REPORT ON

INDUSTRIAL TRAINING
AT

HINDUSTAN AERONAUTICS LIMITED

HELICOPTER DIVISION
BENGALURU, KARNATAKA

Submitted in partial fulfilment of the requirement

For the award of the
Degree of
Bachelor of Engineering
In
Electronics and Communication Engineering

GLOBAL ACADEMY OF TECHNOLOGY

BENGALURU

Submitted by:
DIVYA K R 1GA15EC036
KRUTHIKA R 1GA15EC058
TEJASHWINI N 1GA15EC146

1|Page
 CONTENTS

1. ACKNOWLEDGEMENT

2. INTRODUCTION TO HAL AND HELICOPTER DIVISION

3. ABOUT ALH FINAL ASSEMBLY

4. MACHINE SHOP

5. PROCESS SHOP

6. WELDING AND SHEET METAL SHOP

7. STRUCTURAL ASSEMBLY

8. BLADE SHOP

9. TRANSMISSION ASSEMBLY

10. HEAT TREATMENT

11. LRU

12. QUALITY AND PROGRAMME ENGINEERING

13. DLE

14. CIVIL HELICOPTER

15. CHEETAH, CHETAK AND CHEETAL HELICOPTERS

16. CONCLUSION

17. REFERENCES

2|Page
 ACKNOWLEDGEMENT

We take the opportunity to express our gratitude to all the concerned people who have
directly or indirectly contributed towards completion of this industrial training. We extend
our sincere gratitude towards HAL for providing the opportunity and resources.

The training work would not have been possible without their support, encouragement and
constructive comments we received from them.
We also thank Mr. G H Raju, senior manager (Public relations) and Mr. Khan for their
support and guidance.

Towards the successful completion of the training, we would like to acknowledge our debt to
our advisors.
We extremely grateful to the chief manager, Mr.Shanthakumar for his kind support and
guidance to successfully complete our training.

We would also like to thank Mr.Kishore Samireddy, senior manager of skid section and all
the employees of Helicopter division HAL, who helped us and co- operated with us during
industrial training.

DIVYA K R
KRUTHIKA R
TEJASHWINI N

3|Page
 INTRODUCTION

About HAL:

The aerospace industry ranks top among the world’s largest manufacturing industries in terms
Of people employed and value of output. The aerospace industry is one of the defining
industries of this century. Aerospace manufacturing is a high-technology industry that
produces aircraft, guided missiles, space vehicles, aircraft engines. Also included among its
concerns are major flight-vehicle subsystems such as propulsion and avionics (aviation
electronics) and key support systems necessary for the testing, operation, and maintenance of
flight vehicles. The Indian Aerospace Industry is witnessing an unprecedented growth.
Hindustan Aeronautics Limited (HAL), which is fully owned by the Government of India, is
the premier aerospace company in the country. HAL has played a major role in the Defence
aviation of India through design, manufacture and overhaul of fighters, trainers, helicopters,
transport
Aircraft, engines, avionics and system equipment. HAL is now ranked 34th in the list of
world’s
Top 100 defence companies.HAL is one of the largest aerospace companies in Asia, HAL has
annual turnover of over USD2 billion. More than 40% of HAL's revenues come from
international deals to manufacture aircraft engines, spare parts, and other aircraft
materials.HAL, a Defence PSU, is a major player in the global aviation arena. It has built up
comprehensive skills in design, manufacture and overhaul of fighters, trainers, helicopters,
transport aircraft, engines, avionics, system equipment and as well as operating airports. HAL
was conferred NAVRATNA status by the Government of India on 22nd June 2007. HAL has
won several International & National Awards for achievements in R&D, Technology,
Managerial Performance, Exports, Energy Conservation, Quality and fulfillment of Social
Responsibilities.

HAL has 20 production divisions for manufacture and overhaul of aircraft, helicopters,
engine and accessories. 10 co-located R&D Canter’s to give a thrust to research
&development, which again are divided into various complexes. Each complex is headed by
a Managing Director (MD).

HAL Corporate:
 Bangalore complex
 Mig complex
 Helicopter complex
 Accessories complex
 Design complex

HAL has its five complex and several divisions in

Bangalore, Nasik, Hyderabad, Kasargod, Lucknow, Kanpur, Korwa, Barakpur,
Koraput and Liaison and offices in Delhi, Chennai, and Visakhapatnam. HAL Nasik and
HAL Koraput come under mig Complex.
HAL’s major supplies/services are to Indian Air Force, Indian Navy, Indian Army,

4|Page
Coast Guard and Border Security Force. Transport aircraft and Helicopters
have been supplied to Airlines as well as State Governments. The Company
has also achieved a foothold in export in more than 20 countries, having demonstrated its
quality and price competitiveness. HAL is a major partner for the Space Vehicle programmes
of the Indian Space Research Organization. It has also diversified into the fields of industrial
& marine gas turbine business and real-time software business.

