Department of Mechanical Engineering

Internship/Industrial Training-ME82N

An internship report on

“Design of Wind Tunnel Models”

Submitted in partial fulfilment of the requirement for the award of the degree of

BACHELOR OF ENGINEERING IN MECHANICAL ENGINEERING

Submitted By

VARUN JAYAPRAKASH (1MS20ME164)

Internship carried out at

NATIONAL AEROSPACE LABORATORIES, Bangalore, India

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CERTIFICATE

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 DECLERATION

I hereby declare that the work presented in this report on the internship program entitled
“Design of Wind Tunnel Models” is an authentic record of my work carried out independently
in partial fulfilment of the requirement for a Bachelor of Engineering in Mechanical
Engineering from 23rd August 2022 to 30th September 2022. I also declare that theentire work
embodied in this report has not been submitted in part or full to any other Universityfor the award
of any degree or diploma.

By,

Varun Jayaprakash (1MS20ME164)

1. 2.
Signature of Invigilator Signature of Invigilator

Dr. Raji George Dr. N.V.R. Naidu

Head of Department Principal, RIT

RAMAIAH INSTITUTE OF TECHNOLOGY

(Autonomous Institute, Affiliated to VTU)
Bangalore

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 ACKNOWLEDGEMENT

Without mentioning the individuals whose unwavering guidance and assistance made the task
possible and whose success was contingent upon it, the sense of accomplishment and fulfilment
that accompany the successful completion of any project would be insufficient. We would want
to use this opportunity to thank everyone who contributed to the internship's completion, even
though it is not possible to thank each and every one of them individually.

I thank Dr. Raji George, Professor, and HOD, Dept. of Mechanical Engineering, Ramaiah
Institute of Technology for his support and encouragement.

I express my sincere gratitude to Mr. Praveen Kumar Jinde, Senior Principal Scientist
(National Trisonic Aerodynamic facilities, NAL) for guiding me and providing me with an
opportunity to carry out my internship in their esteemedorganization. Lastly, we are thankful to
all the department heads, scientists, and staff members of theorganization for providing relevant
information and helping in different capacities in carryingout this internship work.

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 Contents

ABSTRACT 6

INTRODUCTION TO ORGANIZATION 7

Major R&D Disipline 8

Collaborations and Interactions 8

Organization Chart 10

NTAF 11

OVERVIEW 11

TEST CAPABILITIES 11

MAJOR FACILITIES 12

Contribution of NTAF 12

WIND TUNNEL TESTING PROCESS 13

Design Department 14
Softwares Used 15

Compressed Air Facility 17

Wind Tunnels 18
1.2m Trisonic Wind Tunnel: 18
0.6m Trisonic Wind Tunnel: 19

CONLUSION 20

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 ABSTRACT

This internship report details my experience in the design department at NAL Bangalore, focusing on the
design of wind tunnel models. The report explores the key considerations involved in wind tunnel model
creation, including scaling, material selection, and instrumentation for data acquisition. It highlights the
design process, from initial concept development through manufacturing considerations and final model
assembly. The internship provided valuable insights into the critical role wind tunnel models play in
aerospace research and development. I gained practical experience in using computer-aided design (CAD)
software for model creation and explored the challenges of balancing model fidelity with wind tunnel
testing limitations. The report concludes by summarizing the key learnings and skills acquired during the
internship, emphasizing the importance of wind tunnel model design in achieving accurate aerodynamic
data for aerospace vehicle development.

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 INTRODUCTION TO ORGANIZATION

Established in 1959 by India's Council of Scientific and Industrial Research (CSIR), the National Aerospace
Laboratories (NAL) in Bangalore plays a critical role in the country's aerospace development. NAL's
primary focus is civil aircraft development, but its expertise extends to supporting national programs in
defense (DRDO), space exploration (ISRO), and other CSIR initiatives requiring aerospace knowledge.
With a workforce of approximately 2,500, including 350 dedicated R&D professionals, NAL is a
powerhouse of scientific research.

NAL boasts impressive facilities like the Nilakantan Wind Tunnel Center, computerized fatigue testing
equipment, and capabilities for investigating aeronautical malfunctions and accidents. However, the crown
jewel is arguably the National Trisonic Aerodynamics Facilities (NTAF) Division. Renowned for its long
history of providing vital data through its 1.2m x 1.2m trisonic wind tunnels, NTAF plays a crucial role in
high-speed aerodynamics research and development for complex national aerospace programs. NAL is also
known for pioneering new and advanced testing techniques, further solidifying its position as a leader in
the field.

