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JNANASANGAMA, BELAGAVI-590018
An Internship Report
“A Study on Manufacturing of Aircraft”
Submitted in partial fulfilment for the award of degree of
Bachelor of Engineering
In
Mechanical Engineering
Submitted by
RAHUL J
1KG15ME033
Internship Carried Out at
HINDUSTAN AERONAUTICS LIMITED
AIRCRAFT DIVISION
BANGALORE COMPLEX
VIMANAPURA POST BANGALORE-560017
i
K S SCHOOL OF ENGINEERING AND MANAGEMENT
Bengaluru-560109
Department of Mechanical Engineering
CERTIFICATE
This is to certify that the internship work entitled “A Study on Manufacturing of Aircraft” is
a bonafide work carried out by
RAHUL J 1KG15ME033
. .
Signature of the HOD Signature of the Principal
Prof. Balaji. B Dr. K. Ramanarasimha
Assoc. Professor and Head Principal/Director
Dept. of Mechanical Engg. KSSEM, Bengaluru –109
KSSEM, Bengaluru – 109
External Viva
Name of the Examiners Signature with date
1.
2.
i
K S SCHOOL OF ENGINEERING AND MANAGEMENT
# 15, Mallasandra, Off. Kanakapura Road,
Bengaluru-560109
DECLARATION
I, Student of Mechanical Engineering, K. S. School of Engineering and Management,
hereby declare that the internship report entitled “A Study on Manufacturing of Aircrafts”
embodies the record of the internship carried out at Aircraft Division HAL, Bangalore Complex
under the guidance of Mr. Vijay Chandan and Mrs. Arockia Jothi, for the fulfilment of the
requirement of the award of the Degree of Bachelor of Engineering.
Place: Bengaluru
Date:
ii
ACKNOWLEDGEMENT
The successful completion of any task would be incomplete without the mention of the
people, whose constant guidance and encouragement crowned our efforts with success. I
consider it as a privilege to express my gratitude and respect to all those who guided me in
the successful completion of this project.
First of all, I am thankful to our college K S SCHOOL OF ENGINEERING AND
MANAGEMENT for providing support guidance and a platform to work.
I express my gratitude to AIRCRAFT DIVISION HAL for providing opportunity and
guidance to carry out internship work.
I take this opportunity to express my deep regards to Dr. K. Ramanarasimha,
Principal/Director, K S School of Engineering and Management for providing an
opportunity to do this Project Work as a part of my curriculum in the partial fulfilment of
the degree course.
I express my gratitude to Prof. Balaji. B, HOD, Department of Mechanical Engineering,
K.S. School of Engineering and Management for providing valuable insights, making the
resources available at right time and all the encouragement for the completion of my project.
I owe my profound gratitude to our project guide Mr. Vijay Chandan, Asst. Professor,
Department of Mechanical Engineering, K S School of Engineering and Management,
Bengaluru & Mrs. Arockia Jothi, Senior Manager (HR), AIRCRAFT DIVISION HAL
BANGALORE, who took keen interest in the work and guided all along and for providing
all the necessary information.
I extend my profound gratitude to my internship coordinator Mr. Prabhu K S, Assistant
Professor, Department of Mechanical Engineering, K. S. School of Engineering and
Management, who took keen interest in the work and guided all along and for providing all
the necessary information.
I also wish to thank all the staff of Department Mechanical Engineering for providing all the
support whenever needed. I would like to thank my parents for supporting and helping in
the completion of the project work. Last but not the least I would like to thank all my friends
without whose support and co-operation the completion of project would not have been
possible.
