Senior Mechanical Design Engineer
Royal El Minya Cement Co
Total years of experience :7 years, 7 Months
● Design and develop drawings and specifications for conveyors, hoppers, transfer chutes, and other equipment in the mining and metals sector
● Perform basic and detailed design of bulk material handling systems for the cement industry
● Prepare general arrangement drawings and hopper calculations as per standards
● Provide guidance for technological structure drawings
● Conduct procurement activities such as preparation of specifications, offer review, bid evaluation, vendor assessment, and technical recommendation
● Review vendor drawings and calculations and approve them for fabrication
● Perform mechanical design calculations, static design calculations of hoppers, and FEA analysis as required
● Coordinate with inter-disciplines and clients for the overall completion of the project
● Provide erection and commissioning assistance by liaising with relevant departments
o Design and fabrication of different machine tools from A to Z, from basic rough sketches to final machine designs with professional 2D drawings sent to suppliers.
o Lead and mentor a team of mechanical engineers for the design of custom machinery.
o Creating macros to facilitate the design for colleagues.
o Work with cross-functional teams to achieve product performance, schedule, cost, reliability, and quality targets.
o Prototype fabrication/management, assembly, test and validation, optimization, and refining
o Continuous product and process improvement
o Drafting/ Design Checker
o GeoTol/ANSI Standards
o Translation to manufacturing, tooling, and fixture design
o PDM Administrator
o Perform DFM/standard check doc process as required.
o Provide design support for custom and proprietary product development.
o Rendering the designs that I develop
o Working on the SEO and modifying the meta tags of the website, while writing some posts that are relevant to the company.
o Reviewing teammates' designs before production.
o Experience with G-Suite.
o Abilities to layout and format documents.
Projects Designed at Cerebrus Corp.:
1- Mail Tray Transfer Cell
2- Dock to Ledge Transfer Cell
3- Electric Parallel 3-Axis Gripper
4- Miniature Lathe
o Inspection of Hitachi Turbine Vanes: Inspected turbine blades and other components using
visual examination and fluorescent magnetic particle examination, focusing on detecting cracks
and severe pitting corrosion to reduce the cost of replacements and enhance the performance of
the turbine.
o Flawed Specimen Manufacturing
o Execution of Inspection processes
o Fabrication of calibration blocks.
o Fabrication of welded flawed specimen in time.
o Marketing of training courses inside the head office.
o Resolving 3D printers’ stability issues by lowering their weight, increasing the toughness, lowering the vibration, and improving the feed drive systems.
o Provide design for additive manufacturing (DFAM) feedback of different parts to internal and external customers.
o Develop accurate cost models for AM processes to ensure component pricing is profitable and competitive in the marketplace.
o Operate required CAD modeling & AM software packages to generate and optimize 3D printer programs.
o Conduct quality inspection and evaluation of parts.
o Monitor and analyze ongoing AM builds to optimize processes, reduce build & delivery times, and further improve part quality.
o Had a hands-on experience on a CNC unit, where real life experience was covered, including
safety measures and unexpected situations and unique requests. I drew the demanded complex
plastic parts as requested using Solidworks taking mold flow into consideration. Excellent
success was achieved during the work period with customer appreciation.
o Gathering information about all the frame designs used suspension systems in other teams’ cars and analyzing their performance.
o Put the preliminary design constraints and boundaries.
o Designing the frame and seat for the vehicle on Solidworks.
o Material selection for the different components per specifications
o Perform an FEA using ANSYS on all designed parts to ensure its validity.
o Manufacture all designed parts, and test all the manufactured parts to ensure their validity.
Simulation Requirements (using Ansys mainly):
1- Torsional and static stiffness.
2- Increasing strength to weight ratio of the chassis
3- Modifying chassis members' thicknesses according to their stresses
4- Impact analysis
5- Validation of the model
Graduation Project: Modeling and Simulation of Linear Feed Drive Systems using Matlab
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