The shear rheology of an emulsion of viscous drops in the presence of finite inertia is investigated using direct numerical simulation. In the absence of inertia, emulsions display a non-Newtonian rheology with positive first and negative second normal stress differences. However, recently it was discovered that a small amount of drop-level inertia alters their signs – the first normal stress difference becomes negative and the second one becomes positive, each in a small range of capillary numbers (Li & Sarkar,J. Rheol., vol. 49, 2005, pp. 1377–1394). Sign reversal was shown numerically and analytically, but only in the limit of a dilute emulsion where drop–drop interactions were neglected. Here, we compute the rheology of a density- and viscosity-matched emulsion, accounting for the interactions in the volume fraction range of 5 %–27 % and Reynolds number range of 0.1–10. The computed rheological properties (effective shear viscosity and first and second normal stress differences) in the Stokes limit match well with previous theoretical (Choi–Schowalter in the dilute limit) and simulated results (for concentrated systems) using the boundary element method. The two distinct components of the rheology arising from the interfacial stresses at the drop surface and the perturbative Reynolds stresses are investigated as functions of the drop Reynolds number, capillary number and volume fraction. The sign change is caused by the increasing drop inclination in the presence of inertia, which in turn directly affects the interfacial stresses. Increase of the volume fraction or capillary number increases the critical Reynolds number for sign reversals due to enhanced alignment of the drops with the flow directions. The effect of increasing the volume fraction on the rheology is explained by relating it to interactions and specifically to the contact pair-distribution function computed from the simulation. The excess stresses are seen to show an approximately linear behaviour with the Reynolds number in the range of 0.1–5, while with the capillary number and volume fraction, the variation is weakly quadratic.

Experimentally observed drop-chain formation in sheared drop monolayers is explained in terms of Hele-Shaw quadrupolar interactions and swapping-trajectory repulsion.

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The shear-induced collective diffusivity down a concentration gradient in a viscous emulsion is computed using direct numerical simulation. A layer of randomly packed drops subjected to a shear flow, shows the layer width to increase with the $1/3$ power of time, consistent with a semi-dilute theory that assumes a diffusivity linear with concentration. This characteristic scaling and the underlying theory are used to compute the collective diffusivity coefficient. This is the first ever computation of this quantity for a system of deformable particles using fully resolved numerical simulation. The results match very well with previous experimental observations. The coefficient of collective diffusivity varies non-monotonically with the capillary number, due to the competing effects of increasing deformation and drop orientation. A phenomenological correlation for the collective diffusivity coefficient as a function of capillary number is presented. We also apply an alternative approach to compute collective diffusivity, developed originally for a statistically homogeneous rigid sphere suspension – computing the dynamic structure factor from the simulated droplet positions and examining its time variation at small wavenumber. We show that the results from this alternative approach qualitatively agree with our computation of collective diffusivity including the prediction of the non-monotonic variation of diffusivity with the capillary number.