iii
CONTENTS
1.INTRODUCTION ......................................................................................................... 1
1.1 BREIF HISTORY ................................................................................................... 1
1.2 DIVISIONS OF H.A.L ............................................................................................ 2
1.3 PRODUCTS OF H.A.L ........................................................................................... 3
1.4 AIRCRAFT DIVISION ........................................................................................... 4
1.5CUSTOMERS OF HAL ........................................................................................... 5
2 DEPARTMENTS VISITED AT AIRCRAFT DIVISION .............................................. 6
2.1 CUSTOMER SERVICES DEPARTMENT ............................................................. 6
2.2 METHODS AND PROGRAMMING ENGINEERING ........................................... 6
2.3 EXPORT MACHINE SHOP ................................................................................... 9
2.4 EXPORT ASSEMBLY SHOP ............................................................................... 11
2.5 NC SHOP AND NC PROGRAMMING ................................................................ 14
2.6 SHEET METAL AND WELDING ........................................................................ 15
2.6 HEAT TREATMENT DEPARTMENT ................................................................. 17
2.7 PROCESS SHOP................................................................................................... 19
2.8 PLASTICS DEPARTMENT ................................................................................. 21
2.9 HONEYCOMB WORKSHOP ............................................................................... 23
2.10 DROP TANK ...................................................................................................... 25
2.11 WORK TEST LAB.............................................................................................. 26
2.12 HAWK WING ASSEMBLY ............................................................................... 27
2.13 HAWK FINAL ASSEMBLY .............................................................................. 28
3 CONCLUSION ............................................................................................................ 30
4 REFERENCE .............................................................................................................. 31
iv
LIST OF FIGURES
v
A Study on Manufacturing of Aircraft 2018-2019
1.INTRODUCTION
Hindustan Aeronautic Limited [HAL] a premier Aerospace Company in Asia is engaged
in design, development and manufacture of military and civil aircraft for over 75 years. The
product r a n g e covers basic piston engine trainer aircraft to helicopters to sophisticated state
of the art deep penetration strike aircraft. Hindustan Aeronautic Limited is an organization
where integrated air borne weapons platforms are conceived, developed, manufactured and
serviced. It is one of the few corporate giants in Asia whose capabilities span the entire range
of activities from product conception to after sale support. HAL is also involved in the
manufacture and assembly of structures required for India's space programs.
riveted structural assemblies and welded propellant tankages for the Polar Satellite Launch
Vehicle (PSLV-C25). Today, HAL has 19 Production Units and 9 Research and Design
Centers in 7 locations in India. The Company has impressive product track record-12 types
of aircraft manufactured with in-house R&D and 14 types produced under license. HAL
has manufactured 3550 aircraft (which includes 11 types designed indigenously), 3600 engines
and overhauled over 8150 aircraft and 27300 engines.
HAL has been successful in numerous R & D programs developed for both defense and
Civil Aviation sectors.
HAL has made substantial progress in its current projects:
2. HJT-Kiran Mk I, Mk II (IJT).
3. Jaguar.
4. HJT-36 Sitara - Intermediate Jet Trainer (IJT).
5. LCA- Tejas.
1.5CUSTOMERS OF HAL
Major customers
DEFENCE & SPACE CIVIL
Indian Air Force Border Security Force
Indian Army Govt. of Karnataka
Indian Navy Govt. of Jharkhand
Indian Coast Guard Govt. of Maharashtra
Indian Space Research Organization Geological Survey of India
Defense Research & Development Oil & Natural Gas Cooperation of India
Organization
Ordnance Factory Board Bharat Heavy Electricals Ltd.
Minor customers
1. Airbus Industries, France.
2. Boeing, USA.
3. GE Aviation, USA.
4. Israel Aircraft Industries, Israel.
5. Nepal Army, Nepal.
6. Rolls Royce Plc, UK.
7. Royal Malaysian Air Force, Malaysia.
8. Roseboro export, Russia.
9. Vietnam Air Force, Vietnam.
10. Honeywell International, USA.
11. Mauritius Police Force, Mauritius.
Design and planning, IMM, MSD and by Considering the capacity of the machining
equipment and the technology available the methods department.
4. This route book contains detailed steps of what processes It contains the raw material
detail, CAD drawing of parts, processes, sequential operations into which the raw
material has to undergo to produce a finished product.
2.
