FORM 2
THE PATENTS ACT 1970
[39 OF 1970]
&
The Patents Rules, 2003
COMPLETE SPECIFICATION
[See section 10 and rule 13]
TITLE: “A METHOD FOR DETERMINING A CORRELATION FACTOR FOR MECHANICAL PROPERTIES OF A COMPONENT”
Name and address of the Applicant:
TATA MOTORS PASSENGER VEHICLES LIMITED, an Indian company having its registered office at Floor 3, 4, Plot-18, Nanavati Mahalaya, Mudhana Shetty Marg, BSE, Fort, Mumbai, Mumbai City, Maharashtra, 400 001, INDIA.
Nationality: INDIAN

TECHNICAL FIELD
Present disclosure generally relates to determining mechanical properties of polymer components. Further, embodiments of the present disclosure describe a method for determining a correlation factor which to be applied to the mechanical property of the material for the component before performing computer aided analysis of the component.
BACKGROUND OF THE DISCLOSURE
Generally, systems employs multiple components for aesthetic and/or functional objectives. More particularly, systems such as but not limiting to vehicles include injection molded components such as bumpers, dashboards etc., that are made of plastic or other materials. These components are an integral part of a vehicle and are required to comply with pre-defined quality standards and regulatory requirements.
Further, components in particular vehicles, are required to comply with pre-defined safety standards or regulations which ensures the safety of commuters in the vehicle. It is therefore crucial for the components in the vehicle to meet the quality standard for compliance with the pre-defined safety standards or regulations. The components of the vehicle may be subjected to multiple computer aided analysis for ensuring that subject component meets requirement digitally and hence gives confidence for physical testing
Conventionally, the results of the component obtained from the computer aided analysis based on material characterization test results which are given as inputs. However, the same component when subjected to practical tests or physical tests, sometimes fails to meet the pre-defined safety requirements, which is undesired as it results in catastrophic failures. Therefore, conventional methods of computer aided analysis resulted in erroneous outcomes and resulted in premature failure of components in the vehicle. Digitally acceptable parts indicates a very poor correlation between physical and digital testing. This physical failure of parts calls for redesigning of the component which increases the development time and also development costs.
The present disclosure is directed to overcome one or more limitations stated above or any other limitations associated with the conventional methods of determining and analyzing the properties and quality of components in a vehicle.
SUMMARY OF THE DISCLOSURE

One or more shortcomings of the conventional system or method are overcome, and additional advantages are provided through the provision of the method as claimed in the present disclosure.
Additional features and advantages are realized through the techniques of the present disclosure. Other embodiments and aspects of the disclosure are described in detail and are considered a part of the claimed disclosure.
In a non-limiting embodiment of the disclosure, a method for determining a correlation factor for mechanical properties of a component is disclosed. The method includes aspects of performing a mold flow analysis of the component. Further, one or more samples are obtained from at least one location of the component based on the mold flow analysis. Further, the method includes determining at least one actual mechanical value of one or more samples. The determined actual mechanical value is then compared with a pre-determined optimum mechanical value. Furthermore, the method includes determining the correlation factor based on the comparison of the determined actual mechanical value with the optimum mechanical value. The obtained correlation factor from the method of the present disclosure may be applied to the optimum value such that, the obtained value which is a result of applying the correlation factor may be used to perform computer aided analysis to improve the accuracy of the results and to match with the results obtained by practical testing.
In an embodiment of the disclosure, the mold flow analysis of the component is performed to determine at least one of flow angles, weld lines, fiber orientations, hesitation and racetrack effect of the component.
In an embodiment of the disclosure, one or more samples are obtained from at least one location of the component where the flow angles in the component ranges between ± 0 to 90 degrees.
In a non-limiting embodiment of the disclosure, the one or more samples are obtained from at least one location of the component where the fiber orientation in the component is at least one of parallel orientation, perpendicular orientation, and random orientation.
In a non-limiting embodiment of the disclosure, one or more samples are obtained from at least one location of the component where the weld lines are defined in the component.