HELICOPTER DIVISION
Role of Helicopters
Few roles of helicopters are as follows:-
 Warfare
 Army troops transportation
 Air ambulance
 Rescue operations
 Patrolling

Advanced Light Helicopter(ALH-DHRUV)

The Advanced Light Helicopter is a twin engine ,multirole, multi-mission new generation
helicopter in the 5.5 ton weight class .The basic Helicopter is produced in skid version and
wheeled version . DHRUV is “ type-Certified” for Military operations by the centre for

5|Page
Military Airworthiness Certification(CEMILAC) and civil operations by the
Directorate General of Civil Aviation (DGCA).

Role of ALH Training

Roles of ALH training are aa follows:-
 Familiarization of maintenance
 Pre-flight and ground training to pilots
 Training to newly inducted training personnel

Features of ALH
Features of ALH are as follows : -
 Advanced Cockpit
 4-Axis digital Automatic Flight Control System
 6-Axis freedom
 Anti-resonance isolation system
 Bearing less rear motor
 Hinge less main motor

ALH Training Classification

 Airframe: The airframe of an aircraft is its mechanical structure. It is typically
considered to include fuselage, wings and undercarriage and exclude the propulsion
system. Airframe design is a field of aerospace engineering that combines
aerodynamics, materials technology and manufacturing methods to achieve balances of
performance, reliability and cost
 Electrical: ALH is equipped with two electrical systems both DC and AC
1.AC: 115/200V,3-phase,400Hz, AC power is generated by an alternator coupled to
the main gear box. 400Hz frequency is used to make the size smaller or compact in size
2.DC: The DC power specifications is 28A, The DC generator also charges a 24V that
provides a stand by time of 30min
 Power plant: Two types of power plants used in ALH are as following:-
1. TM 333-2B2(for DHRUV MK-I and MK-II)& ARDIDEN 1H1 SHANKTI( for
DHRUV MK-III & MK-IV)
2. Max power is 801 KW
 Avionics: Avionics are the electronic systems used on aircraft, artificial satellites, and
spacecraft. Avionic systems include communications, navigation, the display and
management of multiple systems, and the hundreds of systems that are fitted to aircraft
to perform individual functions
 Instruments: There are two types of instruments system:-
1.Direct Sensing Type: The measured data reaches the system directly from the sensor
module.

6|Page
 2.Remote Sensing Type: The measured data from the sensor is stored
and converted in a subsystem and then further retired.

Customers
Customers of HAL which use ALH are IAF, Navy, Army, Coast guards, Border security force,
Govt. of Jharkhand, ONGC, GSI, Mauritius, Nepal, Afghanistan, Maldives, Namibia, Ecuador
and Suriname

7|Page
 ALH FINAL ASSEMBLY
Final Assembly is the final stage in the manufacture of a helicopter. During final assembly,
subassemblies and other components are installed into the airframe. These parts come from
internal and17external suppliers around the world. Quality checks and operational checks are
performed as assembly progresses. Flight operations include painting defueling of the aircraft,
performing a ground run to ensure proper operation of aircraft systems prior to flight, and
passing flight acceptance tests.

Final assembly begins with receipt of the airframe. The airframe is the basic fuselage structure
of the aircraft and is constructed of sheet metal or, in some cases, composite materials. During
final assembly, subassemblies and other components are installed into the airframe. Systems
installed include the wiring, tail rotor pylon, exhaust systems, engines, transmission, oil cooler,
control systems, and avionics. The final assembly build is comprised of hundreds of
installations to install these systems into the helicopter. Each installation is called an AOS
(Assembly Operation Sequence). Each AOS consists of many operations that must be followed
to ensure proper assembly of the helicopter. These include quality checks performed by the
Quality Assurance (QA) department. If there is a problem with the installation of a component,
QA inspectors record the problem, and it must be fixed before that operation can be completed
and signed off.

The structure of the helicopter is installed with the various systems such as transmission,
electrical, avionics, automatic flight control system, missile system integration and weapon
system integration.
It also includes the mounting of the helicopter blades.
Final paint job and finishing of the helicopter is done as per the requirements of the customer.