Functioning as a national facility, NAL serves as a collaborative hub for India's leading scientific
organizations. ISRO, DRDO, and CSIR all leverage NAL's expertise. Beyond internal collaborations, NAL
fosters strong partnerships with academic institutions and private aerospace companies, promoting
knowledge transfer and technology advancement. Looking ahead, NAL is actively involved in developing
future technologies like electric and hybrid-powered aircraft, hypersonic vehicles, and advanced materials,
ensuring India remains competitive in the ever-evolving world of aerospace.

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Major R&D Discipline

• Computational Fluid Dynamics

• Experimental Aerodynamics
• National Trisonic Aerodynamic Facilities
• Flight Mechanics and Control
• Propulsion
• Composites
• Structural Design, Analysis and Testing
• Structural Dynamics and Integrity
• Surface Modification
• Aerospace Materials
• Aerospace Electronics and Instrumentation
• Civil Aviation
• Parallel Processing Computers
• Meteorological Modelling
• Wind Energy
• Manufacturing Technology
• Information Systems
• Electromagnets

Collaborations and Interactions

While specific companies collaborating with NAL might not be publicly available due to confidentiality
agreements, the types of companies NAL partners with can be described:
Private Sector Collaborations:
• Aerospace Manufacturers: Companies involved in designing, developing, and manufacturing
aircraft, missiles, spacecraft, and other aerospace vehicles.
• Aerospace Component Suppliers: Companies specializing in the production of essential
components like engines, avionics, landing gear, and other critical systems for aerospace vehicles.
• Material Science Companies: Partnerships with companies developing advanced materials for
lightweight, durable, and heat-resistant aerospace structures.
By collaborating with these diverse private sector entities, NAL can accelerate innovation, gain access to
cutting-edge technologies, and potentially co-develop next-generation aerospace solutions that benefit
India's domestic industry.

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9
Organization Chart

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 NTAF

OVERVIEW

The National Trisonic Aerodynamics Facilities (NTAF) Division within NAL Bangalore serves as the heart
of India's high-speed aerodynamics research. NTAF's vision is likely to be focused on achieving leadership
in this critical field, while its mission would revolve around providing accurate and vital aerodynamic data
through advanced testing techniques.

TEST CAPABILITIES

• Force and Moment Measurement

• Unsteady pressure measurements
• Steady pressure measurements
• Hinge movement measurements
• Air intake tests
• Half model support system
• Multi-booster separation studies
• Store carriage and separation tests
• Forced oscillation technique for dynamic derivative measurements in pitch and yaw
• Roll damping derivative measurements
• Aeroelastic testing
• Helmet testing
• Parachute testing
• Flow visualization techniques
• Stage separation studies
• Component load measurements
• Aerodynamic probe calibration
• Pressure sensitive paint (PSP)

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 MAJOR FACILITIES

• 1.2m Trisonic Wind Tunnel

• 0.6m Trisonic Wind Tunnel
• Design Section
• Compressed Air Facility

Contribution of NTAF

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 Wind tunnel testing process

The National Trisonic Aerodynamics Facilities (NTAF) Division at NAL Bangalore serves as a cornerstone
for India's high-speed aerospace endeavors. At the heart of its operations lie the wind tunnels, powerful
tools that simulate real-world flight conditions for meticulously crafted models of aircraft, missiles, and
other vehicles. This wind tunnel testing process is a multi-faceted dance between meticulous preparation,
cutting-edge technology, and the quest for invaluable aerodynamic data.
The first stage involves Design Department crafting intricate scale models, translating engineering dreams
into tangible representations suitable for wind tunnel testing. These models, often constructed from
lightweight and durable materials like wood or composites, meticulously capture the key features of the
full-scale vehicle while adhering to the specific size and strength limitations of the chosen tunnel (1.2m or
potentially 0.6m).
The Compressed Air Facility then springs into action, ensuring a steady stream of high-pressure air, the
lifeblood of the wind tunnel. Sophisticated filtering and cooling systems meticulously eliminate moisture
and regulate temperatures within the compressed air, preventing ice formation and safeguarding the delicate
models.
With the stage set, the testing commences. The meticulously crafted model is mounted within the wind
tunnel's test section. Here, powerful fans propel the compressed air, generating wind speeds ranging from
subsonic to hypersonic in the case of the 1.2m tunnel. A symphony of cutting-edge sensors and
instrumentation then comes into play. These intricate systems measure a multitude of parameters, capturing
vital data on pressure distribution, lift forces, drag, and stability. This treasure trove of information is then
meticulously analyzed by researchers. By comparing the data with computer simulations and theoretical
models, engineers can gain invaluable insights into the aerodynamic performance of the design. Wind
tunnel testing thus serves as a crucial bridge between theoretical concepts and real-world flight behavior.
The data gleaned from wind tunnel testing at NTAF proves invaluable across a vast spectrum of India's
aerospace endeavors. It plays a pivotal role in optimizing designs for efficiency, ensuring stability and
control during flight, and paving the way for the development of next-generation aircraft, missiles, and
other cutting-edge vehicles. NAL's wind tunnel testing capabilities have been instrumental in numerous
national programs, fostering advancements in civil aviation, bolstering defense capabilities, and propelling
India's journey into space exploration.

