FORM 2
THE PATENTS ACT, 1970
(39 of 1970)
As amended by the Patents (Amendment) Act, 2005
AND
The Patents Rules, 2003
As amended by the Patents (Amendment) Rules, 2005
COMPLETE SPECIFICATION
(See section 10 and rule 13)
TITLE OF THE INVENTION
A designing system and method for casting / moulding processes in relation to predicted shrinkage and calculated thickness for a component
APPLICANTS
Crompton Greaves Limited, CG House, Dr Annie Besant Road, Worli, Mumbai 400 030, Maharashtra, India, an Indian Company
INVENTOR
Sathe Mahesh of Crompton Greaves Ltd, Industrial Design Centre, Global R&D, Crompton Greaves, Kanjurmarg (East), Mumbai- 400042 Maharashtra, India and Keshawatkar Baburao of Crompton Greaves Ltd, Conition Monitoring & Diagnostic Centre, Global R&D Centre, Kanjur (E), Mumbai 400042, Maharashtra, India; both Indian Nationals
PREAMBLE TO THE DESCRIPTION :
The following specification particularly describes the nature of this invention and the manner in which it is to be performed:

Field of the Invention
This invention relates to the field of designing systems.
Particularly, this invention relates to the system of designing systems for casting / moulding processes for a component.
Still particularly, this invention relates to a designing system and method for casting / moulding processes in relation to predicted shrinkage and calculated thickness for a component.
Background of the Invention:
Casting process includes a step of designing a component to be cast, based on shape and features of the component. Further, it should incorporate the material used for casting. The steps of designing, typically, include predicted shrinkage aspect, in relation to shape of the component, and also stresses and forces incumbent in the component during the curing process. Based on trial and error, known mechanical engineering formulae, conforming shapes are designed.
However, it has been observed that these during the actual casting process, factors due to shrinkage and / or solidification of material allow cracks to develop in the finished product. In spite of trial and error changes, a perfect design or a perfect design methodology was never sought.

In an exemplary cylindrical design with protruding laterally located boxes, it was also observed that, cracks occurred on the longitudinal edges of the boxes protruding out of the lateral surface of the cylinder.
There is a need for a system and method which allows predicting and formulating a crack free design.
Objects of the Invention:
An object of the invention is to predict thickness of a designed shape for the purposes of casting.
Another object of the invention is to prevent cracking of cast components, due to shrinkage / solidification.
Yet another object of the invention is to achieve an optimum design in relation to crack-free casting.
Summary of the Invention:
For the purposes of this specification, a 'component' or a 'casting component' is a fairly tubular or cylindrical shaped casting component.
According to this invention, there is provided a designing system for casting / moulding processes in relation to predicted shrinkage and calculated thickness for a component, said system comprises:
a. first volume computation means adapted to compute a volume of a newly (theoretically) designed casting component;

b. first surface area computation means adapted to compute a surface
area, of a newly (theoretically) designed casting component;
c. designing means adapted to design a perfect tubular or cylindrical
casting component which roughly maps on to said newly
(theoretically) designed casting component;
d. second volume computation means adapted to compute a volume of a
said perfect tubular or cylindrical casting component;
e. second surface area computation means adapted to compute a surface
area, of a newly (theoretically) designed of said perfect tubular or
cylindrical casting component;
f. outer diameter measurement means adapted to measure outer diameter
of said designed perfect tubular or cylindrical casting component;
g. inner diameter measurement means adapted to measure inner diameter
of said newly (theoretically) designed casting component;
h. height measurement means adapted to measure height of said newly (theoretically) designed casting component;
i. re-designing means adapted to re-design said newly (theoretically) designed casting component using said measured outer diameter, said measured inner diameter, said measured height, such that the volume of said newly (theoretically) designed casting component is equivalent to volume of said designed perfect tubular or cylindrical casting component;
j. stress computation means adapted to compute a plurality of stress values in accordance with pre-defined equations and predicted shrinkage values in order to compute stress values for said re-designed casting component;