8|Page
9|Page
Electrical System
There are 3 main system for electrical power- EPR (electrical power receptacle), generators
and battery.
 EPR provide power to helicopter externally when it is on the ground.
 Generators is the primary source for 28 V DC power and also charges the batteries.
 It is also includes the various lighting installed on the helicopter.
 Integrated Architectural Display has two DMC (display management computer), two
DIU (digital interface unit), two CDS (cockpit display unit) and four MFDs (main flight
display).
 FADEC (fully authority digital engine control) controls the sequence for engine starting
engine idling and engine shutdown. The ALH FADEC control also comes with auto
reflight features which is a system that executes the start up when a previous attempt
has failed, usually used for cold starts.

Avionics
 Intercom which enables the communication between the pilot and the co-pilot.
 HFSSB (high frequency single sideband) communication is used to send messages over
long distances but is rarely used due to excessive interference.
 V/UHF is used to enable the communication exterior to the aircraft
 IFF (identification of friend and foe) is a system that transmit a coded message that
contains the information about the pilot, the squadron he’s flying. A friend aircraft will
have the same system transmit back a message of the same format and a foe aircraft
will not.
 MADRAS also known black box contains two module FDR (flight data recorder) and
CVR (cockpit voice recorder). It can withstand up to 3400g, 260°C for 10 hours and
1100°C for 1 hour.

AFCS (automatic flight control system)

 It contains a PCU (pilot control unit), AFSC computer, AHRS (attitude and heading
reference system), ADU (air data unit), Vertical Gyro and Magnetometer.
 The AFCS has a control module in the cockpit that has the following functions: hold
height, hover height airspeed, turn coordinator and heading.
 It includes subsystem like AFCS and TRIM and it has AHRS/APIRS, BACARA,
RMM, Trim actuator-collective, Trim actuator-pitch, Trim actuator-Roll, Trim
actuator-Yaw

MSI (mission system integration)

 EW (electronic warfare) Suite contains the three sensor i.e. missile, laser and radar in
four quadrants. It can detect an approaching missile radar tracking signal and laser
tracking signals falling on the helicopter.

10 | P a g e
  FCD (flare and chaff dispenser) is a counter measure system that
dispenses high temperature flares or metallic chaffs, to divert heat sinking and metal
seeing missiles respectively.
 HPS (helmet pointing system) comes in the form of HUD (head up display)
manufactured by IAI (Israel aerospace industries).The system comprises of a set of
cameras and laser device that scan the retina of the eye and project a virtual screen.
 EO (electro optical) pod is a spherical module that contains two cameras, one for day
time use and one for night vision.

WSI (weapon system integration)

 Weapon Jettison is a system to designed to dispense all weapons when a crash landing
might occur.

 Turret gun is a gun of capable of firing 300 round at once.

 ALH is capable of carrying the four missiles. The missile firing system is at a default
to fire the outboard missiles first.
 ALH can also carry four rocket launchers that can house 12 rockets.
 Fixed Sight is a system used to guide the missiles. It uses EO pod to pin point the target
and guide the missiles.

Mechanical section
It has flight controls, hydraulics, fuel and power plant, doors, skid, cowling and firewall

 Flight controls: Control from ground stations of airplanes in flight by means of

messages transmitted to the pilot electronically
 Hydraulics: Hydraulics systems in aircraft provide a means for the operation of
aircraft components. The operation of aircraft components. The operation of Fuel
and power plant: It has 5 fuel tanks that has two supply tanks, front main tank,
middle main tank, rare main tank and few contains two additional tanks. It has
reference probes with 8 sensors to check complete low level and it works on the
principle of capacitance
 Doors: Due to the air pressure within the aircraft cabin being higher than that of the
surrounding atmosphere, the door seals itself closed as the aircraft climbs and the
pressure differential increases. Plug doors are used on most modern airliners,
particularly for the small passenger doors
 Skid: Skids are used mainly because they weigh less than wheels. In order to move
a skid-equipped helicopter on the ground, one has to attach a set of ground-handling
wheels, jack up the helicopter, and roll it (into the hangar for maintenance.
 Cowling and Firewall: A cowling is the covering of the vehicle’s engine, most
often found on automobiles and aircraft A firewall is a fire-resistant barrier used to
prevent the spread of fire for a prescribed period of time.

