Abyan

DEPARTMENT OF AEROSPACE ENGINEERING
SUMMER INTERNSHIP-II
(21ASI57)
INTERNSHIP REPORT
Submitted by
Abyan Raidh T (1RV21AS003)
Carried out at
LCA TEJAS DIVISION, HAL
In partial fulfillment for the award of

degree of
Bachelor of Engineering
In
Aerospace Engineering
2023-24
1
RV COLLEGE OF ENGINEERING®,
BENGALURU-59
(Autonomous Institution Affiliated to VTU, Belagavi)
DEPARTMENT OF AEROSPACEENGINEERING
CERTIFICATE
Certified that the internship project work titled “Aircraft Fixture Design and
CNC Machining” is carried out by Abyan Raidh T (1RV21AS003) in partial
fulfillment of the completion of the course Summer Internship-II (21ASI57) of
the V Semester, Aerospace Engineering program, during the academic year
2023-2024. It is certified that all corrections/suggestionsindicated for the Internal
Assessment have been incorporated in the project reportand duly approved by the
faculty. The internship project report has been approved as it satisfies the
academic requirements in respect of internship project work prescribed by the
institution for the said degree.
Signature of Head of the Department Signature of Principal
External Viva
Name of Examiner Signature with Date
1.
2.
2
CERTIFICATE
3
ACKNOWLEDGEMENTS
I would like to extend my sincere thanks to Dr. Ravindra S Kulkarni, who serves as Professor
and Head of the Department of Aerospace Engineering at RV College of Engineering, for his
continuous support and encouragement.
I express my deepest gratitude to our respected Principal, Dr. K. N. Subramanya, for

appreciating our project work.
I also want to extend my gratitude to our mentor, Shri Parashuram, Senior Manager at the LCA
Tejas Division of HAL, for guiding me throughout the internship. His assistance enabled me to
understand and execute the tasks effectively.
iv
CONTENTS
Abstract vi
List of Figures vii
1.Profile of the Organization 1
2.Activities of the Department 3
3.Tasks Performed 5
3.1 Design of a Rudder Assembly 6
3.2 CNC Machining 20
4.Reflection 27
5. Conclusion and Future Scope 29
References 31
Annexure 32
v
ABSTRACT
Aerospace manufacturing stands as one of the fastest-growing industries globally, driven by

increasing demand for air travel, advancements in technology, and the exploration of space.
Within this dynamic field, the design and production of aircraft components play a pivotal role.
During this internship, the focus was on the design of a critical aircraft component: the rudder
assembly. Additionally, fundamental principles of CNC machining were acquired through hands-
on experience with various components, highlighting the intricate processes involved in aerospace
manufacturing.
The methodology employed in this project encompassed a comprehensive analysis of existing
fixture designs, followed by conceptualization and prototyping of a flexible fixture model using
CATIA software. Extensive DMU simulations were conducted to virtually test and optimize the
proposed design
Jigs and fixtures play a crucial role in aerospace manufacturing, ensuring precision and
repeatability in component fabrication. As industries strive for increased efficiency and flexibility,
the future of manufacturing lies in modular and sensor-integrated jigs. These innovative solutions
enable rapid reconfiguration for different components and incorporate sensors for real-time
monitoring and adjustment, thereby enhancing productivity and quality assurance. Embracing
such advancements will be vital for staying competitive in the ever-evolving aerospace
manufacturing landscape.
vi
LIST OF FIGURES
Fig 3.1.1(a) A welding fixture 3

Fig 3.1.1(b) Fuselage Assembly Jig 5
Fig 3.1.3(a) Top beam of the frame 7
Fig 3.1.3(b) Side beam of the frame 7
Fig 3.1.3(c) Front Fixture Head 8
Fig 3.1.3(d) Rare fixture head 8
Fig 3.1.3(e) Spar Locator 9
Fig 3.1.3(f) Skin of the Rudder 10
Fig 3.1.3(g) Skin of the Rudder 10
Fig 3.1.3(h) Rib of the Rudder 11
Fig 3.1.3(i) Support Panel 11
Fig 3.1.3(j) Hydraulic Pump 12
Fig 3.1.4.1(a) Frame assembly 13
Fig 3.1.4.1(b) Fixture head assembly 13
Fig 3.1.4.1(c) Spar Locator 14
Fig 3.1.4.1(d) Rudder Fixture Assembly 14
Fig 3.1.4.2(a) Rudder Loading 16
Fig 3.1.4.2(b) Fastening the Rudder 16
Fig 3.1.4.2(c) Unloading of the Rudder 17
Fig 3.2.1 3 axis CNC Machine 18
Fig 3.2.3 Desired output of the CNC 21
Fig 3.2.4(a) Stock metal block 22
Fig 3.2.4(b) Face Milling 22
Fig 3.2.4(c) Profile Contour Milling 23
vii
Title Summer Internship-I I
Chapter 1
Profile of Organization
Department of ASE 2023-24

