Despite of the fact that numerical simulation of two-phase flows in microchannels has been attempted by many investigators, most efforts seem to have failed in correctly capturing the flow physics, especially the slug flow regime characteristics. The presence of a thin liquid film in the order of 10 μm around the bubble (sometimes called gas pocket or gas slug) may be a contributing factor to the above difficulty. Typically, liquid films have a significant effect on the flow field. Thus, there is a strong motivation to employ numerical simulation methods in order to avoid some of the experimental difficulties. In this paper, the characteristics of two-phase slug flows in microchannels are calculated with the help of the Volume-of-Fluid (VOF) method. Formation of the slugs for different superficial velocities, Capillary numbers, and gas volume fractions are investigated. The minimum mesh resolution required to capture the liquid film surrounding the gas bubble is reported employing a dynamic mesh adaption methodology with interface tracking. Results are shown to be in good agreement with experimental data and empirical correlations.

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