Simulation & Analysis

Test, optimize, and validate your designs with precision before they hit production.

At Mech Flow Designs, our Simulation & Analysis services empower engineers to make data-driven decisions. We provide Computational Fluid Dynamics (CFD), Finite Element Analysis (FEA), and thermal simulations to evaluate real-world performance, identify potential design flaws, and optimize products for safety, efficiency, and reliability. By simulating scenarios before manufacturing, we reduce risks, save costs, and ensure that your designs perform as intended under real operating conditions.

  • Computational Fluid Dynamics (CFD) Analyze fluid flow, pressure, and thermal behavior to optimize aerodynamics, cooling, and performance of your designs.
  • Finite Element Analysis (FEA) Assess structural integrity and mechanical performance under loads, stress, and vibrations to ensure safety and durability.
  • Thermal & Multiphysics Simulation Predict heat transfer, thermal stresses, and interactions between multiple physical phenomena to guide critical engineering decisions.

Our Work in Action

Computational Fluid Dynamics

CFD Analysis For a Solar Panel

A solar panel water heating system was analyzed in ANSYS Fluent using a transient model to simulate water flow and heat absorption. Solar radiation, conduction, and convection effects were included for accuracy. The study revealed heat flux patterns, temperature rise, and outlet temperature variation over time, enabling efficiency prediction, design optimization, and validation for sustainable water heating applications.

Battery Cell Mass Transfer Simulation

A battery cell was analyzed in ANSYS Fluent (transient model) to study species diffusion and ion transport in the electrolyte. The simulation captured mass transfer, concentration gradients, and flow coupling for realistic predictions. Results showed diffusion patterns, electrolyte concentration variation, and mass flux distribution, supporting efficiency improvement, performance optimization, and validation for advanced energy storage applications.

CFD For Forced Convection For Fins

A finned surface was analyzed in ANSYS Fluent (transient model) to study airflow and heat transfer behavior. The model included convection, conduction, and thermal gradients for accurate results. Results showed temperature variation, velocity contours, and heat flux distribution over time, enabling better fin design, improved cooling efficiency, and validation for electronics and power system applications.

CFD Flow Analysis in a Turbocharged Pipe

A CFD study was performed in ANSYS Fluent to evaluate compressible airflow through a turbocharger pipe. The model accounted for turbulence, pressure gradients, and velocity profiles to ensure accuracy. Results showed pressure drop, velocity contours, and flow separation regions, enabling improved pipe design, reduced energy losses, and validation for enhanced turbocharging efficiency and engine performance.

 

CFD Flow Analysis of Multiple Refrigerants in an Expansion Valve

A CFD study was conducted in ANSYS Fluent to analyze multiple refrigerants in an expansion valve. The model captured compressible flow, turbulence, and phase-change effects for realistic predictions. Results highlighted pressure and velocity distribution, cavitation tendencies, and refrigerant mass flow rates. This analysis supports optimized valve design, efficient refrigerant selection, and performance validation for HVAC and refrigeration systems.

 

Finite Element Method

FEM For Stent Design

A finite element model of a stent was analyzed to assess structural stability under blood pressure. The simulation included radial expansion, contact interactions, and material properties of biocompatible alloys. Results highlighted stress distribution, deformation, and safety factors, ensuring improved reliability, fatigue life, and validation for cardiovascular implant applications.

FEM of Composite Beam using Ansys Composite module(ACP)

A finite element model of a composite channel beam was developed in ANSYS Composite Module to study structural performance. Ply orientations, stacking sequence, and anisotropic material behavior were included for accuracy. Results showed stress contours, deflection patterns, and failure indices, supporting optimized design, higher load-bearing capacity, and validation for lightweight engineering applications.

FEM of Composite Pipe using Ansys Composite module(ACP)

A finite element model of a composite channel pipe was analyzed in ANSYS Composite Module to evaluate strength and deformation. Multiple ply angles, stacking sequences, and anisotropic material behavior were considered. Results showed stress contours, displacement fields, and the influence of ply orientation, enabling optimized ply selection, improved load capacity, and validated design for lightweight structural applications.

3-Point Bending Test

finite element model of a 3-point bending test was simulated in ANSYS Static Structural using fracture mechanics principles. The model included pre-cracked geometry under bending loads to study crack propagation. Results showed stress intensity factors, deformation patterns, and crack initiation zones, providing insights into fracture toughness, material selection, and validation for structural applications.

FEM For The DOG-BONE TEST

A finite element model of a dogbone specimen was analyzed in ANSYS Mechanical to study material performance. Remote displacement loading was applied to evaluate force response, stress, and strain. Both porous and non-porous models were simulated, showing deformation patterns, stress–strain curves, and failure tendencies. This analysis improves understanding of porosity effects, supports material selection, and validates experimental testing for structural applications.

Behind every line and model lies our passion to create, refine, and deliver excellence.

  • mechflowdesigns@gmail.com
  • +92 3135166673

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