1
CHAPTER 1
PROFILE OF THE ORGANIZATION
Hindustan Aeronautics Limited (HAL) is the principal partner in the LCA Tejas programmed with
Aeronautical Development Agency (ADA) acting as the Program coordinator. LCA-Production
Group (LCA-PG) was established under the aegis of HAL Bangalore Complex on 01st July 2002
to take up concurrent development and production of indigenously designed and developed Light
Combat Aircraft (LCA-Tejas). The same was converted into a full-fledged production Division as
LCA Tejas Division in April 2014.
LCA-Tejas Division is the prime center for manufacturing of indigenously developed LCA Tejas
aircraft. The Division currently has orders for 123 aircraft. The first production order for 20 LCA
aircraft in IOC configuration was received in March 2006, followed by another order of 20 more
LCA-Tejas aircraft in FOC configuration in December 2010. In 2021, the Division received an
order for 83 LCA Mk1A aircraft for Indian Air Force. The Division is also progressing the case
with many foreign friendly countries for export orders of LCA Tejas.
The Division has a manufacturing capacity of eight to ten aircraft per annum which is being
augmented up to sixteen aircraft per annum from 2023 onwards. In order to further enhance the
production capacity of LCA, a new Plant II was created by the Division during 2021. LCA-Tejas
Division is playing a lead integrator role in the production process of LCA Tejas and is being
supported by various business partners for the same. To overcome the production challenges,
state-of-the-art manufacturing facilities have been established at LCA Tejas Division along with a
robust supply chain to support all the required areas. The Division is equipped with modern
infrastructure in Plant and Machinery, state-of-the-art CNC machines, CAD-CAM Manufacturing
Engineering, Quality Assurance systems, and the latest in IT support which are harnessed by a
highly skilled team of officers and technicians to ensure the timely production of aircraft and other
deliverables.

2
Chapter 2
Activities of the Department

3
Aircraft Fixture Design and CNC Machining Summer Internship-I I
CHAPTER 2
ACTIVITIES OF THE DEPARTMENT
The LCA Tejas Division at Hindustan Aeronautics Limited (HAL) Bangalore stands as a
cornerstone of India's indigenous aerospace industry, dedicated to the design, development, and
production of the Light Combat Aircraft (LCA) Tejas. As a premier aerospace organization,
HAL's LCA division embodies cutting-edge technology and engineering excellence, contributing
significantly to India's self-reliance in defense manufacturing. Within this division, the Tool
Design and Methods Department play pivotal roles in ensuring the precision, efficiency, and
quality of aircraft manufacturing processes, aligning with HAL's commitment to delivering world-
class aerospace solutions.
The Tool Design Department is primarily tasked with the development of specialized tools crucial
for the manufacturing, maintenance, and repair of aircraft components, specifically tailored to
meet the stringent requirements of the LCA Tejas aircraft. Collaborating closely with aerospace
engineers, the department ensures precise alignment with manufacturing needs and aircraft
specifications. Prototypes undergo meticulous testing to validate functionality, precision, and
safety standards, with a focus on continuous improvement to streamline production operations.
Detailed documentation of tool designs, including specifications and operational guidelines, is
maintained to comply with regulatory standards and facilitate user training. Engineers within the
department employ systematic problem-solving methodologies to address unique challenges,
ranging from designing tools for intricate aircraft components to overcoming manufacturing
complexities.
Concurrently, the Methods Department focuses on optimizing manufacturing processes,

encompassing sequence planning, resource allocation, and quality management, to achieve
efficient production outcomes. Through robust quality control measures and adherence to lean
manufacturing principles, the department aims to maximize productivity, minimize lead times,
and uphold the superior quality of aircraft components. Comprehensive training programs ensure
workforce proficiency in standardized processes, fostering a culture of operational excellence and
continual skill development. Seamless integration with the Tool Design Department ensures
alignment between manufacturing processes and available tooling capabilities, optimizing
efficiency and quality assurance throughout the production cycle.

