amplitude for different values of permeability parameters using CLT and ELT, as discussed in Sec. VII A. Additionally, the prediction from the domain perturbation method8 is cross-validated with the present NS, as discussed in Sec. VII B. The aforementioned sections reveal the limitations of existing models in the literature. Finally, Sec. VII C compares predictions from the spectral model (SM) with numerical simulations (NS) and discusses a non-linear behavior of scaled flow rate at different values of permeability parameters. The behavior of flow parameters (e.g., scaled flow rate, velocity, and wall shear stress) is examined with pattern amplitude, wavelength, and permeability of the porous medium.

The impact of dimensionless pattern amplitude (ω) on the scaled flow rate for various κl values and perturbation parameters (δ) is depicted in Fig. 2. The solid and dashed curves illustrate the predictions from ELT and CLT, respectively. Equations (18) and (19) are utilized for CLT and ELT, respectively. Panel (a) of Fig. 2 demonstrates the variation of scaled flow rate with pattern amplitude (ω) for κl=0.5,2.0 at δ=0.1. When the channel height (h) is 0.1 times channel length (L), the scaled flow rate ratio (Ql/Qls) increases with pattern amplitude across a range of κl values. Both the numerical study and theoretical approaches (CLT and ELT) indicate an increasing trend in flow rate with κl, as depicted in panel (a) of Fig. 2. This comparison highlights the higher accuracy of ELT over CLT, and a close agreement is found between ELT and numerical values at both the Stokes flow limit (κl0) and the Darcy flow limit (κl1). CLT is accurate at smaller pattern amplitudes (ω0.2). Conversely, when the channel height is 0.5 times a channel length (δ=0.5), the scaled flow rate decreases with increasing pattern amplitude, as illustrated in panel (b) of Fig. 2. This decreasing behavior is predicted by both ELT and NS. In contrast, CLT consistently predicts an increasing flow rate with pattern amplitude at both limits, which shows the unphysical behavior of the scaled flow rate. The ratio between h and L is second order in the governing equation [Eq. (3)], and the CLT provides the solution for O(δ0), which is an incomplete investigation to capture the viscous stress. Consequently, the higher order correction in the CLT, which corresponds to a more accurate evaluation of viscous stresses, improves the applicability of lubrication theory from a significantly higher wavelength. Therefore, the higher-order term plays a significant role in the perturbation analysis to understand fluid behavior. Considering the higher-order term in the CLT accurately captures the viscous stress. Panel (b) indicates that the current theoretical models align closely with numerical values at smaller pattern amplitudes (ω0.10.2) from the Stokes to Darcian flow limits.

FIG. 2.

Variation of the scaled flow rate with pattern amplitude across different permeability mediums (κl) is presented for δ=0.1 and δ=0.5, as illustrated in panels (a) and (b), respectively. Equations (18) and (19) are used to show the prediction from the classical lubrication theory (CLT) and extended lubrication theory (ELT). Numerical simulations (NS) are represented symbolically.

FIG. 2.

Variation of the scaled flow rate with pattern amplitude across different permeability mediums (κl) is presented for δ=0.1 and δ=0.5, as illustrated in panels (a) and (b), respectively. Equations (18) and (19) are used to show the prediction from the classical lubrication theory (CLT) and extended lubrication theory (ELT). Numerical simulations (NS) are represented symbolically.

Close modal

The error percentage of the current theoretical model is assessed against numerical simulations to gauge accuracy. For example, at a perturbation parameter δ=0.1 and a permeability parameter κl=0.5, ELT exhibits an error percentage of 2.644  %, whereas CLT shows a significantly higher error percentage of 9.54  %, both calculated at a pattern amplitude ω=0.8. When the perturbation parameter is increased to δ=0.5, ELT maintains an error percentage below 10  % at ω=0.3 and κl=2. However, the error percentage for ELT surpasses the 10  % threshold at ω=0.32. It is observed that the relative difference between NS and ELT models increases as the pattern amplitude ω grows, indicating that the model's accuracy diminishes with larger pattern amplitudes. Section VII B presents a discussion of the results derived from the domain perturbation approach [ O(α2)], spectral method (SM), and numerical simulations (NS).

Ng and Wang8 investigated Darcy–Brinkman flow through a sinusoidal grooved microchannel using the domain perturbation method (DPM). They developed a second-order solution for the scaled flow rate, providing a foundation for understanding the behavior of flow with reference to the pattern surface. This model is accurate at significantly small pattern amplitudes. The present study is an extension of the existing literature model and will develop a model for large pattern amplitudes. In this section, we compare different mathematical models, including DPM and SM, against finite-element-based numerical simulations (NS). Equation (31) represents the prediction from SM, whereas Eq. (34) is a prediction from DPM, which is accurate up to O(α2). By comparing SM and DPM with NS, we aim to evaluate the accuracy and consistency of these models against numerical results, providing deeper insights into their predictive capabilities.

