Osama M.

Experience

• Senior Mechanical Design Engineer Royal El-Minya Cement Company · Full-time Dec 2022 – Present 3 yrs 6 mos Cairo, Cairo Governorate, Egypt • Pressurized Equipment Design: Designed a pressurized gravity dust collector with a flat roof according to ASME BPVC Sec. VIII Div.I using PV Elite. Performed comprehensive FEA analysis on all load cases (including thermal, pressure, and mechanical loads) with ANSYS Mechanical.
  • Rotating Equipment Sizing: Sized vacuum and pressure root pumps for pneumatic conveyor systems using hand calculations, and validated designs with PneuCalc software to ensure efficiency in operation.
  • Thermal Analysis: Conducted thermal hand calculations for the EAFD Waelz plant, verifying and refining results through detailed CFD analysis using ANSYS Fluent for multiple operational stages.
  • Steel Silos Design: Designed steel silos in compliance with EN 1991-4, calculating filling and discharge loads, followed by detailed FEA analysis with RFEM5 and ANSYS Mechanical to ensure structural integrity.
  • Stacks Design: Developed an Excel-based tool utilizing the Gaussian Dispersion Model and Available Draft approach to size process stacks. Designed stacks per ASME STS-1-2011, ASCE 7-10, and ASCE 7-16 standards, using MecaStack software for analysis.
  • Hoppers and Bins Design: Designed various hoppers and bins using SolidWorks, detailing structural elements with AutoCAD, ensuring material efficiency by selecting appropriate plate and section sizes.
  • Tank Design: Engineered process tanks that are compliant with API 650 using AMETank software. Performed FEA analysis with ANSYS Mechanical to assess roof, shell, and agitator loads under different operational scenarios.
• Mechanical Design Engineer Freelance · Freelance Aug 2018 – Present 7 yrs 10 mos Cairo, Cairo Governorate, Egypt • Contract-Based Mechanical Design: Delivered mechanical design and development services, earning consistent positive feedback for providing efficient and optimized CFD solutions across various industries.
  • Two-Way FSI Analysis for Flowmeter: Conducted a Two-Way Fluid-Structure Interaction (FSI) analysis using ANSYS Fluent and ANSYS Mechanical for a Coriolis flowmeter development project in collaboration with a Russian company, optimizing the flowmeter’s design for improved accuracy and performance.
  • HVAC CFD Analysis: Managed multiple small-scale projects, including CFD analysis for HVAC systems in apartments, applying the RANS K-omega model for airflow optimization, and utilizing the Boussinesq approximation for a natural flow analysis of chimneys.
  • Aerodynamic Performance Enhancement: Performed CFD analysis on race vehicle external flow, improving aerodynamic efficiency and reducing drag by optimizing the vehicle’s body design.
  • Electronics Cooling & ICE Combustion Analysis: Progressed to advanced projects, including electronics cooling using LES models and internal combustion engine (ICE) combustion simulations with the SAGA combustion model, delivering high-precision results.
• R&D Product Development Engineer Al Nasr Automotive Manufacturing Company · Full-time Jan 2022 – Dec 2022 11 mos Cairo, Cairo Governorate, Egypt • EV Homologation: Coordinated with EOS and FEV teams to prepare Egypt's first EV Homologation Plan, ensuring compliance with Euro NCAP and ISO regulations. Focused on safety and reliability testing protocols for electric vehicles.
  • E70 Dynamic Testing: Led dynamic testing for the E70 EV, analyzing vehicle responses to various conditions (speed, road surfaces, and weather). Collected and analyzed CANbus data using specialized logging and analysis tools for performance insights.
  • Battery Thermal-Runaway Analysis: Performed detailed CFD analysis using ANSYS Fluent to study the thermal runaway scenarios for high-voltage batteries, improving the BMS thermal management system for Egypt's working conditions.
  • Egypt EV Driving Cycle Development: Developed the first Egypt-specific EV driving cycle, tailoring test and analysis protocols to Egypt's unique driving conditions for more accurate powertrain assessments.
  • EV Range Extender Development: Led a project to develop a high-power density rotary internal combustion engine (ICE) powered by CNG as an EV range extender. Completed engine architecture, 1D modeling with GT-Power and AVL Cruise-M, cycle CFD simulations using ConvergeCFD, and began detailed modeling in Siemens NX.