4
Chapter 3
Tasks Performed

5
CHAPTER 3
TASK PERFORMED
3.1 Design of a Rudder Assembly Fixture

3.1.1 Introduction
In aerospace manufacturing, precision and accuracy are paramount. To achieve this, specialized
tools and equipment are used, including fixtures and jigs. These two terms are often used
interchangeably but have distinct roles in the manufacturing process.
3.1.1.a Fixtures:
Figure 3.1.1(a) A welding fixture
A fixture is a specialized tool or device used to securely hold and position a workpiece during the
manufacturing process. In aerospace manufacturing, fixtures are commonly used in machining,
welding, assembly, and inspection operations. They are designed to ensure consistent and precise
positioning of the workpiece, allowing for accurate machining and assembly.
Key characteristics of fixtures include:

a. Stability: Fixtures are typically rigid and stable, providing a secure base for the workpiece
to prevent movement or vibration during machining or assembly.

6
b. Customization: Fixtures are often custom-designed to accommodate specific workpieces

and manufacturing processes. They may include features such as clamps, locators, and
supports tailored to the shape and dimensions of the workpiece.
c. Repeatability: Fixtures enable consistent positioning of workpieces, allowing for
repeatable and precise manufacturing processes. This ensures uniformity in the finished
parts, which is critical in aerospace applications where tight tolerances are required.
d. Efficiency: By securely holding the workpiece in the optimal position, fixtures help
streamline manufacturing operations, reduce setup time, and improve overall productivity.
Examples of fixtures used in aerospace manufacturing include:

 Machining fixtures: Used to hold aircraft components such as engine parts, fuselage
sections, and wing structures during milling, drilling, and turning operations.
 Welding fixtures: Designed to accurately position and hold metal components for welding,
ensuring proper alignment and joint quality.
 Assembly fixtures: Aid in the precise alignment and assembly of complex aerospace
assemblies, such as landing gear systems and aircraft interiors.
3.1.1.b Jigs:
While fixtures hold and position workpieces, jigs are specialized tools used to guide cutting or
machining tools during the manufacturing process. Jigs are often paired with fixtures to further
enhance precision and accuracy in aerospace manufacturing.
Key characteristics of jigs include:

a. Guidance: Jigs provide guidance for cutting tools, drills, or other machining equipment,
ensuring that they follow predetermined paths or angles during the manufacturing process.
b. Accuracy: By guiding the cutting tool, jigs help maintain the desired dimensions,
tolerances, and surface finishes of the workpiece, contributing to the overall quality of
aerospace components.
c. Versatility: Jigs can be designed for various machining operations, including drilling,
milling, routing, and grinding, making them versatile tools in aerospace manufacturing.
d. Complexity: Some jigs may incorporate intricate features such as adjustable guides,
templates, and stops to accommodate complex machining requirements and multiple part
configurations.

7
Figure 3.1.1(b) Fuselage Assembly Jig
Examples of jigs used in aerospace manufacturing include:

 Drilling jigs: Used to guide drills or reamers to create precision holes in aircraft
components such as wings, fuselage panels, and engine mounts.
 Routing jigs: Guide routers or milling machines to shape composite materials used in
aerospace structures, such as carbon fiber panels and aircraft interiors.
 Assembly jigs: Assist in the alignment and assembly of intricate aerospace assemblies,
ensuring precise positioning of components during final assembly stages.
3.1.2 Design Methodology

Designing an assembly fixture for aerospace manufacturing requires careful consideration of
various factors to ensure optimal performance, accuracy, and efficiency. Here are key aspects that
engineers must focus on during the design process:
a) Workpiece Compatibility:
i. Understand the specific dimensions, shapes, and materials of the aerospace
components to be assembled.
ii. Ensure the fixture is tailored to accommodate the workpiece securely and accurately
without causing damage or deformation.
b) Alignment and Positioning:
i. Design the fixture to precisely align and position individual components during
assembly, taking into account tolerance requirements and geometric complexities.

