El Refay for Engineering Services

We have grown over the past 4 years with our enthusiastic followers. Your comments and suggestions will take us to a new horizon. Thank you to the 2000 followers on our LinkedIn page, we made the following simulations using FLOW-3D HYDRO & CAST to celebrate that milestone 🎊🎉
#2000

Hello 🤗, Attention to Additive Manufacturing (AM) Experts
We would like to share with you our last simulation by FLOW-3D AM software (Direct Energy Deposition with Two Nozzles)

The following video shows the printing process of direct energy deposition (DED) with two sources of metal particles. Fe-316 stainless steel was selected in this example. Both the heat source and powder nozzles move along the y-direction at 3 mm/sec velocity. The laser power was set at 1000 W.
From what we see in this video, there are some particles that failed to melt. This can be attributed to either low power or high printing velocity.

What do you think that we could have done to improve the layer uniformity?
Share your thoughts with us in the comment section. 🤗

Hello 🤗, Attention to All Hydrodynamics & Water Experts
We would like to share with you our last parameterization simulation by CFD software FLOW-3D HYDRO & and automation software FLOW-3D (x) for water flow over the Broad Crested Weir.

We changed the inlet water flow elevation as a changeable parameter by three values: 1 m, 2 m, and 3 m, then we measured the effect on water volume flow rate (Q) above the weir and velocity magnitude (V) after the weir during 20 secs as a simulation time

For the first case, with 1 m inlet water elevation less than the weir height, the water couldn't go across the weir, so the Q = 0 m^3/s & V = 0 m/s. Q & V increases with the water elevation as shown in case #2 with elevation 2 m with Q = 2 m^3/s & V = 5 m/s and in case #3 with elevation 3 m with Q = 9 m^3/s & V = 6.5 m/s

Question: What is the difference between the broad-crested weir & sharp-crested weir?
Leave a comment with your answer 🤗

We wish you a New Year full of joy and peace 🤗
Note: this is a simulation by FLOW-3D HYDRO software of a floating object connected with mooring lines and the type of wave used is Stokes & Cnoidal With a wave height of 10 m and frequency of 0.125 1/s
#2024

We wish you a New year full of joy and peace!!
#2024

Hello 🤗, We would like to share with you a simulation of concrete 3D printing by FLOW-3D AM. A single layer is printed at a speed of 30 mm/sec. The concrete extrusion rate (out of the printing nozzle) is 33.6 mm/sec. A cross-sectional view is provided to visualize the layer width, which is approximately 56 mm.

Concrete Physical Properties: Density = 2100 kg/m^3 & Viscosity = 7.5 Pa.sec & Yield Strength = 630 Pa & Shear Modulus = 100 KPa
The data was extracted from the following publication:
DOI: https://doi.org/10.21809/rilemtechlett.2021.142

What would happen if the extrusion rate was lower than the printing velocity?
Share your thoughts with us in the comment section ☺.

Hello 🤗
This is our first optimization project using FLOW-3D(X) based on AI
The original cas is a case made by FLOW-3D team and it’s used as a template in FLOW-3D HYDRO .

The objective is to minimize the average velocity at the 3 probes .
the original case velocity was the same at the 3 props : 0.055 m/s
and the suction diameter for pumps was the same 0.71 m.

The optimal case velocity : 0.0423 m/s for pump 1 and 0.0436 m/s for pump 2 and 0.0435 m/s for pump 3
and the suction diameter for pumps : 1.2283 m for pump 1 and 1.3348 m for pump 2 and 1.3348 m for pump 3
Now based on your experience where we should apply minimizing the average velocity or maximizing the average velocity on your designs?
(x)

Hello 🤗
Attention to Automotive & Hydrodynamics Experts
We would like to share with you our last simulation model (Fuel Tank Filling Process) by FLOW-3D HYDRO CFD software

Back splash (Back flow) are challenge faced when designing filler pipes for fuel tanks which must take complex paths to fit the design of the automobile. FLOW-3D HYDRO can accurately simulate the trajectory of the fuel flow to test design variations to ensure proper fuel filling without any backflow to the feeding source.

In this model, we used Gasoline as a fluid with a complement feature in FLOW-3D that makes internal flow simulation very easy and fast
Backpressure backflow is the reversal of normal flow in the system which is due to an increase in the downstream pressure that becomes greater than that of the supply pressure. We used a FLOW-3D ready example and edited it to generate a backsplash flow

If you have seen or read before about this problem, may you share with us how to solve it?
The first correct answer would get a discount on our upcoming workshop

In this video, a simulation for Zigzag Pattern Material Extrusion , we see a thermoplastic material flowing out of a 1-mm diameter nozzle at a rate of 1.6 mm^3/sec. The nozzle follows a zigzag path, which was created by specifying the velocity profiles in both x- and y- directions. The velocity magnitude in each direction is 2 mm/sec. This model can be replicated to serve the following applications:
- Fused Deposition Modeling (FDM).
- Food 3D Printing
- 3D Concrete Printing
What other applications can we add to this list?
Share your thoughts with us in the comment section.

Attention to Hydrodynamics and water applications experts
Simulating an oil platform is a critical aspect of the offshore oil and gas industry, allowing engineers to model and analyze complex scenarios in a controlled virtual environment. Through advanced simulation tools like FLOW-3D, professionals can assess the structural integrity, hydrodynamics, and various operational conditions of an oil platform. These simulations help optimize design parameters, enhance safety protocols, and mitigate potential risks associated with harsh offshore environments. Additionally, computational fluid dynamics (CFD) simulations aid in understanding the impact of ocean currents, wave forces, and extreme weather conditions on the platform's performance. By employing simulation techniques, engineers can make informed decisions, improve the efficiency of oil platform designs, and contribute to the overall safety and sustainability of offshore drilling operations.

finally what's the major hazards in the oil platform operation?

