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VISVESVARAYA TECHNOLOGICAL UNIVERSITY
JNANASANGAMA, BELAGAVI-
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
1KG15ME
Internship Carried Out at
HINDUSTAN AERONAUTICS LIMITED
AIRCRAFT DIVISION
BANGALORE COMPLEX
VIMANAPURA POST BANGALORE-
Internal Guide External Guide
Mr. VIJAY CHANDAN Mrs. B AROCKIA JYOTHI
Asst. Professor Senior Manager (HR)
KSSEM, Bengaluru AIRCRAFT DIVISION HAL
DEPARTMENT OF MECHANICAL ENGINEERING
K S SCHOOL OF ENGINEERING AND MANAGEMENT
# 15, Mallasandra, Off. Kanakapura Road, Bengaluru-
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K S SCHOOL OF ENGINEERING AND MANAGEMENT
Bengaluru-
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 1KG15ME
In partial fulfilment for the award of Bachelor of Engineering in Mechanical Engineering of the Visvesvaraya Technological University, Belagavi during the year 2018-19. It is certified that all corrections/suggestions indicated for Internal Assessment have been incorporated in the Report deposited in the departmental library. The internship report has been approved as it satisfies the academic requirements in respect of internship work prescribed for the said Degree.
.. Signature of the Guide Signature of the Guide (External) Mr. VIJAY CHANDAN Mrs. B Arockia Jyothi Asst. Professor Senior Manager (HR) Dept. of Mechanical Engg. Aircraft Division HAL KSSEM, Bengaluru – 109 Bangalore – 560 017 .. 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 – KSSEM, Bengaluru – 109
External Viva Name of the Examiners Signature with date
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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.
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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.
1.1 BREIF HISTORY
The Company which had its origin as the Hindustan Aircraft Company was incorporated on 23 Dec 1940 at Bangalore by Shri Walchand Hirachand a farsighted visionary in association with the Government of Mysore with an Authorized Capital of Rs.4crores (Paid up capital Rs.40 lakhs) and with the aim of manufacturing aircraft in India. In March 1941, the Government of India became one of the shareholders in the Company holding 1/3 of its paid- up capital and subsequently took over its management in 1942. Hindustan Aeronautics Limited (HAL) came into existence on 1st October 1964. The Company was formed by the merger of Hindustan Aircraft Limited with Aeronautics India Limited and Aircraft Manufacturing Depot, Kanpur. HAL is a fully owned Government of India undertaking under the administrative control of Ministry of Defense, Department of Defense Production. H.A.L is the largest Public Sector Unit (PSU) under the department of Defense production and is a Navaratna Company. The Company takes up maintenance and overhaul services to cover the life cycle requirement of all the old and new products. Presently, 13 types of aircraft/ helicopters and 17 types of engines are being overhauled. In addition, facilities exist for repair/ overhaul of various accessories and avionics fitted on aircraft of Russian, Western and Indigenous designs. HAL is currently meeting the requirements of structures for aerospace launch vehicles and satellites of ISRO t h r o u g h its dedicated Aerospace Division. Infrastructure has also been set up to undertake completed assembly of the strap-on L-40 stage booster. Structures for GSLV Mk III have been produced. HAL has also contributed to Mars mission by supplying
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:
- Dhruv- Advanced Light Helicopter – Weapon System Integration (ALH-WSI)
- Tejas - Light Combat Aircraft (LCA)
- Intermediate Jet Trainer (IJT)
- Light Combat Helicopter (LCH)
- Various military and civil upgrades.
1.2 DIVISIONS OF H.A.L
There are several divisions under Hindustan Aeronautical Limited. They are as under: Bangalore complex
- Aircraft Division Bangalore.
- Overhaul Division Bangalore.
- Aerospace Division Bangalore.
- Engine Division Bangalore.
- IGMT Division Bangalore.
- Aircraft Services Bangalore.
- Foundry and Forge Bangalore.
- Facilities Management Bangalore. Mig complex
- Aircraft Division Nasik.
- Engine Division Koraput.
- Aircraft Overhaul Division Nasik.
- Sukhoi Engine Division Koraput. Accessories complex
- TAD-Kanpur Division.
- Hawk Mk 132- Advanced Jet Trainer. Helicopters
- Dhruv (ALH).
- Cheetah.
- Chetak.