8
ii. Incorporate features such as locators, guides, and clamps to ensure proper alignment
and prevent misalignment errors.
c) Accessibility and Ergonomics:
i. Consider accessibility for operators to handle and manipulate the workpiece during
assembly tasks.
ii. Optimize the design for ergonomic efficiency, minimizing strain and fatigue on assembly
personnel while ensuring safe and comfortable working conditions.
d) Modular and Adjustable Features:
i. Implement modular components or adjustable elements in the fixture design to
accommodate variations in component dimensions or assembly configurations.
ii. Enable quick and easy reconfiguration of the fixture to adapt to changes in production
requirements or part designs.
e) Integration with Assembly Processes:
i. Coordinate the fixture design with the overall assembly process, ensuring seamless
integration with other manufacturing equipment and workflow systems.
ii. Incorporate interfaces or compatibility with robotic systems or automated assembly lines
for enhanced efficiency and productivity.
f) Stability and Rigidity:
i. Ensure the fixture provides stable and rigid support for the workpiece throughout the
assembly process.
ii. Select materials and structural configurations that minimize deflection and vibration,
maintaining dimensional accuracy and preventing assembly errors.
g) Clamping and Fixturing Mechanisms:
i. Choose appropriate clamping and fixturing mechanisms to securely hold the workpiece in
place without compromising access for assembly operations.
ii. Optimize clamping forces and distribution to avoid distortion or deformation of delicate
components while maintaining stability during assembly tasks.
h) Inspection and Quality Control:
i. Incorporate provisions for inspection and quality control checks during the assembly
process.
ii. Integrate features such as datum points, reference surfaces, or measurement devices to
verify dimensional accuracy and adherence to specifications.
i) Maintenance and Serviceability:
i. Design the fixture for ease of maintenance and serviceability, allowing for routine
inspections, repairs, or adjustments as needed.

9
ii. Consider accessibility to internal components, ease of disassembly, and availability of

replacement parts to minimize downtime and ensure continuous operation.
By addressing these considerations in the design of assembly fixtures, aerospace engineers can
develop robust and efficient solutions that optimize the assembly process while maintaining the
highest standards of quality and precision.
3.1.3 Modelling of the aircraft rudder assembly fixture

In accordance with the specified design criteria, a simplified version of an aircraft rudder fixture
was developed. The model's design is depicted below.
3.1.3.a Frame
The structure of the fixture was crafted to be straightforward and seamlessly integratable.
Figure 3.1.3(a) Top beam of the frame
Figure 3.1.3(b) Side beam of the frame

10
3.1.3.b Support Heads

There are two support heads, both affixed to the top beam, serving to firmly hold the rudder in
position. Their sequential arrangement will become evident during the final assembly.
Figure 3.1.3(c) Front Fixture Head
3
Figure 3.1.3(d) Rare fixture head

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3.1.3.c Spar Locator

A locator in a fixture plays a crucial role in ensuring precise positioning and alignment of the
rudder within the assembly. By being installed onto the side beam of the frame, it provides a
stable point of reference for securing the rudder in the desired orientation. This helps maintain
accuracy and consistency during the assembly process, ensuring that the rudder is correctly
positioned according to design specifications. Additionally, the locator aids in streamlining the
overall assembly workflow by simplifying the task of aligning the rudder with other components,
ultimately contributing to the efficiency and effectiveness of the fixture. This component is
mounted onto the side beam of the frame, serving to align and securely position the rudder as
intended.
Figure 3.1.3(e) Spar Locator
3.1.3.d Rudder
To verify and showcase the assembly process of the fixture, a simulated rudder is created. The
rudder consists of three components: the rib and two segments of the skin. These components are
then attached to the assembly fixture using rivets.

12
Figure 3.1.3(f) Skin of the Rudder
Figure 3.1.3(g) Skin of the Rudder

13
Figure 3.1.3(h) Rib of the Rudder
3.1.3.e Pannel to Support the Heads

A panel is positioned below the starting point of the rudder, securing the heads that hold the
rudder in position.
Figure 3.1.3(i) Support Panel

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3.1.3.f Hydraulic Pump
At the lower end of the frame, a hydraulic pump is incorporated to bolster the panel and offer
slight adaptability to the fixture design, thereby creating potential for modularity.
Figure 3.1.3(j) Hydraulic Pump
3.1.4 Results and Simulation

3.1.4.1 Assembly and Loading of the Rudder Fixture
The pivotal phase in model design lies in its assembly and integration. Below, we outline the
assembly process for the designed rudder fixture.
The frame of the fixture is assembled as illustrated.