Figure 3 illustrates the variation of the scaled flow rate (Q/Q*) as a function of pattern amplitude (α). It compares predictions from the theoretical model with numerical results across various wavelengths (λ) and porous media permeabilities (κf). For a smaller wavelength (λ=1), an increase in α leads to the reduced scaled flow rate in the Stokes flow limit (κf0), as shown in panel (a) of Fig. 3. This behavior is captured by all approaches. This compression suggests that the O(α2)-solution is accurate at smaller values of pattern amplitude (α0.2) for κf=0.1,1.0, and it fails for large values of α. In contrast, the prediction of scaled flow rate from SM is found to have a good agreement with numerical values at significantly large α and κf=0.1,1.0. Furthermore, we analyzed for a large wavelength (λ=5), and the permeability of porous media varies from 0 to 1; QQ* increases with dimensionless pattern amplitude as shown in panel (c) of Fig. 3. At intermediate wavelength (λ=3) and κf=0.1,1, the flow rate ratio decreases monotonically with increasing α. This trend is captured by only O(ε2)-solution, as shown in dotted lines in panel (b) of Fig. 3. By contrast, a non-monotonic behavior of QQ* is observed using SM [Eq. (31)] and numerical study at both values of κf=0.1,1.0. This observation suggests that the behavior of the scaled flow rate is non-linear, and the minimum flow rate is noticed at an intermediate wavelength for the Stokes and Darcian flow limits. For significantly large pattern amplitudes (α1), it is noticed that SM and NS exhibit a good agreement at both limiting flow, as indicated by the compression. The case of the large characterizing porous medium (κf1) or Darcian flow limit is discussed in detail in Sec. VII C. We also discussed the increasing and decreasing behavior of the scaled flow rate in the later section.

FIG. 3.

Variation of scaled flow rate (QQ*) with pattern amplitude (α) for different permeability mediums (κf) at different wavelengths (λ). Panels (a), (b), and (c) represent variations for λ=1, λ=3, and λ=5, respectively. Equations (31) and (34) illustrate the predictions derived from the spectral model (SM) and the asymptotic model [ O(α2)], respectively. Numerical simulations (NS) are denoted symbolically.

FIG. 3.

Variation of scaled flow rate (QQ*) with pattern amplitude (α) for different permeability mediums (κf) at different wavelengths (λ). Panels (a), (b), and (c) represent variations for λ=1, λ=3, and λ=5, respectively. Equations (31) and (34) illustrate the predictions derived from the spectral model (SM) and the asymptotic model [ O(α2)], respectively. Numerical simulations (NS) are denoted symbolically.

Close modal

This section examines the variation in the scaled flow rate with respect to pattern amplitude for large values of permeability parameter (κf1), employing both SM and NS. The analysis is also conducted across various wavelengths (λ). Equation (31) is employed to plot the scaled flow rate as shown in panels (a) and (b) of Figs. 4 and 5. This compression clearly reveals that Q/Q* initially decreases with α, followed by an increase as α continues to rise at medium (λ=3) to large (λ=15) wavelengths. A similar trend is also captured by the numerical study. Figures 4 and 5 reveal that the parameter κf plays a crucial role in determining the transition behavior of the scaled flow rate. At the Stokes limit (κf0) and κf1, the non-monotonic behavior of the scaled flow rate is valid for intermediate wavelength (λ=3). By contrast, a similar trend is also noticed at Darcian flow at any values of wavelength (λ3). As demonstrated in the literature model8 and the present lubrication theory model, the dimensional flow rate may exhibit either a monotonic increase or decrease with respect to the wavelength and permeability parameter, as discussed in Secs. VII A and VII B. However, in the spectral model's prediction, the dimensionless flow rate reveals non-linear behavior at both the Stokes and Darcy flow limits. The factors contributing to the observed fluctuations in the dimensional flow rate are examined at the end of this section. Figures 4 and 5 elucidated a good agreement between the numerical values and the prediction from SM. Panels (a) and (b) of Figs. 4 and 5 show that the SM prediction for the scaled flow rate always captured the minimum at large values of κf. Each wavelength with respect to κf has a different pattern amplitude, where flow rate behavior captured the minimum. The transition behavior of scaled permeability occurs at a critical pattern amplitude (αcrt). Table I shows the values of αcrt; at this point, a non-linear behavior of scaled flow rate is observed. When α>αcrt, the flow rate through a grooved channel is lower than that of standard Poiseuille flow. Conversely, when α<αcrt, the flow rate through a grooved channel exceeds the standard Poiseuille flow rate. When λ is constant, for example, λ = 3, the critical pattern amplitude is ∼0.61 for κf = 0.5, which is lower than that observed for κf = 3.0. This finding indicates that αcrt increases with κf. A similar behavior is also captured for other values of λ.

FIG. 4.

Variation of scaled flow rate (QQ*) with pattern amplitude for different permeability (α) mediums (κf) at different wavelengths (λ). Panels (a) and (b) are variations for λ=3 and λ=5, respectively. The solid lines represent the prediction from the spectral model (SM), and Eq. (31) is used to obtain the variation of dimensional flow rate. Numerical simulations (NS) are represented symbolically.

FIG. 4.

Variation of scaled flow rate (QQ*) with pattern amplitude for different permeability (α) mediums (κf) at different wavelengths (λ). Panels (a) and (b) are variations for λ=3 and λ=5, respectively. The solid lines represent the prediction from the spectral model (SM), and Eq. (31) is used to obtain the variation of dimensional flow rate. Numerical simulations (NS) are represented symbolically.