k. comparator means adapted to compare said computed stress with pre-defined parameters to check if re-designed casting component is a crack-free designed casting component; and
1. iteration means adapted to iterate a new design by repetitively engaging said first volume computation means first surface area computation means, designing means, second volume computation means, second surface area computation means, outer diameter measurement means, inner diameter measurement means, height measurement means, re-designing means, stress computation means, comparator means such that a crack-free design of a casting component is achieved.
According to this invention, there is provided a designing method for casting / moulding processes in relation to predicted shrinkage and calculated thickness for a component, said method comprises the steps of:
a. computing a volume of a newly (theoretically) designed casting
component;
b. computing a surface area, of a newly (theoretically) designed casting
component;
c. designing a perfect tubular or cylindrical casting component which
roughly maps on to said newly (theoretically) designed casting
component;
d. computing a volume of a said perfect tubular or cylindrical casting
component;

e. computing a surface area, of a newly (theoretically) designed of said
perfect tubular or cylindrical casting component;
f. measuring outer diameter of said designed perfect tubular or
cylindrical casting component;
g. measuring inner diameter of said newly (theoretically) designed
casting component;
h. measuring height of said newly (theoretically) designed casting component;
1. re-designing said newly (theoretically) designed casting component using said measured outer diameter, said measured inner diameter, said measured height, such that the volume of said newly (theoretically) designed casting component is equivalent to volume of said designed perfect tubular or cylindrical casting component;
j. computing a plurality of stress values in accordance with pre-defined equations and predicted shrinkage values in order to compute stress values for said re-designed casting component;
k. comparing said computed stress with pre-defined parameters to check if re-designed casting component is a crack-free designed casting component; and
1. iterating a new design by repetitively engaging said first volume computation means first surface area computation means, designing means, second volume computation means, second surface area computation means, outer diameter measurement means, inner diameter measurement means, height measurement means, re-designing means, stress computation means, comparator means such that a crack-free design of a casting component is achieved.

Brief Description of the Accompanying Drawings:
The invention will now be described in relation to the accompanying drawings, in which:
Figure 1 illustrates a schematic of the designing system and method for casting / moulding processes in relation to predicted shrinkage and calculated thickness for a component;
Figure 2 illustrates an exemplary original design of an component to be cast;
Figure 3 illustrates an exemplary first iteration of the design of the component to be cast, in accordance with the designing system and method of this invention;
Figure 4 illustrates an exemplary second iteration of the design of the component to be cast, in accordance with the designing system and method of this invention;
Figure 5 illustrates an exemplary third iteration of the design of the component to be cast, in accordance with the designing system and method of this invention;

Figure 6 illustrates an exemplary fourth iteration of the design of the component to be cast, in accordance with the designing system and method of this invention;
Figure 7 illustrates an exemplary fifth iteration of the design of the component to be cast, in accordance with the designing system and method of this invention;
Figure 8 illustrates an exemplary sixth iteration of the design of the component to be cast, in accordance with the designing system and method of this invention; and
Figure 9 illustrates an exemplary seventh iteration of the design of the component to be cast, in accordance with the designing system and method of this invention.
Detailed Description of the Accompanying Drawings:
According to this invention, there is provided a designing system and method for casting / moulding processes in relation to predicted shrinkage and calculated thickness for a component. Particularly, this designing system and method is adapted to cater to designing components with a fairly tubular or cylindrical shape. For the purposes of this specification, a 'component' or a 'casting component' is a fairly tubular or cylindrical shaped casting component.

Figure 1 illustrates a schematic of the designing system (100) and method for casting / moulding processes in relation to predicted shrinkage and calculated thickness for a component;
The designing system and method is adapted to predict whether cracking due to shrinkage of material or due to solidification of material shall take place. The system of this invention aims to provide a crack-free design of said component. As each polycrete design that was worked out had produced a crack during a first sample lot production, which demanded theoretical check during design to avoid cracking based wastages and rework, the system and method of this invention aimed to obviate such limitations.
In accordance with an embodiment of this invention, there is provided a first volume computation means (VDC) adapted to compute a volume of a newly (theoretically) designed casting component (CC).
In accordance with another embodiment of this invention, there is provided a first surface area computation means (SADC) adapted to compute a surface area, of a newly (theoretically) designed casting component.
In accordance with yet another embodiment of this invention, there is provided a designing means (DM) adapted to design a perfect tubular or cylindrical casting component which roughly maps on to said newly (theoretically) designed casting component.