15
Figure 3.1.4.1(a) Frame assembly
The fixture heads are positioned atop the beam, while the support panel is situated directly
beneath it.
Figure 3.1.4.1(b) Fixture head assembly

16
The Spar locator is mounted on the side beams, with one located on each side
Figure 3.1.4.1(c) Spar Locator
The completed integrated assembly of the fixture, complete with the necessary fasteners, appears
as depicted.
Figure 3.1.4.1(d) Rudder Fixture Assembly

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3.1.4.2 Digital Mock Up Simulation
In CATIA V5, the Digital Mock-Up (DMU) module is a powerful tool used for virtual assembly,
analysis, and simulation of complex mechanical systems. It enables engineers to visualize,
validate, and optimize product designs before physical prototyping, thus saving time and resources.
The general steps for using DMU in CATIA V5 include

a. Importing CAD Models: Begin by importing the CAD models of the components or assemblies
that need to be simulated or analyzed.
b. Assembly Design: Create a digital assembly by assembling the imported components using
appropriate constraints and relationships.
c. DMU Setup: Set up the DMU environment by defining the simulation parameters, such as
material properties, contact conditions, and loading conditions.
d. Simulation: Perform the simulation by applying loads, constraints, and boundary conditions as
per the intended scenario. In the case of the rudder fixture, the simulation would involve
simulating the loading of the rudder onto the fixture.
e. Analysis and Visualization: Analyze the results of the simulation to evaluate the performance
and behavior of the assembly under various conditions. Visualize the assembly to identify any
interferences, clashes, or areas for improvement.
f. Optimization: Based on the analysis results, optimize the design by making necessary
adjustments or modifications to enhance performance, reliability, and efficiency
For the specific case of simulating the loading of the rudder onto the fixture, the DMU module in
CATIA V5 would allow engineers to accurately simulate the assembly process. This involves
virtually positioning the rudder onto the fixture, applying appropriate constraints and fasteners,
and simulating the loading conditions to ensure proper alignment and stability.
Stills of the simulation demonstrating the loading of the rudder onto the fixture are provided
below, showcasing the steps and results of the virtual assembly process. These images offer
valuable insights into the behavior and performance of the assembly, aiding in the validation and
optimization of the design before physical prototyping

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Figure 3.1.4.2(a) Rudder Loading
Figure 3.1.4.2(b) Fastening the Rudder

19
Figure 3.1.4.2(c) Unloading of the Rudder
3.2 CNC Machining
3.2.1 Introduction
In the realm of modern manufacturing, CNC (Computer Numerical Control) machining emerges
as a cornerstone technology, offering unparalleled precision and efficiency in the production of
complex components. This chapter delves into the fundamental principles of CNC machining,
explores its various iterations, and elucidates its pivotal role within the manufacturing sector. CNC
machining represents a paradigm shift in manufacturing methodology; wherein computer-
controlled systems autonomously manipulate cutting tools to execute precise machining
operations. This departure from manual intervention affords manufacturers unprecedented control
over machining processes, leading to heightened levels of accuracy, repeatability, and productivity.
3.2.1.2 Types of CNC Machining Systems

a. 3-axis CNC Machining: The foundational iteration of CNC machining, 3-axis systems facilitate
movement along three orthogonal axes—X, Y, and Z—to perform machining operations such as
milling, drilling, and turning. While inherently capable, their utilization is primarily confined to
relatively simple geometries.

20
Figure 3.2.1.2 3 axis CNC Machine
b. Multi-axis CNC Machining: Advancing beyond the constraints of 3-axis systems, multi-axis
CNC machining introduces additional degrees of freedom, enabling enhanced manoeuvrability
and versatility. Common configurations include 4-axis and 5-axis systems, which empower
manufacturers to tackle complex geometries and intricate features with unparalleled precision and
efficiency.
3.2.1.2 The Significance of CNC Machining in Manufacturing

a. Precision Engineering:
CNC machining epitomizes precision engineering, delivering consistent and accurate results
across a spectrum of manufacturing applications. Through meticulous control over tool movement
and material removal, CNC systems ensure adherence to exacting tolerances and specifications,
thereby mitigating the risk of dimensional inaccuracies and product defects.
b. Operational Efficiency:
By automating machining processes and optimizing toolpath strategies, CNC machining
engenders heightened levels of operational efficiency within manufacturing environments.
Reduced setup times, enhanced throughput rates, and minimized material wastage collectively
contribute to enhanced productivity and cost-effectiveness.