Spec: 35NCD16UTS-1230/1380MPa
Size:
Operation
no/dept
Tool no/Operation description quantity shop inspection
Inspection
Thread rolling
Thread rolling
Inspection
Inspection
Dichromate passivation
Program engineering
Supervising project engineering related tasks including planning, control & troubleshooting for
achieving the planned periodic schedules and process control. Coordinating with the other
departments for smooth functioning and accomplishing production as per customer’s
requirement & organizational guideline.
Functions
1. It plans the targets on the basis of tasks from customers and finalizes the production plan
and involves production control.
2. Prepares the schedules for sequential operations to produce a finished product.
3. Loading of raw materials, fabricating the products.
1. Turning.
2. Facing.
3. External threading.
4. Knurling.
5. Drilling.
6. Boring.
7. Tapping.
8. Reaming.
9. Counter boring.
10. Chamfering.
Drilling machines
1. Bench or sensitive drilling machines.
2. Radial drilling machines.
The various drilling operations carried out are: -
Drilling, reamingBoring, Tapping, Reaming, Counter boring, counter sinking, Parting-off, spot-
facing, trepanning.
Milling machines
1. Vertical milling machine (6 m/c).
2. Horizontal milling machine (6 m/c).
3. Heavy duty milling machine (7 m/c).
4. Copy milling machine:
i. 2D copy milling (1 m/c).
ii. 3D copy milling (4 m/c).
The various milling operations carried out are: -
Plane or slab milling, Face milling, End milling, slot milling, angular milling, straddle milling, gang
milling, gear cutting, form milling, gang milling, saw milling, key way milling, thread milling.
Grinding machines
1. Surface grinding machine.
i. Horizontal spindle type with reciprocating table.
ii. Vertical spindle type with reciprocating table.
2. Center type cylindrical grinding machine.
3. Centerless type cylindrical grinding machine.
3. Mechanical installation: gear box, clamp assembly, plate assembly, fitting hinge lower &
upper, fitting hook, handle assembly, bearings etc.
4. Equipping: electrical wire connections.
5. Icy check: check whether all the components are settled, sufficient gap between parts, no
misplaces, distance between rivets etc.
6. Furnishing, packing and dispatch as shown in figure 1.
Special process approvals
1. Installation of bearing and ball joints.
2. Sealant application
3. Installation of tight fit bushes.
4. Riveting(manual).
5. Bonding of bushes and ball bearings.
6. Raw material procurements.
7. Silver plating.
8. Cadmium plating.
9. Hard chrome plating.
10. Magnetic particle inspection.
11. Die penetrant inspection.
12. Chromic acid anodizing.
13. Heat treatment of Al and solid rivets.
14. Allochromatic touch-up.
6. Ironing
7. Press brake forming
8. Stretching
9. Punching
10. Roll forming
11. Rolling
12. Spinning
13. Water jet cutting
14. Fastener
In this shop different machines are there for forming process: -
Stretch forming machine
Type of machine: Hydraulic sheet metal stretcher press (ecru)
Capacity : Operating pressure- 2000p s i
Grab length- 96 inch
Tonnage- 300 tons
Table size- 17 x 98 inch2
Basic functions:
1. To form double curvature skins
2. Angular adjustment of cross beams on carriages is 150 or included angle of 300
3. Length of cross beam 134inch
4. Distance between clamps when set aircraft beam ends 122 inches
Stretch forming simultaneously stretches and bends a piece of sheet metal to form a large
contoured shape as shown in figure 4. Auto manufacturers use the process to produce outer
body panels; aircraft manufacturers stretch form fuselage skin sections. Benefits of the
process include a lack surface marring, distortions and ripples, and accurate alignment of
complex profiles. Stretch forming occurs in a stretch press, with the Sheet metal securely held
along its edges by gripping jaws. The gripping jaws, attached to a carriage, are pulled by
pneumatic or hydraulic force to stretch the sheet as shown in figure. The tooling used-a
stretch form block - comprises a solid contoured piece against which the sheet metal is pressed.
As the form die drives into the sheet, tensile forces increase until the sheet plastically deforms
into its new shape.