11 | P a g e
 COMPOSITE SECTION
Composite material is made up of 2 or more different materials fabricated together in
an different materials fabricated together in an object for enhancing mechanical
properties like strength, flexibility for technical or constructional use.

 landing gear, flags, flight control surfaces, and brakes is largely accomplished with
hydraulic power systems

Functions of the Department

 Monitor and review information about interested parties and internal or external
issues
 Ensuring proper disposition of parts as per CQAG guidelines
 Ensuring recording, recording, reporting, rectification and analysis of the snaps and
implementation of corrective measures
 Close the findings(NCR) and implement recommendations
 Control of nonconforming components and prevention of counterfeit parts as per
application procedures
 Ensuring that the measuring instruments, gauges fitted to equipments test rigs are
calibrated and bear calibration label. Tools and fixtures as called for in the process/
procedure sheets are used during assembly
 Ensuring that all the aircraft items remain identified throughout the assembly
sequence and proper handling of parts during all the stages of assembly
 Ensure the systems procedures and practices to detect, control and prevent FOD
during build and handling of helicopters

12 | P a g e
 MACHINE SHOP
A machine shop is a room or building where machining is done. In a machine shop machine
tools and cutting tools to make parts, usually of metal or plastic or other materials such as glass
or wood is used. The parts produced can be the end product of the factory to be sold to the
customers in the machine industry, the car industry, the aircraft industry or others. In other
cases companies in those fields should have their own machine shops.
The production can consist of cutting, shaping, drilling, finishing, and other processes. The
machine tools typically include metal lathes, milling machines, machining centres,
multitasking machines , drill presses, or grinding machines , many controlled with CNC. Other
processes, such as heat treating , electroplating or painting of the parts before or after
machining are often done in a separate facility . A machine shop can contain some raw
materials (such as bar for machining) and an inventory of finished parts. These items are often
stored in warehouse.

CNC Machines
A numerical control system in which data handling, control sequences, and response to input
is determined by an on-board computer system at the machine tool. In general CNC stands for
Computer Numerical Control. Its uses G-code or M-code

G-code is one of a number of computer code languages that are used to instruct CNC machining
devices what motions they need to perform such as work coordinates, canned cycles, and
multiple repetitive cycles. The industry has standardized on G-code as its basic set of CNC
machine code.
CNC programming software creates program codes and instructions used to run a machine tool
controlled by a computer. Each unique part requires its own CNC program.

Operations in Machine Shop

Various types of operations performed in machine shop are following: -
 Turning
 Grinding
 Taper Turning
 Gear Cutting

13 | P a g e
  Milling
 Drilling
 Boring

Turning
Turning is a machining process in which a cutting tool, typically a non-rotary tool bit, describes
a helix toolpath by moving more or less linearly while the workpiece rotates. The tool’s axes
of movement may be literally a straight line, or they may be along some set of curves or angles,
but they are essentially linear. The cutting of faces on the workpiece, whether with a turning
tool, is called “facing”, and may be lumped into either category as a subset. CNC lathes are
able to make fast precision cuts, generally using indexable tools and drills. They are similar to
CNC mills and can often read G-code as well as the manufacture’s proprietary programming
language. CNC has three axis (X, Y and Z) , but newer models have more axis allowing for
more advanced jobs to be machined

Grinding
Grinding is an abrasive machining process that uses a grinding wheel as the cutting tool. A
wide variety of machines are used for grinding are: -
 Hand-cracked knife-sharpening stones(grindstones)
 Handheld power tools such as angle grinders and die grinders
 Various kinds of expensive industrial machine tools called grinding machines
 Bench grinders often found in residential garages and basement

Taper Turning
When the diameter of apiece changes uniformly, from one end to the other, the piece is said to
be tapered . Taper turning as a machining operation is the gradual reduction from one part of
the cylindrical workpiece to another part. Tapers can be either external or internal.

14 | P a g e
Gear Cutting
Gear cutting is any machining process for creating a gear. The most common gear-cutting
processes include broaching, milling and grinding. Such cutting operations may occur either
after or instead of forming processes such as forging, extruding, investment, casting, or sand
casting.