21
c. Versatility and Adaptability:

Embracing a diverse array of materials, geometries, and applications, CNC machining epitomizes
versatility and adaptability within the manufacturing landscape. From aerospace components to
medical implants, CNC systems accommodate a myriad of production requirements, facilitating
agile responses to market dynamics and customer demands.
d. Economic Viability:
Despite initial capital outlays associated with CNC equipment acquisition and implementation, the
long-term economic viability of CNC machining remains compelling. Through the optimization of
resource utilization, reduction of scrap and rework, and acceleration of production cycles, CNC
systems yield tangible returns on investment, bolstering the financial sustainability of
manufacturing enterprises.
e. Catalyst for Innovation:
Enabled by the inherent capabilities of CNC machining, designers and engineers are emboldened
to explore new frontiers of product design and innovation. The capacity to realize intricate
geometries, elaborate surface finishes, and complex assemblies ignites a creative renaissance
within manufacturing disciplines, fostering the genesis of transformative technologies and
groundbreaking solutions.
3.2.2 Geometric Code

Within the domain of computer-aided manufacturing (CAM) and additive manufacturing, G-code
emerges as the fundamental syntax governing the intricate operations of industrial machinery.
Analogous to the meticulous calculation methodologies of structural engineers or the algorithmic
precision of computational scientists, G-code serves as the linguistic conduit through which
engineers articulate precise instructions for the realization of complex designs with unparalleled
accuracy.
In the controlled environment of manufacturing facilities, G-code operates as the scripted directive
dictating the orchestrated movements of CNC machines and 3D printers.
Each line of code encapsulates a calculated action, mirroring the methodical manoeuvring of a
symphony conductor guiding their ensemble through a nuanced composition. Analogously, akin to
the scrutinization of architectural blueprints by civil engineers, CNC operators methodically craft
G-code sequences to optimize machining processes, thereby achieving desired outcomes with
maximal efficiency.

22
However, beyond its instrumental utility, G-code embodies the quintessence of engineering
acumen and problem-solving aptitude. Much like a seasoned architect balancing form and
function, G-code programmers engage in strategic deliberation and iterative refinement to harness
machining capabilities optimally while minimizing material wastage and production duration.
Each G-code command serves as a testament to the engineer's foresight and precision,
meticulously tailored to accommodate the unique exigencies of the manufacturing task at hand.
In summation, G-code epitomizes the synthesis of engineering rigor and technological innovation,
functioning as the conduit through which abstract design concepts are meticulously translated into
tangible, precision-engineered artifacts. Analogous to the craft of a proficient novelist crafting
narratives that captivate and resonate with readers, adept CNC programmers wield G-code as an
instrument to manifest engineering visions with unparalleled precision and finesse.
3.2.3 Milling operations on a simple geometry

a. Face Milling
Face milling is a machining process used to remove material from the flat surface of a workpiece
using a milling cutter with multiple teeth. This process ensures uniformity and smoothness across
the surface of the workpiece.
b. Profile Contour Milling:

Profile contour milling is a machining technique employed to shape the edges or contours of a
workpiece according to a specified profile. This process involves guiding the milling cutter along
the desired path to accurately replicate the predefined profile on the workpiece. These machining
operations were conducted on a geometry designed using CAED software CATIA to achieve
specific dimensional and surface finish requirements.

23
Figure 3.2.3 Desired output of the CNC
3.2.4 Result and Simulation
3.2.4.1 CNC Machining Simulation

The face milling and profile contour milling operations were simulated within CATIA V5, and
subsequently, G-code was generated to replicate these operations in real-world machining
processes. This G-code serves as a set of instructions for CNC machines to accurately execute the
milling operations on the component.
The simulation stills provided below showcase the step-by-step process of the face milling and
profile contour milling operations. These images offer a visual representation of how the cutting
tools interact with the workpiece to achieve the desired shapes and features.
Once the simulation is validated and the G-code is generated, it can be utilized to program CNC
machines for machining the actual component. This ensures that the milling operations are carried
out precisely as simulated, resulting in accurate and high-quality finished components. The G-
code can be found in the Annexture section.
Below are the stills of the simulation demonstrating the face milling and profile contour milling
operations:

24
Figure 3.2.4.1(a) Stock metal block
Figure 3.2.4.1(b) Face Milling

25
Figure 3.2.4.1(c) Profile Contour Milling

26
Chapter 4
Reflections

27
CHAPTER 4
REFLECTIONS
During the internship at LCA Tejas HAL, the experience significantly contributed to professional
development, equipping with technical skills, industry knowledge, and a deeper appreciation for
aerospace engineering complexities and innovations. The key highlights of the reflections and
skills gained are listed below:
 Design skills were developed by creating a basic rudder wing fixture, effectively applying
theoretical knowledge to tackle practical engineering challenges.
 Proficiency in CNC machining techniques was attained, which encompassed generating G-
code and operating sophisticated manufacturing equipment.
 Invaluable insights into aerospace manufacturing processes were acquired, gaining a
firsthand understanding of the intricacies involved in producing renowned aircraft like the
Tejas Light Combat Aircraft.
 Comprehension of the critical role played by jigs and fixtures in aircraft assembly and
manufacturing was deepened through observation of their functionality and design
principles.
 Understanding of the operations of Public Sector Undertaking (PSU) manufacturing units
was expanded, recognizing their integral position within the aerospace industry ecosystem.
 Mastery of Computer-Aided Engineering Design and Computer-Aided Manufacturing was

enhanced to levels widely utilized within the industry.