1.4 AIRCRAFT DIVISION
Aircraft Division was established in the year 1940. Since inception, the Division has manufactured a variety of Aircraft both license as well as indigenously designed and developed. The Division is equipped with modern infrastructure in Plant and Equipment like CAD-CAM Manufacturing Engineering, Quality Assurance and Customer support System with 2179 highly skilled personnel including more than 511 officers working in a covered area of 2,25,000sq.m. The Division has so far manufactured over 2010 aircrafts of various types. With experience and capabilities built over past seven decades, the Aircraft Division is bidding for substantial share in the International Aeronautical market. Apart from 1st of Hawk Mk 132 Aircraft (66 Nos.), the division has signed contract with Indian Air Force and Indian Navy to supply additional 57 Hawk Aircraft (40 Hawk for Indian Airforce and 17 Hawk for Indian Navy). Components manufactured
- Structural sub-assemblies such as Doors, Pylons, Fairings, Drop Tanks, Control Structures, etc.
- Precision sheet metal forming (Cold or Hot Forming) of Aircraft components out of Light alloys.
- Honeycomb Sand witch bonded structures, metal-to-metal bonded components, Composite components in Carbon, Kevlar, etc.
- Glass Fiber Reinforced Plastic components like Fairings, Ducts, Pipes, etc.
- Aircraft Transparencies like Windshields, Canopies, Helicopters Panel, etc.
- Electrical Cable Looms (Harnesses).
- Landing Gears. Products
- Hawk Mk 132- Advanced Jet Trainer.
- HJT-Kiran Mk I, Mk II (IJT).
- Jaguar.
- HJT-36 Sitara - Intermediate Jet Trainer (IJT).
- 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 Organization
Oil & Natural Gas Cooperation of India Ordnance Factory Board Bharat Heavy Electricals Ltd.
Minor customers
- Airbus Industries, France.
- Boeing, USA.
- GE Aviation, USA.
- Israel Aircraft Industries, Israel.
- Nepal Army, Nepal.
- Rolls Royce Plc, UK.
- Royal Malaysian Air Force, Malaysia.
- Roseboro export, Russia.
- Vietnam Air Force, Vietnam.
- Honeywell International, USA.
- 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.
- 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.
A Sample ROUTE BOOK Work order Part number Quantity Department
Part name: Bolt Outsource details
Next assembly part number
Raw material detail Alternate material Manufacturing inspection Metal code: Spec: 35NCD16UTS-1230/1380MPa
Batch no-
Nom: 25mm diameter steel rod Size:
inspection Sign
Operation no/dept Tool no/Operation description quantity shop inspection Inspect material (35 NCD16 UTS-1230/ MPa) HRC: 38.3 – 42. Actual hardness HRC: 40 – 41 Caution: material is prone to corrosion, protect with oil between operations Machining operations- Tools Turning, facing, step turning Inspection
Grind the shank to required diameter (cadmium plating allowance added on shank diameter) Thread rolling Thread rolling Chamfer for Thread rolling De-burring, remove sharp edges
Stress relieve at 190^0 ±10^0 C, 1-3 hrs. Date: Time in: Time out: Inspection Vapor degrease – cadmium plating – De- embrittlement at 1900 C Inspection Magnetic particle inspection and demagnetize Degrease, clean thoroughly, ultrasonic clean Dichromate passivation Inspection and issue tag Stock in stores in polythene bag Serial no: date:
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
- It plans the targets on the basis of tasks from customers and finalizes the production plan and involves production control.
- Prepares the schedules for sequential operations to produce a finished product.
- Loading of raw materials, fabricating the products.
- Turning.
- Facing.
- External threading.
- Knurling.
- Drilling.
- Boring.
- Tapping.
- Reaming.
- Counter boring.
- Chamfering. Drilling machines
- Bench or sensitive drilling machines.
- 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
- Vertical milling machine (6 m/c).
- Horizontal milling machine (6 m/c).
- Heavy duty milling machine (7 m/c).
- 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
- Surface grinding machine. i. Horizontal spindle type with reciprocating table. ii. Vertical spindle type with reciprocating table.
- Center type cylindrical grinding machine.
- Centerless type cylindrical grinding machine.
- Internal grinding machine.
- External grinding machine.