In a non-limiting embodiment of the disclosure, the one or more samples are obtained from the at least one location of the component where the hesitation is defined and the fibers are oriented next to each other.
In a non-limiting embodiment of the disclosure, the one or more samples are obtained from the at least one location of the component where the racetrack effect is defined, and the fibers are oriented farther away from each other in unbalanced flow paths.
In a non-limiting embodiment of the disclosure, the actual mechanical value is at least one of tensile strength and strain obtained by performing a tensile test on one or more samples.
In a non-limiting embodiment of the disclosure, determining includes obtaining a quotient of the determined actual mechanical value of the one or more samples and the optimum mechanical value.
In a non-limiting embodiment of the disclosure, the determined quotient is the correlation factor for the mechanical properties of the component.
The foregoing summary is illustrative only and is not intended to be in any way limiting. In addition to the illustrative aspects, embodiments, and features described above, further aspects, embodiments, and features will become apparent by reference to the drawings and the following detailed description.
BRIEF DESCRIPTION OF THE ACCOMPANYING FIGURES
The novel features and characteristics of the disclosure are set forth in the appended claims. The disclosure itself, however, as well as a preferred mode of use, further objectives, and advantages thereof, will best be understood by reference to the following detailed description of an illustrative embodiment when read in conjunction with the accompanying figures. One or more embodiments are now described, by way of example only, with reference to the accompanying figures wherein like reference numerals represent like elements and in which:
Figure 1 is a flowchart of a method for determining a correlation factor for mechanical properties of a component, in accordance with an embodiment of the present disclosure
Figures 2-5 illustrate a mold flow analysis of the component, in accordance with an embodiment of the present disclosure.

The figure depicts embodiments of the disclosure for purposes of illustration only. One skilled in the art will readily recognize from the following description that alternative embodiments of the method for pre-heating an exhaust gas after treatment unit without departing from the principles of the disclosure described.
DETAILED DESCRIPTION
The foregoing has broadly outlined the features and technical advantages of the present disclosure in order that the description of the disclosure that follows may be better understood. Additional features and advantages of the disclosure will be described after which form the subject of the disclosure. It should be appreciated by those skilled in the art that the conception and specific embodiments disclosed may be readily utilized as a basis for modifying or designing other systems for carrying out the same purposes of the present disclosure. It should also be realized by those skilled in the art that such equivalent constructions do not depart from the spirit and scope of the disclosure. The novel features which are believed to be characteristic of the disclosure, as to its organization, together with further objects and advantages will be better understood from the following description when considered in connection with the accompanying figures. It is to be expressly understood, however, that each of the figures is provided for the purpose of illustration and description only and is not intended as a definition of the limits of the present disclosure.
In the present document, the word “exemplary” is used to mean “serving as an example, instance, or illustration.” Any embodiment or implementation of the present subject matter described as “exemplary” is not necessarily to be construed as preferred or advantageous over other embodiments.
While the disclosure is susceptible to various modifications and alternative forms, specific embodiments thereof have been shown by way of example in the drawings and will be described below. It should be understood, however, that it is not intended to limit the disclosure to the particular forms disclosed, but on the contrary, the disclosure is to cover all modifications, equivalents, and alternative falling within the scope of the disclosure.
The terms “comprises”, “comprising”, or any other variations thereof, are intended to cover a non-exclusive inclusion, such that a system that comprises a list of components does not include only those components but may include other components not expressly listed or