In accordance with still another embodiment of this invention, there is provided a second volume computation means (VPC) adapted to compute a volume of a said perfect tubular or cylindrical casting component.
In accordance with an additional embodiment of this invention, there is provided a second surface area computation means (SAPC) adapted to compute a surface area, of a newly (theoretically) designed of said perfect tubular or cylindrical casting component.
In accordance with yet an additional embodiment of this invention, there is provided an outer diameter measurement means (ODMM) adapted to measure outer diameter of said designed perfect tubular or cylindrical casting component.
In accordance with still an additional embodiment of this invention, there is provided an inner diameter measurement means (IDMM) adapted to measure inner diameter of said newly (theoretically) designed casting component.
In accordance with still an additional embodiment of this invention, there is provided a height measurement means (HMM) adapted to measure height of said newly (theoretically) designed casting component.
In accordance with another additional embodiment of this invention, there is provided a re-designing means (RDM) adapted to re-design said newly (theoretically) designed casting component using said measured outer

diameter, said measured inner diameter, said measured height, such that the volume of said newly (theoretically) designed casting component is equivalent to volume of said designed perfect tubular or cylindrical casting component.
In accordance with yet another additional embodiment of this invention, stress computation means (SCM) adapted to compute a plurality of stress values in accordance with pre-defined equations and predicted shrinkage values in order to compute stress values for said re-designed casting component.
In accordance with still another additional embodiment of this invention, there is provided a comparator means (CM) adapted to compare said computed stress with pre-defined parameters to check if re-designed casting component is a crack-free designed casting component.
In accordance with another additional embodiment of this invention, there is provided an iteration means (IM) adapted to iterate a new design by repetitively engaging said first volume computation means (VDC), first surface area computation means (SADC), designing means (DM), second volume computation means (VPC), second surface area computation means (SAPC), outer diameter measurement means (ODMM), inner diameter measurement means (IDMM), height measurement means (HMM), redesigning means (RDM), stress computation means (SCM), comparator means (CM) such that a crack-free design of a casting component is achieved.

According to the system and method of this invention, it was observed that the correct application of Hoop stress, radial stress, longitudinal stress' calculation, and the like stress calculation formulae present to (polycrete) casting design was explored by experimentation and following was found out:
a. A newly designed casting (fairly tubular or cylindrical) is considered.
Its volume is to be found out along with surface area, excluding top and
bottom surfaces, with respect to orientation of casting during pouring.
b. A volume and fairly surface equivalent perfect tubular or cylinder
casting is considered. Its outer diameter is to be found out keeping the
internal diameter and height same as that of original designed component
which is fairly tubular or cylindrical.
c. With this outer diameter and newly designed casting internal diameter
and height, the aforesaid stress values are found out which gives fairly
accurate prediction of cracking and also gives optimum (pre-calculated)
thickness that may be needed throughout the periphery and length of casting.
Respecting very small value of casting material bonding strength, internal surface shrinkages in case of tubular deigns, are to be eliminated to avoid cracking, with perfect thermal insulating material plugged into hollow portion of tubular casting and then with only outer surface lateral or radial shrinkage/displacement value the external pressure due to shrinkage value to be found out for aforesaid stress calculations.

Figure 2 illustrates-an exemplary original design of a component to be cast. An exemplary casting component (20) for a transformer coil is seen. This figure shows the original (newly theoretically) designed shape. There are provided two end discs (12, 14) with hollow in between.
Figure 3 illustrates an exemplary first iteration of the design of the component to be cast, in accordance with the designing system and method of this invention. The design of Figure 2 went through the iteration procedure of the designing system to provide an improved re-designed casting component (30). Here, hollow ducting (32) was provided to have optimum (pre-calculated) thickness through the casting component volume.
Figure 4 illustrates an exemplary second iteration of the design of the component to be cast, in accordance with the designing system and method of this invention. The design of Figure 3 went through the iteration procedure of the designing system to provide an improved re-designed casting component (40). Here, larger fillets (42) were introduced.
Figure 5 illustrates an exemplary third iteration of the design of the component to be cast, in accordance with the designing system and method of this invention. The design of Figure 4 went through the iteration procedure of the designing system to provide an improved re-designed casting component (50). Here, top end plate and bottom end plate was removed. And the side plates had a 'C cut-out (52) for providing optimum (pre-calculated) thickness throughout volume.