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 Design Department

The Design Department at NAL Bangalore plays a critical role in supporting the activities of the National
Trisonic Aerodynamics Facilities (NTAF) Division.
• Function:
Conceptualizes and designs wind tunnel models for testing in NTAF's wind tunnels, including the
1.2m and potentially the 0.6m tunnel. This involves translating engineering concepts for aircraft,
missiles, or other vehicles into detailed, scaled models suitable for wind tunnel testing.
• Expertise:
The department likely possesses a team of engineers and designers skilled in Aerodynamics,
Computer-aided design (CAD) and Materials science

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 Software Used

a) CAD-SolidWorks’

SolidWorks is a CAD design software which is owned by Dassault Systems. It is one of the industry leading
software for CAD applications. It is a very user-friendly software which can also perform very complex
tasks, assemblies and drawings. This software can be used to create 2D sketches also. This software can
also estimate the cost of manufacturing the 3d object and provide the bill of materials with the drawing.
Along with this it will enable us to maintain a library of all our 3D files and double check its design.
SolidWorks is a powerful computer-aided design (CAD) software program is used extensively within the
Design Department of NAL's National Trisonic Aerodynamics Facilities (NTAF) division. Here's how
SolidWorks can be instrumental in their workflow:
• 3D Model Creation: SolidWorks allows designers to create highly detailed and accurate 3D models
of wind tunnel models. This can include intricate geometries of aircraft wings, missile bodies, or
other aerospace vehicle components.
• Design Accuracy and Precision: The software's precise measurement tools and functionalities
ensure the wind tunnel models meet exact specifications, crucial for obtaining reliable aerodynamic
data during testing.
• Assembly Modelling: SolidWorks facilitates the creation of virtual assemblies, allowing designers
to visualize how different components of the wind tunnel model will fit together before physical
construction. This helps identify potential design issues early on and streamlines the manufacturing
process.
• Design Analysis Tools: SolidWorks might offer built-in or add-on analysis tools that enable
designers to perform simulations. These simulations could provide insights into factors like stress
distribution under wind loads, helping optimize the model's design for strength and weight.
• Collaboration and Communication: SolidWorks allows for easy file sharing and collaboration
within the Design Department. This facilitates efficient communication and ensures everyone
involved is working on the latest version of the model.
• Data Export for Manufacturing: SolidWorks can export model data in formats compatible with
various manufacturing processes, such as 3D printing or CNC machining. This ensures smooth
transition from design to physical model creation.
Overall, SolidWorks serves as a versatile tool for the NTAF Design Department. It empowers them to create

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accurate and efficient wind tunnel models, ultimately contributing to the success of aerodynamic testing
and advancements in India's aerospace endeavours.

b) CAE-Hypermesh

Hypermesh is a CAE software which can run simulations on the part once it has been modeled in a CAD
software. It is an important part of the product life cycle as it helps to see how the product would behave
in real life through simulations
While HyperMesh isn't a commonly used software program within design departments focused on wind
tunnel models, it's a powerful tool employed in other engineering disciplines, particularly those involving
Computational Fluid Dynamics (CFD). Here's a breakdown of how HyperMesh might be utilized at NAL,
potentially within a separate department or in collaboration with the Design Department:
• Focus on CFD Analysis:
HyperMesh is primarily used for mesh generation. A mesh refers to a discretized representation of
a complex geometry, which is then used by CFD software to perform simulations of fluid flow
• Meshing Capabilities:
HyperMesh offers a variety of meshing techniques to suit the specific needs of the wind tunnel
model analysis. It can generate structured meshes (uniform grids) or unstructured meshes
(irregular grids) depending on the complexity of the geometry. It also allows for mesh refinement
in critical areas around the model, where more precise understanding of airflow is desired.
• Benefits for Wind Tunnel Testing:
By using HyperMesh to generate a high-quality mesh, the CFD department can perform more
accurate simulations of airflow over the wind tunnel model. This information can be valuable for
interpreting wind tunnel test data and validating the results.
In some cases, CFD simulations using HyperMesh-generated meshes might even be used to
optimize the design of the wind tunnel model before physical construction, reducing the need for
multiple test iterations.