Close modal
FIG. 5.

Variation of dimensional flow rate (QQ*) with pattern amplitude for different permeability (α) mediums (κf) at different wavelengths (λ). Panels (a) and (b) are variations for λ=10 and λ=15, respectively. The solid lines represent the prediction from the spectral model (SM), and Eq. (31) is used to obtain the variation of the scaled flow rate. Numerical simulations (NS) are represented symbolically.

FIG. 5.

Variation of dimensional flow rate (QQ*) with pattern amplitude for different permeability (α) mediums (κf) at different wavelengths (λ). Panels (a) and (b) are variations for λ=10 and λ=15, respectively. The solid lines represent the prediction from the spectral model (SM), and Eq. (31) is used to obtain the variation of the scaled flow rate. Numerical simulations (NS) are represented symbolically.

Close modal
TABLE I.

The transition behavior of dimensional flow rate (Q/Q*) is calculated with critical pattern amplitude (αcrt) at various wavelengths (λ) and permeability mediums (κf). The boldface value denotes approximate values of critical pattern amplitude, where the dimensionless flow rate is calculated and transmission behaviour is captured.

λ κf αcrt Q/Q*
0.5  0.61  0.9494 
0.80  0.9298 
10  15  0.58  0.9974 
10  25  0.79  0.9967 
λ κf αcrt Q/Q*
0.5  0.61  0.9494 
0.80  0.9298 
10  15  0.58  0.9974 
10  25  0.79  0.9967 

We can draw the following conclusions based on the trends observed in Figs. 4 and 5, as well as the aforementioned discussion regarding the impact of α, λ, and κf. As α increases, there is an increase in the additional area on the lower wall [as shown in panel (b) of Fig. 1] over which viscous forces can enforce the no-slip condition. This increase in area is higher than that of a channel with a flat lower wall at Y = 0. When the wavelength of the pattern is short, the most significant gradients of the flow occur near the lower wall and are inversely proportional to the wavelength. This amplifies the role of the viscous forces acting on the lower surface for the DB flow. Due to this effect, the scaled flow rate decreases with α at short wavelengths. For short waves, the grooves behave as roughness elements that enhance drag. However, in the long-wave limit, the x-gradients in the flow, which are influenced by the wavelength, become less significant than the y-gradients that are determined by the local channel thickness. As a result, when α is small initially and at moderate to large wavelengths with significantly large κf, grooves behave as roughness elements that enhance friction. This leads to a negative slope in the flow rate vs amplitude curve, as seen in Figs. 4 and 5. On the other hand, when α is increased, a transition is observed in the flow rate vs amplitude curve. Initially, a minimum is reached, as seen in the figures. However, on further increasing α, the slope of the curve changes toward a long wave-like positive slope. This is because the y-gradients become more significant than x-gradients due to the formation of progressively narrower constrictions with an increase in α.

1. Wall shear stress (WSS) distribution near to the grooved wall

This study aims to elucidate the effects of pattern amplitude (ε) and permeability parameter (κf) on wall shear stress (WSS) behavior along a grooved wall. We present a graphical representation of WSS distribution in Figs. 6–8. The investigation is performed for small (λ=1) and long (λ=10) wavelengths of the channel. Panels (a) and (b) of Fig. 6 illustrate the variation of WSS across different values of ε at a fixed value of κf=15. If the channel length (L) equals the mean channel height (h) or λ=1, WSS reaches its maximum value at the center of the channel (X=0) for all values of ε. The maximum value of WSS increases with increasing pattern amplitude, as illustrated in panel (a) of Fig. 6. The viscous forces are more prominent near the crest of the grooved surface for a shorter wavelength. For the case where Lh (λ=10) with κf=15, the maximum wall WSS is observed at X=0 for ε=0.2 and ε=0.3, as shown in panel (b) of Fig. 6. However, for a slightly larger pattern amplitude (ε=0.4), the maximum WSS decreases, and its location shifts away from X=0. This indicates that the viscous effects become less significant as the channel length increases relative to its height.

FIG. 6.

Variation of wall shear wall stress is calculated on the bottom grooved wall for κf = 15 and various values of ε. Panel (a) corresponds to λ=1, while panel (b) corresponds to λ=10. Numerical simulations (NS) are represented symbolically.

FIG. 6.

Variation of wall shear wall stress is calculated on the bottom grooved wall for κf = 15 and various values of ε. Panel (a) corresponds to λ=1, while panel (b) corresponds to λ=10. Numerical simulations (NS) are represented symbolically.

Close modal
FIG. 7.

Variation of wall shear wall stress is calculated on the bottom grooved wall for ε = 0.4 and various values of κf. Panel (a) corresponds to λ=1, while panel (b) corresponds to λ=10. Numerical simulations (NS) are represented symbolically, whereas the solid lines are prediction from the spectral method (SM).

FIG. 7.

Variation of wall shear wall stress is calculated on the bottom grooved wall for ε = 0.4 and various values of κf. Panel (a) corresponds to λ=1, while panel (b) corresponds to λ=10. Numerical simulations (NS) are represented symbolically, whereas the solid lines are prediction from the spectral method (SM).

Close modal
FIG. 8.

