Mustafa Ezzuldeen Email & Phone Number

Alexandria, Eg

Alexandria, Eg

Alexandria, Egypt

• Developed an integrating solver used to calculate shearing forces, considering MVF, 2D Thermal Distribution across profile, and Knives' rake angle.• Successfully predicted the cutting force of steel products across 8 different steel grades, 4 different QTB configurations, and 2 different rolling speeds.• Modeled cutting energy storage of 3 different types of shears for rebars and slabs, including flywheel and reducer calculations.• Designed and evaluated token-level experiments for validation. The complete shearing model aided in securing a $30 million USD contract for Defence-grade steel sheets.• Created a CFD QTB model of 5-7-12 cooler configurations for operational optimization of water flow rate for MVF of steel. The model was multiphase, incorporating the effect of the vapor layer and steel ribs.• Used ICEM-CFD to create structured mesh and optimize mesh for acceptable y+ values.• Experimented with turbulence models and validated them using previous research papers, and completed model validation using Laboratory MVF.• The model saved the plant an estimated 70 hours of trials and 2100 tons of products.

Alexandria, Egypt

• Led a team of engineers to develop a spray-cooled roof for EAF capable of withstanding 350 kW/m2 heat flux for 65 minutes.• Conducted numerical analysis to optimize refractory arrangements for minimum weight and required roof protection.• Performed FEA/non-linear analysis to design roof lifting lugs capable of withstanding different scenarios of loading and dynamics.• Led failure analysis/investigation of recurring defects in TSC submerged nozzles using FSI analysis, FEA analysis, and X-ray inspection.• The study included fume flow modeling, combustion of carbon particles, CO post-combustion modeling, built DPM model of spray nozzles, DPM-VOF for modeling the cooling film, and monitoring for Leidenfrost temperature convergence problems.• Led failure analysis/investigation of recurring defects in TSC submerged nozzles (SEN) using FSI and testing prospective SEN designs for flux powder ingestion with Weber number at meniscus level as an indicator, checking also for mold level stability.

• Redesigned two coil and billet shuttle cars with a 120-ton capacity to mitigate power train failures using ANSYS RBD and Mechanical. The redesign mainly focused on suspensions and GD&T.• Designed a crane-hung C-hook for transporting multiple coils, ensuring balance in all loading scenarios and proving to be less susceptible to cracks than the OEM design.• Successfully completed failure analysis and reinforcement of ladle and billet cranes using crack propagation techniques, fatigue analysis, and multiple scenario analysis, considering corner tolerance values.• Used 3D printing (Dimension 1200 ES ) with breakable support to efficiently print more that 97 parts in 5 complex assemblies.

Suez Governorate, Egypt

• Designed a bubbling station-powered cover to withstand a given heat load, including the structural design of the frame to endure both heat and dynamic loads, and the selection of powering actuators.• Conducted a comprehensive analysis for the design of a manual rebar bending machine tailored for rebars of grade B500DWR, ranging in size from 6 to 12 mm. This analysis involved a nonlinear model of steel plastic deformation, potentially saving hours of trial and error and enabling the product rollout within one week.• Authored 5 operational FEA standards to be included in the design files, covering transient extreme loading and unloading scenarios, as well as design considerations for post-plastic hardening strength. This initiative led to saving more than 30% of BOMs in some designs and earned 2 distinguished performance awards.• Built a VOF model to optimize desulfurization and mixing efficiency in the bubbling process, minimizing heat loss. This model was validated through token experimentation of a water model and extensively utilized adaptive mesh to increase resolution.• Utilized ANSYS Fluent and Chemkin to model a non-premixed methane flame in the MIDREX Direct Reduction Plant Bustle gas duct, ensuring flame stability at various operation parameters and guarding against flame blowouts for safety concerns.

• Utilized ANSYS Fluent/CFX with DPM particle tracking and thermal convection to analyze various arrangements of torch cutting fume extraction hoods.• Conducted full CFD analysis on two steel meltshops FTP, emphasizing thermal distribution across the network to optimize performance and media life, validated by thermocouple readings.• Employed VOF-DPM using ANSYS Fluent modeling to design dust suppression using misting devices, covering 40 meters of flammable dust-emitting areas.

Alexandria, Egypt

• Created layouts of plant equipment modifications using AutoCAD to effectively communicate plans across all concerned parties.• Utilized Siemens NX and Autodesk Inventor for 3D CAD modeling of 25 designs developed by senior engineers.• Conducted simple mechanical hand calculations to support conceptual proposals, including shear and moment diagrams, shaft slope calculations, bearing selection, and ensuring standards compliance.• Developed an MS Access program to automate daily reporting tasks.• Documented the final outputs of design projects for record-keeping and reference purposes.

Alexandria, Egypt

• Conducted extensive research in mechanical ventilators, encompassing physics, previous art, and patents. This included studying 25 patents, detailed designs from Siemens Maquet, and theories of breathing.• Built a mathematical model of customizable human lungs and a mechanical ventilator using MATLAB, Simscape, and Stateflow.• Aided in designing the process flow of the EzVent prototype and contributed to valve selection.• Provided support for the systems control team, which utilized Python and C++ for automation programming.

Egypt Air Bases

• AK47 Sharp Shooters Award• Role model Airman Award (for following orders and discipline) • Participated in 2011 Revolution fast deployments• Armed security for voting ballets• Member of air force fast response offense group

Master Of Science - Ms, Mechanical Engineering Related Technologies/Technicians

Masters in Computational fluid flow Engineering Thesis : Exploring different approaches to model Experimental centrifugal pump.

Bachelor'S Degree, Mechanical Engineering

Activities and Societies: UN volunteers as a part of a team of more than 100 members,ANSYS CFX course instructor at Alexandria University.

High School Diploma, Igcse