Hydraulic press
Type of machine: Hydraulic rubber press
Capacity: Tonnage-1000 tons, bed size- 60 x 144 inch2, Stroke length- 60
inch, Shut height-12 inch
Functions: It used for vertical stretch forming leading edge skins using special gripping
jaws, also can be used for forming sheet metal components using double action male &
female tools for draw forming operation. Also, can be used to form straight and curved
flanges keeping routed blanks on the forming dies by application of moving ram,
Hydraulic gripping attachments to form leading edge skins.
Power brake machine
Type of machine: Mechanical press brake
Capacity: Shut height- 150 mm, stroke length- 70 mm, bed length- 3000 mm.
Functions: straight bending of various sections of flanges from flat sheets using
different types of die such as air brakes, bottoming and goose neck dies, also gang
punching, forming and bending for contoured parts using special dies.
Normalising
1. The components are put into the furnace maintained at the required temperature
and heated to about 500C above the upper critical temperature of steel and
2. Holds at this temperature for sufficient time.
3. Then parts are removed from the furnace and cooled in the surrounding air to room
temperature.
4. The resultant strength of material would be more than the annealed condition.
Hardening
It is carried out to increase the hardness of steel. The hardening of steel requires the formation
of martensite, because martensite has the strongest microstructure than pearlite and austenite.
1. Steel specimen is heated to about 300 to 500C above the critical temperature and
held at this temperature for 15-30 min
2. Rapidly cooling by quenching in oil, water, salt brine or salt bath etc.
3. This results in the transformation of austenite to martensite that is responsible for
increasing the hardness of steel.
Tempering
It is the process that reduces the brittleness of steel without lowering its hardness and
strength.
1. Reheating the hardened steel to a temperature below the lower critical temperature
fallowed by a slow cooling in still air.
2. Reheating permits partial transformation of martensite, and relieving of internal
stresses. With increase in tempering temperatures, transformation of martensite
occurs at a faster rate.
Anodising
It is an electrochemical process that converts the metal surface into a decorative, durable,
corrosion-resistant, anodic oxide finish. Aluminum is ideally s united to anodizing, although
other non-ferrous metals, such as magnesium and titanium, also can be anodized.
Example: Airbus A320- fitting hoist aft, jaguar- ribs, hawk – wing frames wing skin,
bracket.
Chromic acid anodising
The Flow process of Chromic acid anodising is shown in figure 5. The surface treatment
process is done to avoid rusting or corrosion while aircraft in at high altitude.
3. Cold water swill: dip the component in cold water for 3-5 min at ambient temperature.
4. De oxidize tank: Dip the part for 0.5-10 minutes into the pre-mixed solution at ambient
temperature. Sulpho-chroming is used to remove oxide layer using de-oxidizer. See the
section on Aluminum De-oxidizer.
5. Cold water rinse: Rinse work thoroughly in clean water for 3-5 min.
6. Anodize: The aluminum is immersed in an electrolyte consisting of chromic acid
solution. The temperature (330C-370C) of the solution is controlled to give the desired
properties. A DC (direct current) electric current is passed between the aluminum that is
made the anode (positive terminal), the electrolyte and a cathode (often lead). When the
current is applied, the water in the Electrolyte breaks down and oxygen is deposited at
the anode. This oxygen combines with the aluminum to form oxide and thus builds on the
oxide film always present on the surface. The acid in the electrolyte tries to dissolve this
oxide and produces a porous oxide film on the aluminum surface. Coating thickness up to
25 microns is recommended for external use.
7. Cold water rinse: Once the required thickness of anodic film is obtained, the aluminum
is removed from the electrolyte and rinsed in the water thoroughly to remove the acids
from the pores in the film. The anodic film produced is now ready for coloring, if required.
8. Di chromate seal: Sealing is the process in which the pores at the surface of the oxide
layer are closed off. It is affected by placing the anodized object in boiling water for a 15
- 20-minute period or in chemically enriched water at room temperature.
9. Drying: the coated component is kept for drying for required time at temperature from
ambient to 700C. after that process ice completed.
Type of sheet
Cast acrylic and Stretch acrylic plastic sheet is used to produce canopies and wind screens.