Attention to Hydrodynamics and water applications experts
It's our last simulation CFD model by Flow-3D Hydro software
Effective showerhead designs should anticipate and tackle potential challenges that may arise during both the filling and shutoff phases of operation. During the filling stage, it is crucial to ensure uniform flow rates to all nozzles, eliminating any stationary or stuck bubbles that could obstruct the flow. When it comes to shutoff, it is valuable to predict the size and dimensions of residual droplets, as these can lead to lime formation and gradual degradation of system performance over time
the bubble formation and evolution through its unique adiabatic bubble model, while also capturing recirculation zones.

What do you suggest to eliminate any stationary or stuck bubbles through the nozzles?

Attention Additive Manufacturing applications professionals!

It's our pleasure to share with you the last simulation model by FLOW-3D AM software as "Direct Metal Deposition" DMD:

This video shows the process of DMD where metal particles are directed through a nozzle and melted by a laser beam as they intersect over the surface of a substrate. Both the laser beam and powder nozzle move almost at the same speed over a specified pattern until the part is complete.

In the current model, we chose SS 316 for its excellent properties. A laser of 3000 W power was moved at a speed equal to 0.0075 m/s. The particles source moved at the same velocity over the designated path. A total of 5 layers were printed over a solid steel substrate. Each layer was approximately 2-mm thick.

What could we have done to avoid the messy printing lines?
Share your answers below and be a part of FLOW-3D community. 😉

Attention applications professionals!
It's our pleasure to share with you the last simulation model by FLOW-3D CAST software as "Sand Casting of Steel Shredder Pin Cap":

The following video shows the filling and solidification of a pin cap, which is a part of any steel shredder assembly. The casting is made of ductile iron GJS 500. The pouring temperature is 1222 C and the volumetric flow rate is 6.6*10^-5 m^3/s.

In this simulation, we tracked the evolution of both graphite and carbides weight fractions. Also, the porosity distribution was visualized to judge the quality of the proposed gating and feeding systems.
What do you think we should do to eliminate the internal defects observed in the part?
Leave a comment with your answer below in the comment section.
The first correct answer would get a discount on our coming workshop 😎

Attention applications professionals!
It's our pleasure to share with you the last simulation model by FLOW-3D Weld software as "Laser Welding of AA6061 with Filler Wire":

In this video, we see two plates from AA6061 being butt-welded with a laser of 4000 W power. A 0.9-mm diameter filler wire is used to fill the gap between the plates. Both welding and filler feeding speeds are 1 cm/sec. A thermocouple is used to observe the temperature profile over time. The peak temperature at the sensor location is about 460 K (187 C).

What do you think would happen if the welding and filler feeding speeds were not matched?
Stay tuned for our next video of overlap welding. 😉

Leave a comment with your answer below in the comment section.
The first correct answer would get a discount on our coming workshop 😎

Attention applications professionals!
It's our pleasure to share with you the last simulation model by FLOW-3D Weld software as "Laser Butt Welding of Steel Plates":

The video shows the laser welding of two steel plates in a butt configuration. The welding parameters are as follows: Base Metal: 0.2% Carbon Steel (AISI 1026), Laser Power: 3300 Watts, Laser Movement: Wobbling, Welding Speed: 0.6 m/min, Shielding Gas Density: 1200 Kg/m^3, Shielding Gas Velocity: 5 m/sec, Gap width: 0.25 mm

What would happen if we decreased the welding speed for the same laser power?
Leave a comment with your answer below in the comment section.
The first correct answer would get a discount on our coming workshop 😎

Attention Additive Manufacturing applications professionals!

It's our pleasure to share with you the last simulation model by FLOW-3D AM software as "Particles Spreading Over The LPBF Machine Bed":

This is the second video in the LPBD series. Here, we see the blade spreading the particles over the machine's bed before laser activation. Stay tuned for part three of the series.

Attention applications professionals!
It's our pleasure to share with you the last simulation model by FLOW-3D CAST software as "Investment Casting":

The video shows the investment casting of a BCC lattice structure made from stainless steel 316. The pouring temperature is 1524 C and the inlet velocity is equal to 5 m/s.
Lattice structures are perfect for lightweight and energy-absorption applications. Also, they are suitable for heat exchange, vibrations, and acoustics applications. Their properties are directly affected by the lattice geometry. So, by manipulating their design, their performance can be enhanced to outstanding levels.

Please share your opinions and forward the video to your peers 😊

Happy 50th Anniversary of The October War Victory

This simulation was done by FLOW-3D CAST software by the following Process Parameters:
Casting Type: Lost Foam Casting
Foam: Polystyrene
Foam Density: 19.23 Kg/m^3
Metal: AA6061-T6
Pouring Temperature: 800 C
Inlet Pressure: 1.135E+5 Pa

Hello, All Water & Hydrodynamics Experts 🤗

To continue Tank Sloshing Phenomena and how we prevent it.
It's the final post on this topic with a CFD simulation model for a fuel tank with a compartmentalization method, which involves dividing the tank or container into smaller compartments to prevent the fuel tank sloshing

The CFD simulation model was done by FLOW-3D HYDRO software

We are open to discussing with you about the simulation model please leave a comment with your solution 🤗