inherent to such mechanism. In other words, one or more elements in the device or mechanism proceeded by “comprises… a” does not, without more constraints, preclude the existence of other elements or additional elements in the mechanism.
The following paragraphs describe the present disclosure with reference to Figures. 1-3. In the figures, the same element or elements which have the same functions are indicated by the same reference signs. One skilled in the art would appreciate the component disclosed in the claims may be any component which may be used in any given system but not limiting to vehicle, turbines, fans, manufacturing machines and the like.
The term mechanical value of the component may herein be considered as properties of the component that are indicative of the quality of the component (thus, material of the component). In an embodiment, the mechanical value of the material may be considered as values including but not limited to stiffness, toughness, strength, ductility, hardness, impact resistance, tensile strength, strain etc. Further, the term optimum mechanical value (MO) may herein be considered as properties of the component measured in ideal conditions. In an embodiment, the optimum mechanical value may be but not limiting to optimum tensile strength (TO) and the optimum strain (SO), which is determined by subjecting the component to tensile test. In this particular and non-limiting embodiment, the optimum mechanical value (MO) may be measured by initially procuring the required material and moulding/converting the procured material into dumbbell shaped samples under controlled conditions of temperature and pressure and as per the requirements of national or international test standards. These dumbbell shaped samples may further be subjected to tensile test analysis. The results of the tensile test may herein be considered or defined as the optimum mechanical value (MO).
Figure. 1 is a flow chart depicting a method for determining a correlation factor for mechanical properties of the component. The method includes first step 201 of performing a mold flow analysis of a component. As an example, the component may be but not limiting to a bumper of a vehicle. The same cannot be construed as limitation since the component may be any structure of any component. Reference is now made to Figures 2 and 3 which illustrates the mold flow simulation of the component. In an exemplary embodiment, Mold flow simulation may show how a resin is filled in the mold during an injection molding process. Mold flow analysis may be performed to determine multiple defects including but not limited to at least one of flow angles, weld lines, fiber orientations, hesitation, and racetrack effect of the component. Figures 2-5 depict the component that is subjected to mold flow analysis. The

various lines in the components as indicated in Figures 2-5 are representative of at least one of the flow line patterns, weld lines, the fiber orientations, the flow angles, hesitation and the racetrack effect of the material in the component.
Further, the method includes obtaining one or more samples [hereinafter referred to as the samples] from the component [as seen in step 202]. In an embodiment, one or more samples [hereinafter referred to as the samples] may be obtained from at least one location [hereinafter referred to as the location] of the component where the flow angles are exhibited to range from but not limiting to ± 0 to 90 degrees. As seen from Figure 2 a first region (1) may be indicative of the locations on the component where the flow angles ranges from ± 0 to 90 degrees. In an embodiment, obtaining samples from the locations on the components where the flow angles ranges from ± 0 to 90 degrees must not be considered as a limitation and other angular ranges may also be considered. In an exemplary and non-limiting embodiment, Figures 2 and 3 depict the mold flow analysis on a front bumper of a vehicle.
In an exemplary and non-limiting embodiment, the component is manufactured by injecting material into the mould. During the injection process the deposition of the material inside the mould may not be uniform. The material may be evenly deposited at a few locations whereas the material may be excessively deposited in other locations. Consequently, the fiber orientation of the material in the component may not be uniform. The fiber may be oriented in at least one of parallel orientation, perpendicular orientation and may also be randomly oriented. In an embodiment, samples may further be obtained from locations of the component where the fiber orientation in the component is at least one of parallel orientation, perpendicular orientation, and random orientation. As seen from Figure 2 and 5, the location (2) may be considered to obtain samples where the orientations may be at least one of the parallel orientations, the perpendicular orientation, and the random orientation of the fibers in the component. The locations of 2a from Figure 5 depicts the parallel orientation of the fibers in the component. Further, the locations of 2b and 2c from Figure 5 depict the perpendicular orientation, and the random orientation of the fibers in the component, respectively.
In an embodiment, weld lines may be defined as locations where the fibers/ flow lines in the component tend to converge to a unitary point. As seen from figure 3, the regions where the fibers/flow lines in the material of the component converge to a single point may be defined as the weld lines. In an embodiment, samples may also be obtained from locations of the