Variation of wall shear wall stress is calculated on the bottom grooved wall for ε = 0.4 and various values of κf. Panel (a) corresponds to λ=3, while panel (b) corresponds to λ=5. Numerical simulations (NS) are represented symbolically, whereas the solid lines are prediction from the spectral method (SM).

FIG. 8.

Variation of wall shear wall stress is calculated on the bottom grooved wall for ε = 0.4 and various values of κf. Panel (a) corresponds to λ=3, while panel (b) corresponds to λ=5. Numerical simulations (NS) are represented symbolically, whereas the solid lines are prediction from the spectral method (SM).

Close modal

Figure 7 graphically demonstrates the variation of WSS for different values of κf (0.1, 1.0, 5.0, 10.0, 15.0, and 20.0) at ε=0.4 for smaller and large wavelength. If λ=1 and ε=0.4, the maximum WSS is observed in the Stokes limit (κf1), while the minimum WSS is identified in the Darcian limit (κf1), as illustrated in panel (a) of Fig. 7. Conversely, for λ=10, the maximum WSS is found in the Darcian limit, and the minimum WSS is observed in the Stokes limit, as shown in panel (b) of Fig. 7. The viscous shear effect is highly pronounced in the Stokes flow regime and diminishes with increasing permeability of the porous material. Consequently, the maximum wall shear stress (WSS) is observed in the Stokes flow limit compared to the Darcian flow limit, particularly at small wavelengths. This observation indicates that the maximum and minimum WSS values occur at the narrowest section of the channel, corresponding to X=0. Furthermore, we observed that an increase in the permeability parameter significantly affects intermediate wavelengths, such as 3 and 5. Consequently, the influence of WSS on the grooved wall surface becomes less prominent. The distribution of WSS is similar for λ=3 and λ=5 as shown in panels (a) and (b) of Fig. 8. When the channel has a more permeable and shorter wavelength, the viscous effect is less significant. This means there is greater resistance on the grooved wall. As a result, WSS decreases with a more permeable medium. On the other hand, viscous forces are more significant for long wavelengths and larger permeable surfaces. These findings show that amplitude and wavelength strongly depend on the geometrical properties of a porous material. The prediction from the spectral method is perfectly aligned with the numerical values for each case.

2. Variation of scaled flow rate with reference to permeability of porous media (κf)

This section examines the influence of κf on the variation of scaled flow rate. To elucidate its significance, we utilize both spectral method and numerical simulation approaches. Figure 9 demonstrates the transition from the Stokes flow to the Darcian flow. Equation (31) presents the prediction of the scaled flow rate using the spectral approach, while Eq. (34) provides the O(α2) solution for the scaled flow rate. The comparison between the analytical solution and numerical study for λ = 3 and λ = 5 is depicted in panels (a) and (b), respectively. At the Stokes and Darcy flow limits, the results from the current spectral method reveal a good agreement with numerical simulations across all pattern amplitude values. At λ=3, the scaled flow rate first decreases and then increases as κf increases, as shown in panel (a). When κf varies from 0 to 10 with λ=3, the behavior of the scaled flow rate exhibits a decreasing trend, followed by an increasing trend, which can be attributed to the effects of surface roughness and confinement, respectively. Both the numerical simulation and the O(α2) solution show a similar trend; however, a clear difference exists between them. In contrast, for λ=5, the scaled flow rate steadily decreases as κf increases. At moderately large wavelengths, viscous forces become more pronounced with increasing values of κf. The permeability of the porous medium reduces the scaled flow rate. In the Stokes-to-Darcian flow regime (κf6), the flow rate through the grooved channel (Q) matches that of a straight channel (Q*). This behavior is observed from all approaches, as shown in panel (b). As seen in Fig. 9, larger channel wavelengths are associated with higher flow rates in both Stokes and Darcy flow limits. In contrast, moderate wavelengths show a combination of increasing and decreasing flow rates in these two regimes. A non-linear phenomenon is observed at κf= 1.885. For κf<1.885, the observed decreasing trend is attributed to the predominant influence of surface roughness. In contrast, for κf>1.885, the increasing trend indicates the confinement effects are becoming more significant. When analyzing DB flow in a grooved channel, it is essential to consider the channel's wavelength. This factor affects flow behavior and its interaction with the patterned surface, influencing parameters such as pressure drop, flow distribution, and overall channel performance.

FIG. 9.

The effect of permeability medium for the dimensionless flow rate (QQ*) is shown by the spectral method, numerical simulation, and asymptotic results of Ng and Wang.8 Panel (a) corresponds to λ=3, while panel (b) corresponds to λ=5. Numerical simulations (NS) are represented symbolically, whereas the solid lines stand for the prediction from the spectral method (SM).

FIG. 9.

The effect of permeability medium for the dimensionless flow rate (QQ*) is shown by the spectral method, numerical simulation, and asymptotic results of Ng and Wang.8 Panel (a) corresponds to λ=3, while panel (b) corresponds to λ=5. Numerical simulations (NS) are represented symbolically, whereas the solid lines stand for the prediction from the spectral method (SM).