Figure 6 illustrates an exemplary fourth iteration of the design of the component to be cast, in accordance with the designing system and method of this invention. The design of Figure 5 went through the iteration procedure of the designing system to provide an improved re-designed casting component (60). Here, top and bottom end was merged (62) with intermediate section with hollow in centre.
Figure 7 illustrates an exemplary fifth iteration of the design of the component to be cast, in accordance with the designing system and method of this invention. The design of Figure 6 went through the iteration procedure of the designing system to provide an improved re-designed casting component (70). Here, 'H'-shape is partial in relation to the H-shape of Figure 6.
Figure 8 illustrates an exemplary sixth iteration of the design of the component to be cast, in accordance with the designing system and method of this invention. The design of Figure 7 went through the iteration procedure of the designing system to provide an improved re-designed casting component (80). Here, top and bottom end (82) was merged with intermediate middle section in a manner so as to have smooth merger with intermediate section.
Figure 9 illustrates an exemplary seventh iteration of the design of the component to be cast, in accordance with the designing system and method of this invention. The design of Figure 8 went through the iteration procedure of the designing system to provide an improved re-designed

casting component (90). Here, it completely eliminates 'C cut out. Further, top and bottom end (92) was merged with intermediate middle section with simplified cross section and also made hollow in centre.
The same system and methodology can be adopted for metal castings also.

We claim,
1. A designing system for casting / moulding processes in relation to predicted shrinkage and calculated thickness for a component, said system comprising:
a. first volume computation means adapted to compute a volume of a
newly (theoretically) designed casting component;
b. first surface area computation means adapted to compute a surface
area, of a newly (theoretically) designed casting component;
c. designing means adapted to design a perfect tubular or cylindrical
casting component which roughly maps on to said newly
(theoretically) designed casting component;
d. second volume computation means adapted to compute a volume of a
said perfect tubular or cylindrical casting component;
e. second surface area computation means adapted to compute a surface
area, of a newly (theoretically) designed of said perfect tubular or
cylindrical casting component;
f outer diameter measurement means adapted to measure outer diameter of said designed perfect tubular or cylindrical casting component;
g. inner diameter measurement means adapted to measure inner diameter of said newly (theoretically) designed casting component;
h. height measurement means adapted to measure height of said newly (theoretically) designed casting component;
i. re-designing means adapted to re-design said newly (theoretically) designed casting component using said measured outer diameter, said measured inner diameter, said measured height, such that the volume

of said newly (theoretically) designed casting component is equivalent to volume of said designed perfect tubular or cylindrical casting component;
j. stress computation means adapted to compute a plurality of stress values in accordance with pre-defined equations and predicted shrinkage values in order to compute stress values for said re-designed casting component;
k. comparator means adapted to compare said computed stress with pre-defined parameters to check if re-designed casting component is a crack-free designed casting component; and
1. iteration means adapted to iterate a new design by repetitively engaging said first volume computation means first surface area computation means, designing means, second volume computation means, second surface area computation means, outer diameter measurement means, inner diameter measurement means, height measurement means, re-designing means, stress computation means, comparator means such that a crack-free design of a casting component is achieved.
2. A designing method for casting / moulding processes in relation to predicted shrinkage and calculated thickness for a component, said method comprising the steps of:
a. computing a volume of a newly (theoretically) designed casting
component;
b. computing a surface area, of a newly (theoretically) designed casting
component;

c. designing a perfect tubular or cylindrical casting component which
roughly maps on to said newly (theoretically) designed casting
component;
d. computing a volume of a said perfect tubular or cylindrical casting
component;
e. computing a surface area, of a newly (theoretically) designed of said
perfect tubular or cylindrical casting component;
f measuring outer diameter of said designed perfect tubular or
cylindrical casting component; g. measuring inner diameter of said newly (theoretically) designed
casting component; h. measuring height of said newly (theoretically) designed casting
component; i. re-designing said newly (theoretically) designed casting component
using said measured outer diameter, said measured inner diameter,
said measured height, such that the volume of said newly
(theoretically) designed casting component is equivalent to volume of
said designed perfect tubular or cylindrical casting component; j. computing a plurality of stress values in accordance with pre-defined
equations and predicted shrinkage values in order to compute stress
values for said re-designed casting component; k. comparing said computed stress with pre-defined parameters to check
if re-designed casting component is a crack-free designed casting
component; and 1. iterating a new design by repetitively engaging said first volume
computation means first surface area computation means, designing

means, second volume computation means, second surface area computation means, outer diameter measurement means, inner diameter measurement means, height measurement means, re-designing means, stress computation means, comparator means such that a crack-free design of a casting component is achieved.