Cast acrylic
Cast Acrylic is a form of Poly methyl methacrylate, the polymerized methyl ester of
methacrylic acid, is thermoplastic.
Strectch acrylic
Stretched acrylic is obtained by stretching cast acrylic sheets, a process which re-orients the long
polymer chains. This drastically increases the material properties. And shows an improved craze
resistance as well as a far better stress, c r a c k propagation and solvent resistance than acrylic.
It is therefore suitable for bird resistant wind shields, canopies, outer cabin window panes and
other transparencies for pressurized aircraft.
Vaccum forming
1. Vacuum forming process is used to manufacture the canopies and wind screens.
2. First, a wooden mould is made. This is made in the shape to which the acrylic sheet will
form around. Often where possible, the mould should have angled edges, in order to
allow the tooling to pop out of the plastic when made.
3. The mould is then placed into the vacuum former oven. An acrylic sheet is then clamped
above but not on the mould.
4. In the oven, the heater is positioned above the plastic. This will heat up about temperature
1650C, warming the plastic & allowing it to become flexible and moldable.
5. After a few minutes, the plastic should be at a temperature to allow moulding.
6. The shelf on which the wooden mould is sat on, is moved upwards and into the flexible
plastic using a handle.
7. The vacuum is then switched on, removing all air from the oven. This allows the plastic to
form to the shape of the mould.
8. Once cooled, the sheet is then removed from the oven, the mould is removed & any excess
trimmed.
9. Clean the canopy and use emery paper to remove if any tool marks are there. Cut to required
shape and attach the one glass cloth layer on that by using acrifix gel to make the holes on it. If
holes are done directly on canopy, the crack propagation occurs. So that glass cloth is used.
But drilling is done directly on stretched acrylic sheet cracks are not appeared while drilling
because it has good material properties than acrylic sheet.
10. After that sent to next process- fastening, inspection and assembly line.
Figure 7 A wing leading edge formed from honeycomb material bonded to the aluminium spar structure (source: -
https://goo.gl/images/Zn8iVB)
bolts. In some aircraft, the wing spars are continuous through the fuselage depending on
the demands of space.
4. The tail plane is attached to pick up points on the relevant fuselage frames. vertical
stabilizer is generally mounted on aft fuselage with joint. the front and rear spars are
attached to aft fuselage bulkheads by either permanent joint or fittings.
5. Power plants and landing and nose gear are mounted, and avionic components are installed.
6. The functioning of all components is thoroughly tested prior to towing the completed
aircraft to a separate, well ventilated paint hanger, where a protective primer coat
(normally zinc chromate based) is applied, followed by a decorative topcoat of urethane
or epoxy paint as shown in figure10.
7. Prior to deliver the aircraft is put through a rigorous series of ground and flight tests.
3 CONCLUSION
Since its inception in 1940, the company has grown into a giant aviation complex spread all
over India and employing a versatile work f o r c e of trained, highly skilled & experienced
persons. It enjoys a monopoly in India.
Recently a light combat aircraft (LCA) has been designed indigenously in the country with the
advancement of new technology & highly skilled scientists and with the cooperation of various
agencies. It is double that of MIG-21. A time will come when India too will have stood in the
world market of aircraft.
I am grateful to have been able to get the opportunity to pursue my industrial training at
Hindustan Aeronautics Limited. I had a good learning experience at HAL. I was introduced
some state of technologies that are used to manufacture our defence aircrafts. I learnt
various manufacturing techniques that are used in production, how materials are treated based
on their role and finally how assemblies of aircraft are done.
4 REFERENCE
1. https://en.wikipedia.org/wiki/Hindustan_Aeronautics_Limited
2. https://en.wikipedia.org/wiki/BAE_Systems_Hawk
3. http://aermech.in/hal-hawk-mk-132-bae-hawkadvanced-jet-trainer-ajt-
indian-armed-forces/
4. http://www.experimentalaircraft.info/articles/aircraft-construction
5. Welcome to Hindustan Aeronautics Limited | India