Mohamed Elrefaie

Building foundation physics models

Projects


Data Science Research Intern, Voith Hydro – Heidenheim, Germany
As a full-time research intern over three months, conducted time-series analysis of millions of data points from pressure and vibration sensors at the EU’s largest variable-speed pumped storage power plant, Frades II, using MATLAB and machine learning techniques. Analyzed measurement data to gain predictive maintenance insights, enabling early anomaly detection and optimized plant operation.
Student Research Assistant, Toyota Motorsport – Munich, Germany
For my bachelor’s thesis, conducted machine learning and data analysis on large CFD simulations of race cars to optimize aerodynamic analysis and design. This included training models to process thousands of simulations across various designs, using supervised and unsupervised techniques to interpret extensive CFD datasets.
Hands-on Deep Learning Lab Course
Trained Conditional Deep Convolutional Generative Adversarial Networks (cDCGAN) for data generation as part of the Hands-on Deep Learning course in the Multiscale Modeling of Fluid Materials Lab (Prof. Zavadlav).
Simulation of Thermo-Fluids with Open Source Tools Lab Course
Performed CFD simulation of external aerodynamics for the DrivAer model using C++ and OpenFOAM as part of the Simulation of Thermo-Fluids with Open Source Tools course in the Thermo-Fluid Dynamics Lab (Prof. Polifke).
Pallet Jack Design Project
Completed a full CAD design and assembly of a pallet jack, focusing on manufacturability. This project included detailed component modeling, assembly, and technical drawings to optimize strength, functionality, and ease of manufacturing. The design incorporated ergonomic and durability considerations to meet industrial standards.
Gearbox Design Project
Designed a complete gearbox as part of a comprehensive, one-year Machine Elements course. The project involved full calculations for gear ratios, load distribution, and stress analysis to optimize performance. A detailed CAD model and technical drawings were created, along with manufacturing plans and specifications. 
Student Research Assistant, Institute of Machine Elements, Gear Research Center, TUM
Performed data analysis of residual stresses from both mechanical test measurements and finite element (FE) simulations, utilizing machine learning algorithms to interpret and predict stress patterns for enhanced material performance insights.
Aerodynamics of Aircraft Lab Course
Conducted wind tunnel testing on a scaled delta wing model at the Aerodynamics Chair at TUM. This involved measuring pressure and velocity distributions across the wing surface to analyze aerodynamic performance and flow characteristics, providing insights into vortex formation and lift generation under controlled conditions.
Theo Jansen Walking Robot Design Project
Designed and built a Theo Jansen walking robot, including motor sizing, mechanism definition, and gear design. The project involved 3D printing custom gears, assembling all components, and preparing the robot for functional testing and production.
CFD Analysis of Laval (Convergent-Divergent) Nozzle 
Conducted CFD simulations on a Laval nozzle to compare the performance of different turbulence models, including k-omega, k-epsilon, and SST, across various mesh resolutions. The project aimed to assess the accuracy and stability of each model in predicting shock wave formation and flow characteristics within the nozzle.
Full Car Engine Overhaul Training
Learned to overhaul a full car engine in under 30 minutes, including complete disassembly, inspection, lubrication, and reassembly, ensuring all components function smoothly and efficiently.
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