component where the weld lines are identified in the mold flow analysis in the component. The location where weld lines are depicted is indicated in Figure 3 as a third region (3).
Reference is made to Figure 4. In an embodiment, hesitation may be defined as regions in the component where the fibers or flow lines are closely spaced or intimately oriented next to each other. This region is clearly depicted in Figure 4 with the location numbered (4). The location (4) of the component in Figure 4 illustrates a region where the fibers are packed next to each other and this orientation of fibers in the component is defined as hesitation. Further, the samples may be cut from location (4) of the component for analysis. Further, the region with the racetrack effect in the component may be defined as the region where fibers or flow lines are oriented in an unbalanced or non-uniform flow path. The fibers in the racetrack effect region may be randomly oriented and may be oriented to lie farther apart from each other. This region of the racetrack effect is clearly depicted in location (5) of Figure 5. Further, the samples may be obtained from location (5) for further analysis.
Turning back to Figure 1, the method may include determining actual mechanical value (MA) of the samples obtained from the component [as seen in step 203]. In an embodiment, the actual mechanical value (MA) of the samples may be determined by subjecting the samples to tensile test. In an embodiment, the actual mechanical value (MA) may be determined by the tensile test to determine actual tensile strength and strain. In another embodiment, the actual mechanical value may be but not limiting to stiffness, toughness, strength, ductility, hardness, impact resistance and the like. In an embodiment, tensile test may be individually conducted to each of the samples. Further, an average value of the actual tensile strength (TA) or actual strain (SA) was obtained from the tensile test conducted on each of the samples. This average value may also be considered as the actual tensile strength (TA) or actual strain (SA).
Referring further to Figure. 1, as seen in step 204, the method may include comparing the actual mechanical value [thus, average mechanical values] of the samples with an, the optimum mechanical value (MO) and determining the correlation factor based on comparison (as seen in step 205). In an embodiment, the optimum mechanical (MO) may be the value obtained when the component is subjected to the tensile test. In an embodiment, determining the correlation factor may include determining a quotient and the same is represented in the below equation number 1. The quotient is determined by dividing the determined actual mechanical value (MA) of the samples with the optimum mechanical value (MO) as seen from the below equation 1.

Correlation factor (quotient) =

In an embodiment, determining the correlation factor by dividing the actual mechanical value (MA) by optimum mechanical value (MO) must not be considered as a limitation. In an embodiment, other methods such as but not limited to multiplying a numerical value to the optimum mechanical value (MO) for equalizing the optimum mechanical value (MO) to the actual mechanical value (MA) may be used. In this embodiment, the numerical value that equalizes the optimum mechanical value (MO) to the actual mechanical value (MA) may be the correlation factor.
Subsequent to determining the correlation factor, the correlation factor may be multiplied with the optimum mechanical value (MO) to equalize the optimum mechanical value (MO) to the determined actual mechanical value (MA). The mechanical value which is determined by multiplying the correlation factor to the optimum mechanical value (MO) may be referred to as the corrected mechanical value (M). The corrected mechanical value (M) may be further be used in computer aided engineering (CAE) simulation for estimating the quality/mechanical property/durability of the component. The quality/mechanical property/durability of the component that is estimated through computer aided engineering (CAE) simulation using the corrected mechanical value (M) may be closer or equal to the quality/mechanical property/durability of the component that is determined through practical/actual/real world tests on the component. Thus, the correlation factor enables computer aided engineering (CAE) simulation to procure accurate results of the mechanical properties which are closer to the mechanical properties of the component that is subjected to practical/real world tests. In an embodiment, the application of the correlation factor must not be limited to computer aided engineering (CAE) analysis and any other known methods or system may employ the correlation factor for determining accurate quality/mechanical property/durability of the component. In an embodiment, quality/mechanical property/durability of the component may define the point/loads/time at which the component fails.
Example:

The below disclosure describes determining the correlation factor by using actual mechanical value (MA). The actual mechanical value (MA) is the average mechanical value of one or more samples. Further, the below table 1 indicates the determined correlation factor and the corrected mechanical value. Further, the determined mechanical property value of the one or more samples selected as per the method of the present disclosure has been mentioned in table. 1 and the determined correlation factor based on the optimum mechanical value of material which is measured by subjecting standard dumbbell shaped samples to tensile test and the determined actual mechanical value of the one or more samples from the component is mentioned in table 1. The numerical values indicated in the table. 1 are with respect to a component made of certain material and with respect to mechanical value of tensile strength. However, the same cannot be construed as a limitation since the different components and different mechanical values may be considered, which may be subjected to the method of the present disclosure.
Referring to the below table 1, it can be seen that the optimum mechanical value (MO) of the component is 85 MPa. Further, the actual mechanical value (MA) i.e., actual mechanical value of the one or more samples obtained by subjecting the one or more samples to tensile test is 76 MPa.

Sl. Optimum Actual mechanical value (MA) Correlation Corrected
No. mechanical value (MO) factor mechanical value (M) [MO x correlation factor]
1 85 MPa Sample 1: 76 MPa Sample 2: 74 MPa Sample 3: 78MPa 76 MPa ~ (Average) 0.9 76 MPa
Table 1 As seen from the above table, there is difference between the optimum mechanical value (MO) of the component and the determined actual mechanical value (MA) of the samples obtained from the component. Subsequently, the correlation factor is determined in the above-described manner such that the optimum mechanical value (MO) is equalized to the actual mechanical

value (MA). With reference to equation number 1, the actual mechanical value (MA) is divided by the optimum mechanical value (MO). More particularly, an average value of the actual mechanical value (MA) is obtained from the actual mechanical values (MA) of each of the multiple samples. This average value of the actual mechanical value (MA) is divided by the optimum mechanical value (MO) to obtain a quotient. In this exemplary embodiment, the actual mechanical value (MA) of 76 MPa is divided by the optimum mechanical value (MO) of 85 MPa to obtain the quotient of 0.9. The quotient obtained from the division in equation 1 is the correlation factor. The determined correlation factor of 0.9 when multiplied with the optimum mechanical value (MO) of 85 MPa results in corrected mechanical value (M) of 76 MPa which is equivalent to the actual mechanical value (MA) of 76 MPa. In another exemplary embodiment, the correlation factor may also be determined to equalize the optimum strain (SO) to the actual strain (SA) of the component. The corrected mechanical value (M) may further be used for computer aided engineering (CAE) analysis for accurate results on quality/mechanical property/durability of the component.
In an embodiment, the above-described process for the determination of the correlation factor is applicable for all the components that are manufactured of any known materials including but not limited to polymers. In an embodiment, the correlation factor corrects the optimum mechanical value (MO) such that the material property of the component may directly be used for computer aided engineering (CAE) analysis rather than cutting out samples and testing the samples for determining the actual mechanical value (MA).
In an embodiment, the present disclosure considers multiple parameters including but not limited to flow line pattern, flow angles, weld lines, fiber orientation, hesitation, and racetrack effect for determining the correlation factor. The correlation factor is thus used to determine accurate results on quality/mechanical property/durability of the component. The results determined from the computer aided engineering (CAE) analysis where the correlation factor is considered is closer to or equivalent to the results from the practical/real world tests of the component.
Equivalents
With respect to the use of substantially any plural and/or singular terms, those having skill in the art can translate from the plural to the singular and/or from the singular to the plural as is