Close modal

3. Variation of scaled flow rate with reference to the height of the channel

The variation of the scaled flow rate is plotted with scaled minimum spacing between grooved and straight plates for a small amplitude-to-pitch ratio (ε=1) for various permeability medium as shown in Fig. 10. The logarithmic scale is used for the independent variable to capture the low-channel height regime and the minimum in each curve precisely. Similarly, a large amplitude-to-pitch (ε=3) ratio is also investigated here as depicted in Fig. 11. When the flat wall (top wall) is brought closer from a large distance to a patterned surface, two competing phenomena are observed with various amplitude-to-pitch ratios. For example, when the permeability is small (κf=0.05), the dimensional flow rate is larger for a grooved channel as compared to a straight channel. A similar trend is also observed with different values of permeability as shown in Fig. 10. The flow rate ratio decreases with increasing values of permeability if it is scaled with ha rather than h. The flow rate ratio is always higher than the standard Poiseuille flow through a straight channel. For a large amplitude-to-pitch, the flow rate ratio is always less than that of the standard Poiseuille flow through a straight channel. In this situation, the non-linear behavior of dimensionless flow rate is identified with various permeability values, as illustrated in Fig. 11. This transition behavior of flow rate can be summarized dimensionally. When the dimensional amplitude-to-pitch ratio (ε) is 3 and L = 10 μm, then amplitude (a) is equal to 4.75 μm with different permeability (κf) values such as 0.05, 0.5, 1, and 2. Using these quantities, the scaled flow rate reaches a minimum of 45.67  %, 56.65  %, 69.29  %, and 81.88  % of the flow rate of the plane channel flow with the same h and different κf, when h is 30.6 μm. Smaller and larger channel sizes than h = 30.6 μm will result in a larger flow rate ratio to the plane channel flow with the same h. The aforementioned discussion shows that the flow rate strongly depends on the permeability of porous media and the dimension of the pattern amplitude.

FIG. 10.

At the Stokes to Darcian flow limit, variation of dimensionless flow rate (QQ*) with a scaled minimum spacing between patterned and unpatterned plates for the amplitude-to-pitch ratio (ε=1). A logarithmic scale is used for the independent variable to visually resolve the low-channel height regime and the minimum in each curve. Equation (31) is used to obtain the variation of the scaled flow rate.

FIG. 10.

At the Stokes to Darcian flow limit, variation of dimensionless flow rate (QQ*) with a scaled minimum spacing between patterned and unpatterned plates for the amplitude-to-pitch ratio (ε=1). A logarithmic scale is used for the independent variable to visually resolve the low-channel height regime and the minimum in each curve. Equation (31) is used to obtain the variation of the scaled flow rate.

Close modal
FIG. 11.

At the Stokes to Darcian flow limit, variation of dimensionless flow rate (QQ*) with a scaled minimum spacing between patterned and unpatterned plates for the amplitude-to-pitch ratio (ε=3). Equation (31) is used to obtain the variation of the scaled flow rate.

FIG. 11.

At the Stokes to Darcian flow limit, variation of dimensionless flow rate (QQ*) with a scaled minimum spacing between patterned and unpatterned plates for the amplitude-to-pitch ratio (ε=3). Equation (31) is used to obtain the variation of the scaled flow rate.

Close modal

4. Variation of scaled flow rate with wavelengths

The plot in Fig. 12 depicts how the scaled flow rate changes with wavelengths (λ) for a fixed α value of 0.9. This situation is highly constrained, indicating that the thinnest section of the channel is 19 times bigger than the narrowest portion. An investigation is conducted into the Stokes flow limit, as illustrated in panel (a), and the Darcian flow limit, as depicted in panel (b). Equation (31) is used for the prediction by SM, whereas Eq. (34) is considered for an O(α2)-solution. Both theories are compared with NS. A good agreement is found between SM and NS for each value of wavelengths at both limits. For κf=0.5, the flow rate is lower than that of the conventional Poiseuille flow at smaller wavelengths, while it exceeds the Poiseuille flow at larger wavelengths as shown in panel (a). A smaller wavelength is emphasized by the roughness effect, while a longer wavelength is associated with the confinement effect. For κf1, the flow rate is always higher than that of the conventional Poiseuille flow at any values of wavelength as shown in panel (b). The O(α2) model is not accurate at smaller to large wavelengths, whereas the prediction from Eq. (31) is accurate at any value of wavelength for Stokes limit and Darcian limit, as shown in both panels of Fig. 12.

FIG. 12.

The effect of wavelength for the dimensionless flow rate (QQ*) is shown by the spectral method, numerical simulation, and asymptotic results of Ng and Wang.8 Panel (a) corresponds to κf=0.5, while panel (b) corresponds to κf=2. Numerical simulations (NS) are represented symbolically, whereas the solid lines stand for the prediction from the spectral method (SM).

FIG. 12.

The effect of wavelength for the dimensionless flow rate (QQ*) is shown by the spectral method, numerical simulation, and asymptotic results of Ng and Wang.8 Panel (a) corresponds to κf=0.5, while panel (b) corresponds to κf=2. Numerical simulations (NS) are represented symbolically, whereas the solid lines stand for the prediction from the spectral method (SM).