CNC machines
- CNC turn mill Centre
2.4 EXPORT ASSEMBLY SHOP
HAL’s cost-effective and widespread skills are available to the International Aerospace Community. HAL has proven capabilities and offers collaborative arrangements in the areas of manufacturing of machine components, design and development tasks (Structural analysis, 3D modeling and testing). Parts manufactured in export shop are assembled in this shop with help of nut &bolt, rivets & PRC (used to avoid leakage). The current undergoing projects are: -
- Airbus A320 Forward Passenger Doors.
- Boeing 777 Up lock Box Assembly. AIRBUS A320 forward passenger door assembly The single aisle (SA) passenger door is precision ICY item, which is suited to an ICY media and fitted on aircraft directly. This door is common for fall range of single aisle aircraft family i.e. A318, A319, A321. Components of door includes 7 NC machined beams and cross members which are joined to build the box type structure and finally wrapped with outer skin with precisely controlled counter sinking and riveting to form the complete structure. The door is equipped with precision mechanism for controlling effortless though fully equipped door weighs about 89 kgs. Division has equipped with capacity and knows how to supply customized doors, customization means supplying doors to airlines requirement by directly accessing airbus data base and configuring the doors to the airlines predefined customization. Doors are directly being delivered to final assembly line at station Nazaire France. Airbus has recognized HAL as a ―major subcontractor.
Steps for airbus a320 passenger door assembly
- Sub assembly forward and after edge member assembly, Upper, lower and cross beam assembly.
- Build structure by joining these sub-assemblies on the door skin by rivets, apply the PRC and painting is to be done.
BOEING 777 uplock box assembly Uplock box assembly is attached to main landing gear wheel well and is used to secure the main landing gear of being 777 aircraft in closed position. Components of box include web assemblies, stiffness, fittings and brackets made out of aluminum sheets, extrusions and plates. Landing gear hook and latch into the up-lock box when landing gear is up and door are closed for flight. It carries weight of the closed landing gear door during flight. In addition to supporting the closed gear door, the up lock also has two emergency functions: -
- The box has to be strong enough to support the weight of the landing gear, if the gear control system should loose hydraulic pressure and the landing gear releases in the closed wheel well.
- If there is a tire burst in the wheel well, the support box has to be robust enough to resist damage and to retain function after side, bending, and bursting loads. One ship set contains 2 up lock boxes (LH & RH). Over all dimension: 21× 13× 45 in inches. Weight: 18 kgs Fabrication of tools, assembly jigs and detail components as well as inspection have been accomplished through NC data supplied by Boing. HAL is the single source for boing for supplying this structure assembly as shown in figure 2. Special process approvals
- Heat treatment of Al alloys
- Sulphuric acid (H 2 SO 4 ) anodizing (for aluminum type II)
- Chromic acid anodizing of Al type I
- Chromic acid anodizing of Al class 1&
- Chemical conversion coatings on Al (immersion alloy)
- Cadmium plating type I & type II
- Magnetic particle inspection
- penetrant inspection
- chemical milling of Al type I & II
- Mechanical testing
- Metallurgical testing
- Process solution control
- Salt spray testing
- Anodizing aluminum
Figure 2: -Boeing 777 uplock Assembly (source: -https://goo.gl/images/Ey27UA)
2.5 NC SHOP AND NC PROGRAMMING
Numerical control (NC) is the automation of machine tools that are operated by precisely programmed commands encoded on a storage medium, as opposed to controlled manually via hand wheels or levers, or mechanically automated via cams alone. Most NC today is computer numerical control (CNC), in which computers play an integral part of the control. Machining operations like drilling, milling is done using NC programing as shown in figure- 3.NC is not run by codes but instructions are entered by manual.
- Parts are designed using software CATIA & UNIGRAPHICS. To program the CNC machines, we use APT (Automatic Programmed Tool) source. It is used to calculate the path which the tool must follow in order to generate the desired part.
- The resulting compiled file (in the form of G codes and M codes) is then run by the machine to move the tool accordingly in space. IFS software is used for NC programming, which is supplied by SAP Labs.
- 3 axes (the tool holder gives 3 degrees of freedom to the tool) and 5 axes (the tool holder gives 5 degrees of freedom to the tool) CNC (Computer Numeric Control) machines are used to machine the components. There are three parts to be specified for any NC machine, to produce a part:
- Tool geometry- the type and specifications of the tool to be used.
- Part geometry- the geometry of the end product.
- Methods-The instructions fed into the machine for the tool to move in space and produce the desired part.
