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<p>Micro-flow control valves are critical for precise propellant regulation in aerospace propulsion systems, yet existing designs face challenges in flow stability and accuracy under small openings where rarefied gas effects dominate. This study presents a novel zonal design micro-flow control valve optimized via Knudsen number (Kn)-based flow regime partitioning. A gas flow model was established to correlate valve openings (10–50&#xa0;μm) with flow characteristics, enabling derivation of a polynomial-fitted spool profile that aligns with dynamic flow area requirements. Comparative simulations revealed that the polynomial-section spool significantly enhances flow field stability at a 50&#xa0;μm opening, reducing maximum throttle velocity by 35.5% and suppressing turbulent vortices compared to conventional trapezoidal designs. Numerical analysis demonstrated progressive flow stabilization as the opening increased: maximum throttle velocity rose from 7.99 to 52.46&#xa0;m/s, while vortex count decreased from four to one. A prototype was fabricated and tested, achieving a maximum flow deviation of &lt; 0.5% under varying voltages (15–55V DC), validating precision control. By integrating Knudsen number-driven zonal modeling, polynomial spool optimization, and experimental verification, this work advances the design of micro-flow valves for high-accuracy aerospace applications, particularly in slip and transition flow regimes.</p>

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A novel micro-flow control valve with zonal design based on Knudsen number

  • 期刊论文

  • 发表日期：

    2025年4月2日

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  • Yaping Liu,
  • Hui Du,
  • Bincheng Wang,
  • Jingmin Li

摘要

Micro-flow control valves are critical for precise propellant regulation in aerospace propulsion systems, yet existing designs face challenges in flow stability and accuracy under small openings where rarefied gas effects dominate. This study presents a novel zonal design micro-flow control valve optimized via Knudsen number (Kn)-based flow regime partitioning. A gas flow model was established to correlate valve openings (10–50 μm) with flow characteristics, enabling derivation of a polynomial-fitted spool profile that aligns with dynamic flow area requirements. Comparative simulations revealed that the polynomial-section spool significantly enhances flow field stability at a 50 μm opening, reducing maximum throttle velocity by 35.5% and suppressing turbulent vortices compared to conventional trapezoidal designs. Numerical analysis demonstrated progressive flow stabilization as the opening increased: maximum throttle velocity rose from 7.99 to 52.46 m/s, while vortex count decreased from four to one. A prototype was fabricated and tested, achieving a maximum flow deviation of < 0.5% under varying voltages (15–55V DC), validating precision control. By integrating Knudsen number-driven zonal modeling, polynomial spool optimization, and experimental verification, this work advances the design of micro-flow valves for high-accuracy aerospace applications, particularly in slip and transition flow regimes.