Close modal

5. Variation of longitudinal velocity

To gain a better understanding of the role played by κf in the current problem, it is essential to analyze the axial velocity profile. Equation (22) is not only helpful to identify the flow rate through a channel, but it is also utilized to understand other flow behavior such as flow profile (velocity). The depth-wise variation of velocity at different transverse locations within the flow cross section is plotted in Figs. 13 and 14. For Darcian flow, the analysis is performed for both small (λ=1) and large (λ=10) wavelengths. The results focus on the thickest part of the channel (X=π), as illustrated in panels (a) and (b) of Fig. 13. However, Fig. 14 presents the flow profile at the thinnest section of the channel (X=0) for various values of κf. At various values of κf, the comparison in these figures clearly shows that the theoretical distribution matches the numerical distribution in the Y direction when ε= 0.5. At λ=1, the velocity profile deviates from a parabolic shape, exhibiting a flattened characteristic in the center of the channel across all values of κf, as depicted in panel (a) of Fig. 13. It is observed that the axial velocity decreases with increasing κf. Higher values of κf reduce the effective permeability in the flow direction, thereby increasing the overall resistance to flow. As a result, the fluid velocity diminishes with increasing κf. Furthermore, an increase κf from 2 to 10 results in a reduction of velocity at the thickest section of the channel. With a wavelength of λ = 10 and κf = 6, the depth-wise velocity distribution displays a parabolic profile. The maximum velocity occurs at the center of the channel, as illustrated in panel (b) of Fig. 13. When κf increases from 6 to 15, the velocity profile deviates from the parabolic shape. For larger values of κf, the axial velocity profile becomes increasingly uniform, with the influence of the wall confined to a thin boundary layer near the surface. As a result, the wall resistance has a minimal contribution to the overall resistance, which is predominantly governed by the porous medium. This results in a decrease in the overall velocity. This comparison signifies the dominance of Darcian flow over the Stokes flow at different wavelengths. To conclude, if the length of the channel (L) is 10 times the mean height (h), it is essential to employ reduced values of κf in order to achieve a parabolic velocity profile.

FIG. 13.

At various permeability mediums, the variation of velocity profile along the transverse direction is shown at the thickest section of that channel (X=π) for moderately large pattern amplitude (ε=0.5). Equation (22) is used to obtain the variation of the scaled flow rate. Panel (a) corresponds to λ=1, while panel (b) corresponds to λ=10. Panels (c) and (d) illustrate the variation of axial velocity at X=π and X=0 for λ=10, κf = 2, 4. The solid lines represent the predictions obtained using the spectral method (SM), while the symbols correspond to the results from the numerical simulations (NS).

FIG. 13.

At various permeability mediums, the variation of velocity profile along the transverse direction is shown at the thickest section of that channel (X=π) for moderately large pattern amplitude (ε=0.5). Equation (22) is used to obtain the variation of the scaled flow rate. Panel (a) corresponds to λ=1, while panel (b) corresponds to λ=10. Panels (c) and (d) illustrate the variation of axial velocity at X=π and X=0 for λ=10, κf = 2, 4. The solid lines represent the predictions obtained using the spectral method (SM), while the symbols correspond to the results from the numerical simulations (NS).

Close modal
FIG. 14.

At various permeability mediums (κf), the variation of velocity profile along the transverse direction is shown at the thinnest section of that channel (X=0) for moderately large pattern amplitude (ε=0.5). Equation (22) is used to obtain the variation of the scaled flow rate. Panel (a) corresponds to λ=1, while panel (b) corresponds to λ=10. Numerical simulations (NS) are represented symbolically.

FIG. 14.

At various permeability mediums (κf), the variation of velocity profile along the transverse direction is shown at the thinnest section of that channel (X=0) for moderately large pattern amplitude (ε=0.5). Equation (22) is used to obtain the variation of the scaled flow rate. Panel (a) corresponds to λ=1, while panel (b) corresponds to λ=10. Numerical simulations (NS) are represented symbolically.

Close modal

Panels (c) and (d) illustrate the variation in the axial velocity for two values of κf (2 and 4) at two different channel sections (X=π and X=0) for λ=10 and ε=0.5. The results indicate that as κf increases, the velocity magnitude decreases, particularly at the thickest section of the channel (X=π). In regions with high material porosity, the flow velocity is reduced, and the velocity profile transitions from parabolic to flatter, as shown in panel (c) of Fig. 13. In contrast, at the thinnest section of the channel, the velocity profile remains close to parabolic, and the maximum velocity W values are nearly identical for κf = 2 and 4, as shown in panel (d). Overall, κf has a more pronounced effect at shorter wavelengths compared to longer wavelengths. A strong agreement is observed between the spectral and numerical approaches.

At the thinnest section of the channel (X=0), the velocity profile is not parabolic with reference to any values of κf at λ = 1, as illustrated in panel (a) of Fig. 14. For a large wavelength, the velocity profile is always captured in a parabolic nature or similar to Poiseuille flow as illustrated in panel (b) of Fig. 14. The influence of κf becomes more pronounced when the length of the channel (L) is equal to its mean height (h). Conversely, when the channel length is ten times the mean height, the effect of κf diminishes significantly. Overall, the magnitude of the velocity (W) decreases with increasing κf at any wavelength of the channel. The aforementioned discussion reveals that the flow profiles strongly depend on λ and κf. A good agreement is found between the prediction from the spectral model and the numerical simulation. Furthermore, the no-slip boundary condition at both walls is achieved using spectral method and numerical simulations.