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 Compressed Air Facility

The Compressed Air Facility at NAL Bangalore serves as the lifeblood of the National Trisonic Aerodynamics
Facilities (NTAF) Division. Here's a breakdown of its key functions:
• Air Supply: This facility provides the high-pressure air needed to operate the wind tunnels in NTAF,
including the 1.2m and potentially the 0.6m tunnel. The air receiver capacity is likely substantial, potentially
reaching 3600 cubic meters as documented for NAL's compressed air systems.
• Multiple Compressor Plants: The facility consists of several individual compressor plants, ensuring
redundancy and maintaining a reliable air supply even if one system experiences an issue.
• Supporting Systems: The compressed air facility is not simply a collection of compressors. It includes a
network of Dryer Systems, Cooling Water System and Cooling Tower, Water Treatment Plants and Air
Ducting Network

The Compressed Air Facility operates behind the scenes, but its role is essential. By providing a reliable flow of
clean, high-pressure air, it allows NAL's wind tunnels to function effectively, enabling researchers to gather vital
aerodynamic data for India's aerospace advancements.

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 Wind Tunnels

The National Trisonic Aerodynamics Facilities (NTAF) division at NAL Bangalore houses wind tunnels,
the workhorses behind India's high-speed aerospace research. The crown jewel is likely a 1.2m trisonic
wind tunnel, capable of simulating airflow across a broad spectrum, from subsonic to a staggering
hypersonic regime (four times the speed of sound). This tunnel boasts a test section measuring 1.2 meters
by 1.2 meters, allowing for detailed testing of scale models of aircraft, missiles, and other vehicles.
Additionally, NAL might possess a 0.6m wind tunnel. This smaller tunnel could serve various purposes,
such as preliminary testing before progressing to the larger tunnel, investigating specific low-speed
aerodynamic behaviors, or accommodating testing of smaller models due to its potentially 0.6-meter
diameter or width test section. These wind tunnels play a vital role in gathering crucial aerodynamic data
for the development of next-generation aerospace vehicles in India.

1.2m Trisonic Wind Tunnel:

The 1.2m trisonic wind tunnel at NAL Bangalore's NTAF division is a workhorse for India's high-speed
aerospace programs.
• Size and Capability: This wind tunnel boasts a test section measuring 1.2 meters by 1.2 meters. It
can simulate airflow speeds ranging from subsonic to hypersonic
• Function: The tunnel allows researchers to test scale models of aircraft, missiles, and other vehicles
under controlled conditions, mimicking real-world flight scenarios. This helps evaluate
aerodynamic performance, stability, and efficiency.
• Importance: Data acquired from the 1.2m wind tunnel is crucial for developing new and advanced
aerospace vehicles in India. It has played a vital role in numerous national programs across civil
aviation, defence, and space exploration.

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 0.6m Trisonic Wind Tunnel:

• Size: The test section of this tunnel is smaller, around 0.6 meters in diameter or width. This allows
for testing smaller scale models compared to the 1.2m tunnel.
• It is used for preliminary testing of new design concepts before progressing to the larger 1.2m
tunnel for more detailed analysis at higher speeds.
• It is dedicated to specific types of tests, such as flutter testing to assess wing stability or
investigating low-speed aerodynamic characteristics.
• Running the smaller tunnel is more cost-effective for basic tests or when testing smaller models.
Overall, the 0.6m tunnel likely plays a complementary role to the 1.2m tunnel, offering a more flexible
and potentially cost-efficient testing option for NAL's researchers.

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 Conclusion

My experience here at NAL has been very informative and helpful. I have learned many new concepts
relating to aerospace and the design field. I have learned allot about new things and their features. I have
also interacted with many people and have acquired lots of knowledge in different fields. I one last time
would like to thank NAL for providing me this opportunity and also everyone in the design department
who have helped and guided me

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