Stainless steel water flow meter engineered using CFD-optimized internal geometry and FEA-verified construction for accurate, low-loss flow measurement in industrial water treatment systems.

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Project Description

KS Projects engineered a stainless steel water flow meter for industrial water treatment applications where measurement accuracy, low pressure loss, and structural reliability are critical.

A parametric 3D CAD model was developed to allow multiple internal flow geometries to be evaluated efficiently.

Computational Fluid Dynamics (CFD) simulations were used to analyze velocity distribution, turbulence, pressure behavior, and internal flow disturbances.

The internal Venturi geometry was progressively optimized to create a stable velocity profile through the measurement region while minimizing unnecessary pressure loss.

Structural Finite Element Analysis (FEA) was then performed to verify the housing under normal operating and peak pressure conditions.

Corrosion-resistant stainless steel was selected to provide long-term durability in water-based industrial environments, while the external geometry and manufacturing strategy were optimized to simplify CNC machining and reduce production costs.

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Engineering Capabilities

• Parametric 3D CAD Modeling – Internal and external meter geometry

• CFD Analysis – Velocity, turbulence, pressure loss, and flow-profile optimization

• FEA Structural Analysis – Normal and peak-pressure loading

• Fluid Dynamics Engineering – Venturi and measurement-zone optimization

• Material Selection – Corrosion-resistant stainless steel

• Design for Manufacturing – Simplified machining and production

• Technical Documentation – Assembly, calibration, and maintenance documentation

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Project Results

✅ Target measurement accuracy of approximately ±1%

✅ Reduced flow disturbances and unnecessary pressure loss

✅ Housing structurally verified for loads exceeding 4× normal working pressure

✅ Improved reliability and corrosion resistance

✅ Reduced manufacturing complexity through optimized geometry

✅ Delivered a production-ready flow meter design for industrial water treatment applications

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Technologies & Expertise

Water Flow Meter Design | CFD | FEA | Fluid Dynamics | Water Treatment Engineering | Flow Analysis | Pressure Analysis | Stainless Steel | CAD | Mechanical Engineering