The analysis focuses on the behavior of the axial velocity (W) at the Stokes flow limit (κf1) for both the thickest (X=π) and thinnest (X=0) sections of the channel, considering both small (λ=1) and large wavelengths (λ=10), as illustrated in Fig. 15. The investigation is conducted for various values of κf, including 0.1, 0.3, 0.5, and 1. For λ=1 and each value of κf, the maximum velocity is observed at the center of the channel at both sections, as shown in panels (a) and (c). At κf1, the velocity profile closely resembles standard Poiseuille flow (parabolic profile). As κf increases from 0.1 to 0.5 and then from 0.5 to 1, the fluid velocity in the porous medium decreases, with the velocity profile becoming progressively flatter at the center of the channel, approaching the Darcian flow limit. Panels (a) and (c) of Fig. 15 indicate that flow resistance increases with permeability at both channel sections, and the influence of the porous material becomes more pronounced slightly away from the wall. For λ=10 and X=π, similar trends are observed, as shown in panel (b) of Fig. 15. However, at large wavelengths, the effect of κf is less pronounced compared to the small wavelength case. The minimum axial velocity is observed at κf = 1. At X=0, the effect of the permeability of the porous media is less significant compared to X=π, as shown in panel (d). The maximum velocity for the transition from Stokes to Darcian flow is nearly identical for both sections. For all cases, excellent agreement is found between the spectral method and numerical simulations, as shown in Fig. 15. The above-mentioned analysis demonstrates that the presence of a porous medium effectively suppresses the growth of boundary layers on rigid, impermeable plates, preventing them from extending to the center of the channel. This behavior contrasts sharply with that of plane Poiseuille flow, where boundary layers develop uniformly from the plates and merge at the channel center, as indicated by dW(y)dy=0. Consequently, the introduction of a porous medium distinctly modifies the flow dynamics compared to conventional cases.

FIG. 15.

Variation of axial velocity in the Stokes flow regime is examined at different locations within the channel, specifically at the thinnest (X=0) and thickest (X=π) sections for λ=1 and λ=10. The solid lines represent predictions from the special method (SM), while the symbols denote results from the numerical simulations (NS).

FIG. 15.

Variation of axial velocity in the Stokes flow regime is examined at different locations within the channel, specifically at the thinnest (X=0) and thickest (X=π) sections for λ=1 and λ=10. The solid lines represent predictions from the special method (SM), while the symbols denote results from the numerical simulations (NS).

Close modal

Figure 16 presents both the contour and surface plots showing the variation in the magnitude of the velocity (W) with different values of κf for ε=0.5 and λ=10. The figure indicates that as κf increases from the Stokes to Darcian flow limit, the fluid velocity decreases, particularly at the thickest section of the channel (X=π), due to the influence of permeability in the porous medium. For instance, at the Stokes flow limit κf = 0, the maximum velocity is ∼0.224, while for κf = 5, it decreases to around 0.055. In contrast, at the thinnest part of the channel (X=0), the maximum velocity is nearly the same (0.003) for both the Stokes and Darcy limits. This observation suggests that the permeability effect is more pronounced in the thicker sections of the channel than in the thinner sections, particularly for long wavelengths. Additionally, the maximum velocity is observed at the Stokes flow limit, as compared to the Darcy flow limit. In high-permeability conditions, flow resistance in wave channels becomes more pronounced, counteracting the applied pressure gradient. As a result, the velocity profile tends to flatten.

FIG. 16.

For a large wavelength (λ=10) and pattern amplitude (ε=0.5), panels (a)–(h) illustrate the variation in velocity magnitude (W) for different κf under the Stokes and Darcian flow limits.

FIG. 16.

For a large wavelength (λ=10) and pattern amplitude (ε=0.5), panels (a)–(h) illustrate the variation in velocity magnitude (W) for different κf under the Stokes and Darcian flow limits.

Close modal

In this paper, we present a comprehensive study of hydrodynamic flow through a corrugated channel containing sparse porous material. The primary objective is to investigate Darcy–Brinkman flow in a grooved microchannel, focusing on cases with large pattern amplitudes and high permeability in the porous medium, particularly for complex geometries. The analysis is conducted using both spectral and lubrication approaches: the lubrication theory is applied to complex topographies, while spectral methods are utilized for sinusoidal channels. While previous models in the literature, based on the domain perturbation theory, offer accurate predictions for small pattern amplitudes and low permeability, their applicability diminishes as these parameters increase. Furthermore, studies on Darcy–Brinkman flow have predominantly focused on transverse flow, with limited attention given to longitudinal flow in porous media. To address these challenges, we propose a mathematical model that ensures an accurate scaled flow rate even in scenarios with high permeability and large pattern amplitudes. This study employs a systematic perturbation analysis to derive higher-order terms, extending the traditional lubrication approximation. The analytical results are thoroughly compared with numerical simulations, demonstrating the accuracy and reliability of the proposed model.