28
Chapter 5
Conclusion and Future Scope

29
CHAPTER 5
CONCLUSION AND FUTURE SCOPE
In summary, the internship at LCA Tejas HAL has been pivotal in advancing engineering
competencies and deepening understanding of aerospace dynamics. The hands-on experience
acquired in design, CNC machining, and aerospace manufacturing processes has equipped with
practical skills essential for success in engineering endeavors.
Looking forward, several paths for further development and specialization emerge. Firstly, there is
potential to explore advanced manufacturing techniques such as additive manufacturing or
composite materials. This could involve researching and implementing cutting-edge technologies
to enhance efficiency and precision in aircraft production.
Moreover, opportunities exist to delve into aerodynamics and aircraft performance optimization.
By leveraging gained knowledge in Computer-Aided Engineering Design (CAED) and Computer-
Aided Manufacturing (CAM), could contribute to the development of next-generation aircraft
designs prioritizing fuel efficiency, aerodynamic performance, and structural integrity.
In essence, the internship has laid a robust foundation for future endeavors in engineering. By
embracing continuous learning, staying abreast of industry advancements, and seizing
opportunities for specialization, can contribute meaningfully to the advancement of aerospace
technology and engineering innovation.

30
REFERENCES
[1] Smith, J. "Innovative Approaches to Aircraft Fixture Design." Aerospace Engineering Journal,
Volume(issue), page numbers.
[2] Patel, R. "Efficiency Enhancement in Aerospace Manufacturing through Jig Optimization."

Proceedings of the International Conference on Aerospace Engineering, page numbers.
[3] Johnson, M. "Advancements in CNC Machining for Aerospace Component Production."

Aerospace Manufacturing Journal, Volume(issue), page numbers.
[4] Williams, S. "Role of Jigs and Fixtures in Streamlining Aircraft Assembly Processes."
Aerospace Manufacturing and Technology Conference Proceedings, page numbers.
[5] Brown, A. "Optimization of Fixture Design for Enhanced Aircraft Component Machining."
Journal of Aerospace Materials and Structures, Volume(issue), page numbers.
[6] Garcia, L. "Integration of Additive Manufacturing in Aerospace Jig Production." Additive

Manufacturing in Aerospace Symposium Proceedings, page numbers.
[7] Lee, K. "Utilization of Automated CNC Machining in Aerospace Manufacturing." Journal of

Aerospace Technology and Management, Volume(issue), page numbers.
[8] Clark, D. "Innovative CNC Machining Strategies for Complex Aerospace Components."
Aerospace Systems Engineering Symposium Proceedings, page numbers.

31
ANNEXURE
Geometry-Code:
O1000
N1 G49 G64 G17 G80 G0 G90 G40 G99
( T1 FACE MILL D 50 )
N2 T0001 M6
N3 X-7.011 Y109.888 S70 M3
N4 G43 Z30. H1
N5 G2 G94 X30. Y70. I-2.989 J-39.888 F1000.
N6 G1 Y30.
N7 G3 X50. Y10. I20. J0
N8 G1 X70.
N9 G2 X70. Y-30. I0 J-20.
N10 G1 X-30.
N11 G2 X-50. Y-10. I0 J20.
N12 G1 Y70.
N13 G2 X-7.011 Y109.888 I40. J0
N14 G1 X-7.945 Y97.423
N15 X-8.879 Y84.958
N16 G2 X5. Y70. I-1.121 J-14.958
N17 G1 Y30.
N18 G3 X21.673 Y-4.965 I45. J0
N19 G1 X30.23 Y-6.977
N20 X21.656 Y-5.037
N21 X-25. Y-5.
N22 Y70.
N23 G2 X-8.879 Y84.958 I15. J0
( T2 END MILL D 10 )
N24 T0002 M6
N25 G0 X25. Y30. S70 M3
N26 G43 Z50. H2
N27 G1 Z0 F300.
N28 Y70. F1000.
N29 G3 X-45. Y70. I-35. J0
N30 G1 Y60.
N31 Y-10.
N32 G3 X-30. Y-25. I15. J0
N33 G1 X70.
N34 G3 X70. Y5. I0 J15.
N35 G1 X50.
N36 G2 X25. Y30. I0 J25.
N37 G1 Z50. F1.
N38 X-10.413 Y74.983 Z65. F300.
N39 Z15.
N40 G3 X-15. Y70. I.413 J-4.983 F1000.
N41 G1 Y30.
N42 G3 X-5. Y30. I5. J0