appropriate to the context and/or application. The various singular/plural permutations may be expressly set forth for sake of clarity.
It will be understood by those within the art that, in general, terms used, are generally intended as "open" terms (e.g., the term "including" should be interpreted as "including but not limited to," the term "having" should be interpreted as "having at least," the term "includes" should be interpreted as "includes but is not limited to," etc.). It will be further understood by those within the art that if a specific number of an introduced claim recitation is intended, such an intent will be explicitly recited in the claim, and in the absence of such recitation no such intent is present. For example, as an aid to understanding the description may contain usage of the introductory phrases "at least one" and "one or more" to introduce claim recitations. However, the use of such phrases should not be construed to imply that the introduction of a claim recitation by the indefinite articles "a" or "an" limits any particular claim containing such introduced claim recitation to inventions containing only one such recitation, even when the same claim includes the introductory phrases "one or more" or "at least one" and indefinite articles such as "a" or "an" (e.g., "a" and/or "an" should typically be interpreted to mean "at least one" or "one or more"); the same holds true for the use of definite articles used to introduce claim recitations. In addition, even if a specific number of an introduced claim recitation is explicitly recited, those skilled in the art will recognize that such recitation should typically be interpreted to mean at least the recited number (e.g., the bare recitation of "two recitations," without other modifiers, typically means at least two recitations, or two or more recitations). Furthermore, in those instances where a convention analogous to "at least one of A, B, and C, etc." is used, in general such a construction is intended in the sense one having skill in the art would understand the convention (e.g., "a system having at least one of A, B, and C" would include but not be limited to systems that have A alone, B alone, C alone, A and B together, A and C together, B and C together, and/or A, B, and C together, etc.). In those instances where a convention analogous to "at least one of A, B, or C, etc." is used, in general such a construction is intended in the sense one having skill in the art would understand the convention (e.g., "a system having at least one of A, B, or C" would include but not be limited to systems that have A alone, B alone, C alone, A and B together, A and C together, B and C together, and/or A, B, and C together, etc.). It will be further understood by those within the art that virtually any disjunctive word and/or phrase presenting two or more alternative terms, whether in the description, or drawings, should be understood to contemplate the possibilities

of including one of the terms, either of the terms, or both terms. For example, the phrase "A or B" will be understood to include the possibilities of "A" or "B" or "A and B."
While various aspects and embodiments have been disclosed, other aspects and embodiments will be apparent to those skilled in the art. The various aspects and embodiments disclosed are for purposes of illustration and are not intended to be limiting, with the true scope and spirit being indicated in the description.

Referral Numerals:

Referral numerals Description
1 First region
2 Second region
3 Third region
MO Optimum mechanical value
MA Actual mechanical value
TO Optimum tensile strength
TA Actual tensile strength
SO Optimum strain
SA Actual strain

We Claim:
1. A method for determining a correlation factor for mechanical properties of a
component, the method comprising:
performing, a mold flow analysis of the component;
obtaining, one or more samples from at least one location of the component based on the mold flow analysis;
determining, at least one actual mechanical value (MA) of the one or more samples;
comparing, the determined at least one actual mechanical value (MA) with a pre-determined optimum mechanical value (MO); and
determining, the correlation factor based on the comparison of the determined at least one actual mechanical value (MA) and the optimum mechanical value (MO).
2. The method as claimed in claim 1, wherein the mold flow analysis of the component is performed to determine at least one of flow angles, weld lines, fiber orientations, hesitation, and racetrack effect in the component.
3. The method as claimed in claims 1 and 2, wherein the one or more samples are obtained from the at least one location of the component where the flow angles in the component ranges between ± 0 to 90 degrees.
4. The method as claimed in claims 1 and 2, wherein the one or more samples are obtained from the at least one location of the component where the fiber orientation in the component is at least one of parallel orientation, perpendicular orientation and random orientation.
5. The method as claimed in claims 1 and 2, wherein the one or more samples are obtained from the at least one location of the component where the weld lines are defined in the component.
6. The method as claimed in claims 1 and 2, wherein the one or more samples are obtained
from the at least one location of the component where the hesitation is formed.

7. The method as claimed in claims 1 and 2, wherein the one or more samples are obtained
from the at least one location of the component where the racetrack effect is formed.
8. The method as claimed in claim 1, wherein the at least one actual mechanical value (MA) is at least one of tensile strength and strain obtained by performing a tensile test on the one or more samples.
9. The method as claimed in claim 1, wherein determining includes obtaining a quotient of the determined at least one actual mechanical value (MA) of the one or more samples and the optimum mechanical value (MO).
10. The method as claimed in claim 1, wherein the determined quotient is the correlation factor for the mechanical properties of the component.