The key conclusions are as follows: (i) In both the Stokes and Darcy limits, the higher-order extended lubrication theory (ELT) shows excellent agreement with numerical simulations at δ=0.1, demonstrating a significant improvement over the classical lubrication theory (CLT). However, in the case of δ=0.5, ELT fails with increasing pattern amplitude. (ii) The spectral model overcomes these limitations of the lubrication approximation at both limiting flows. Based on the Fourier theory, the current proposed model is more accurate than the domain perturbation theory, regardless of dependent parameters. We developed a model that is accurate when the crest of a grooved wall is very close to the upper wall. (iii) According to the literature model, the dimensional flow rate may increase or decrease with dependent parameters, which provides an incomplete behavior for the Darcy–Brinkmann flow through pattern topographies. The present spectral model predicts a non-monotonic behavior of the scaled flow rate at the Darcian limit and provides a broader view of the effect of micropatterning on Darcy–Brinkmann flow. The non-linear behavior of the scaled flow rate is a significant finding of the present work, whereas the literature models are unable to capture this trend. The Darcy viscous drag force is very prominent and depends on the geometry's orientation. (iv) At smaller wavelengths, the maximum shear stress is observed at the crest of the pattern surface for Stokes flow (κf1) and Darcian flow limit (κf1). In contrast, for a large wavelength, the wall shear stress behavior significantly alters with the permeability medium. The amplitude-to-pitch ratio significantly influences the range of maximum and minimum shear stress values. (v) At the Stokes flow limit, the velocity profile has a parabolic shape, similar to standard Poiseuille flow. However, in the case of a high permeability medium (κf1) or the Darcian limit, the profile becomes flatter.

Equations (22) and (31) are key equations to predict the behavior of flow parameters for Darcy–Brinkman flow through a grooved microchannel. We have demonstrated the influence of dependent variables on the scaled flow rate with micropatterning. The findings of the present study are highly significant and have broad applications in multiple fields, such as chemical reactors, filtering equipment, heat exchangers, and flow through rock fractures.

The author would like to thank Dr. Tim Persoons, Department of Mechanical, Manufacturing and Biomedical Engineering, Trinity College Dublin, Dublin, Ireland, for providing access to the software.

The authors have no conflicts to disclose.

Mainendra Kumar Dewangan: Conceptualization (lead); Data curation (lead); Formal analysis (lead); Investigation (lead); Methodology (lead); Validation (lead); Writing – original draft (lead); Writing – review & editing (lead).

The data that support the findings of this study are available within the article.

Finite-element analysis using COMSOL Multiphysics is employed to evaluate the present model and assess the limitations of existing literature models. The partial differential equation (PDE) module in COMSOL is utilized to solve the governing equations and boundary conditions. The PARDISO (parallel direct sparse solver) direct solver, a stationary solver with relative tolerance τrt=104 was used to obtain the numerical values. For the analysis, a single periodic cell of the microchannel is considered, with periodic boundary conditions applied along the y axis within the computational domain. Numerical simulation is performed for the lubrication approach and spectral approach separately. For the lubrication theory, Eq. (3) with Eqs. (4a) and (4b) is solved using the PDEs module in the software, whereas, for the spectral method, Eq. (20) with Eqs. (21a) and (21b) is considered for the solution. No slip boundary conditions at walls (X-edges) and periodic boundary conditions at Y-edges are chosen. The domain is discretized using a triangular mesh, with mesh refinement ensuring accuracy up to 3–4 decimal places to evaluate mesh dependency. A grid sensitivity analysis is performed to examine how variations in the mesh size affect the computed flow quantities. This includes an independent grid study for each wavelength and pattern amplitude. The size of the computational cells depends on the maximum and minimum element sizes, element size growth rate, and maximum allowed iterations. We found that further refining the mesh did not affect the accuracy of the numerical study. The maximum and minimum element sizes are chosen based on the grid independence test as depicted in Table II. In the numerical simulations (NS), we have assessed the limitations of the computational framework. Our findings indicate that the NS are sufficiently robust to handle extreme scenarios, such as (i) cases where the crest of the grooved surface approaches the upper flat surface (α1) and (ii) situations where the permeability of the porous medium is exceptionally high (κf1). The spectral model is shown to provide faster predictions compared to the numerical simulations, highlighting its computational efficiency.

TABLE II.

Variation of scaled flow rate at λ=10, κf=25, and ε=0.5 for different mesh sizes. The boldface value denotes that the grid sensitivity is accurate up to 4 decimal points.

Element size Number of cell count Q/Q*
0.2  791  0.991 65 
0.1  1 084  0.995 92 
0.08  1 637  0.996 47 
0.05  4 115  0.996 87 
0.03  11 314  0.996 9
0.02  25 255  0.996 9
0.01  101 011  0.996 9
Element size Number of cell count Q/Q*
0.2  791  0.991 65 
0.1  1 084  0.995 92 
0.08  1 637  0.996 47 
0.05  4 115  0.996 87 
0.03  11 314  0.996 9
0.02  25 255  0.996 9
0.01  101 011  0.996 9
(B1)
(B2)
(B3)
(B4)
(B5)
(B6)
It is possible to list the coefficients found in Eq. (12) as follows:
(B7)
(B8)
(B9)
(B10)
(B11)
(B12)
(B13)
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