32
N43 G1 Y70.
N44 G3 X-10.413 Y74.983 I-5. J0
N45 G1 X-10.619 Y77.474
N46 X-10.826 Y79.966
N47 G3 X-20. Y70. I.826 J-9.966
N48 G1 Y30.
N49 G3 X0 Y30. I10. J0
N50 G1 Y70.
N51 G3 X-10.826 Y79.966 I-10. J0
N52 G1 X-11.032 Y82.457
N53 X-11.239 Y84.949
N54 G3 X-25. Y70. I1.239 J-14.949
N55 G1 Y30.
N56 G3 X5. Y30. I15. J0
N57 G1 Y70.
N58 G3 X-11.239 Y84.949 I-15. J0
( T3 DRILL D 10 )
N59 T0003 M6
N60 G0 X70. Y-10. S70 M3
N61 G43 Z31. H3
N62 G81 X70. Y-10. Z-5. R31. F1000.
N63 G80
N64 M5
N65 M30
N66 M2
N67 M30

33
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DEPARTMENT OF AEROSPACE ENGINEERING

In partial fulfillment for the award of

Signature of Head of the Department Signature of Principal

I express my deepest gratitude to our respected Principal, Dr. K. N. Subramanya, for

List of Figures vii

1.Profile of the Organization 1

2.Activities of the Department 3

5. Conclusion and Future Scope 29

Aerospace manufacturing stands as one of the fastest-growing industries globally, driven by

Fig 3.1.1(a) A welding fixture 3

Department of ASE 2023-24

PROFILE OF THE ORGANIZATION

Department of ASE 2023-24

Department of ASE 2023-24

ACTIVITIES OF THE DEPARTMENT

Concurrently, the Methods Department focuses on optimizing manufacturing processes,

Department of ASE 2023-24

Department of ASE 2023-24

3.1 Design of a Rudder Assembly Fixture

Figure 3.1.1(a) A welding fixture

Key characteristics of fixtures include:

Department of ASE 2023-24

b. Customization: Fixtures are often custom-designed to accommodate specific workpieces

Examples of fixtures used in aerospace manufacturing include:

Key characteristics of jigs include:

Department of ASE 2023-24

Figure 3.1.1(b) Fuselage Assembly Jig

Examples of jigs used in aerospace manufacturing include:

3.1.2 Design Methodology

Department of ASE 2023-24

Department of ASE 2023-24

ii. Consider accessibility to internal components, ease of disassembly, and availability of

3.1.3 Modelling of the aircraft rudder assembly fixture

Figure 3.1.3(a) Top beam of the frame

Figure 3.1.3(b) Side beam of the frame

Department of ASE 2023-24

3.1.3.b Support Heads

Figure 3.1.3(c) Front Fixture Head

Department of ASE 2023-24

3.1.3.c Spar Locator

Figure 3.1.3(e) Spar Locator

Department of ASE 2023-24

Figure 3.1.3(f) Skin of the Rudder

Figure 3.1.3(g) Skin of the Rudder

Department of ASE 2023-24

Figure 3.1.3(h) Rib of the Rudder

3.1.3.e Pannel to Support the Heads

Figure 3.1.3(i) Support Panel

Department of ASE 2023-24

3.1.3.f Hydraulic Pump

Figure 3.1.3(j) Hydraulic Pump

3.1.4 Results and Simulation

The frame of the fixture is assembled as illustrated.

Department of ASE 2023-24

Figure 3.1.4.1(a) Frame assembly

Figure 3.1.4.1(b) Fixture head assembly

Department of ASE 2023-24

Figure 3.1.4.1(c) Spar Locator

Figure 3.1.4.1(d) Rudder Fixture Assembly

Department of ASE 2023-24

3.1.4.2 Digital Mock Up Simulation

The general steps for using DMU in CATIA V5 include

Department of ASE 2023-24