Milling
Milling is the machining process of using rotary cutters to remove material from a workpiece
by advancing in a direction at an angle with the axis of the tool. It covers a wide variety of
different operations and machines on scales from small individual parts to large, heavy–duty
gang milling operations. It is one of the most commonly used processes in industry and
machine shops today for machining parts to precise sizes and shapes.
Milling machines are of three types: -
1.Horizontal Milling Machine
2.Vertical Milling Machine
3.Universal Milling Machine

Drilling
Drilling is the cutting process that uses a drill bit to cut a hole of circular cross-section in solid
materials. The drill bit is usually a rotary cutting tool, often multipoint. The bit is pressed
against the workpiece and rotated at rates from hundreds to thousands of revolutions per
minute. This forces the cutting edge against the workpiece, cutting off chips from the hole as
it is drilled

Boring
In machining, boring is the process of enlarging a hole that has already been drilled by means
of a single-point cutting tool, such as in boring a gun barrel or an engine cylinder. Boring is
used to achieve greater accuracy of the diameter of a hole, and can be used to cut a tapered
hole. Boring can be viewed as the internal-diameter counterpart to turning which cuts external
diameter

15 | P a g e
PROCESS SHOP
The surface finishing processes are been covered in process shop.
Surface finishing is a broad range of industrial processes that alter the surface of a
manufactured item to achieve a certain property. Finishing processes may be employed to:
improve appearance, adhesion or wettability, solderability, corrosion resistance, tarnish
resistance, chemical resistance, wear resistance, hardness, modify electrical conductivity,
remove burrs and other surface flaws, and control the surface friction.

Surface finishing processes

Few of surface finishing process are described below

Metal Plating:
Metal plating machines use a chemical bath to coat or alter the surface of a substrate with a
thin layer of metal, such as nickel, silver, copper & cadmium. The electroplating method
generates an electric current to coat the substrate, while electrolyte plating employs an
autocatalytic process in which the substrate catalyzes the reaction. Metal plating provides a
number of advantages as a finishing process. It can improve a product’s durability, corrosion
resistance, surface friction, and exterior appearance. It is also a useful option for coating other
metals. In high-volume production runs, a barrel-finishing machine is a fast and efficient
plating solution. However, plating machines are generally not suited for smoothing out surface
defects.
Anodizing:
Anodizing is an electrochemical process that converts the metal surface into a decorative,
durable, corrosion-resistant, anodic oxide finish. Aluminium is ideally suited to anodizing,
although other nonferrous metals, such as magnesium and titanium, also can be anodized. The
anodic oxide structure originates from the aluminium substrate and is composed entirely of
aluminium oxide. This aluminium oxide is not applied to the surface like paint or plating, but
is fully integrated with the underlying aluminium substrate, so it cannot chip or peel. It has a
highly ordered, porous structure that allows for secondary processes such as colouring and
sealing.
Pickling:
Pickling is a metal surface treatment used to remove impurities, such as stains, inorganic
contaminants, rust or scale from ferrous metals, copper, precious metals and aluminium alloys.
A solution called pickle liquor, which contains strong acids, is used to remove the surface
impurities. It is commonly used to descale or clean steel in various steelmaking processes.
Powder coating:
Powder coating applies a decorative finish that is similar to paint, but with greater durability.
The process involves melting dry plastic powder onto the metal to produce a textured, matte,

16 | P a g e
or glossy coating. A textured powder-coating machine is also highly effective
in removing surface defects
Abrasive blasting:
Abrasive blasting is the operation of forcibly propelling a stream of abrasive material against
a surface under high pressure to smooth a rough surface, roughen a smooth surface, shape a
surface, or remove surface contaminants. A pressurized fluid , typically compressed air, or a
centrifugal wheel is used to propel the blasting material

Sandblasting:
Sand-blasting machines are typically employed in projects requiring a uniform matte texture.
The process (also known as beadblasting) forces sand, steel shots, metal pellets or other
abrasives into a substrate at high speed. This results in a smooth, clean product texture,
particularly in soft metals.

Polishing:
Polishing and buffing are finishing processes for smoothing a workpiece's surface using an
abrasive and a work wheel or a leather strop. Technically polishing refers to processes that use
an abrasive that is glued to the work wheel, while buffing uses a loose abrasive applied to the
work wheel. Polishing is a more aggressive process while buffing is less harsh, which leads to
a smoother, brighter finish.

Superfinishing:
Superfinishing, also known as micromachining, microfinishing, and short-stroke honing, is a
metalworking process that improves surface finish and workpiece geometry. This is achieved
by removing just the thin amorphous surface layer left by the last process with an abrasive
stone or tape; this layer is usually about 1μm in magnitude. Superfinishing, unlike polishing
which produces a mirror finish, creates a cross-hatch pattern on the workpiece.
Choosing a Metal Finishing Process
There are a few considerations that can help to narrow the choices in selecting a metal finishing
technique suitable for the project. Some helpful things to keep in mind are :-
 Production speed & Process speed

 Cost-effectiveness: Certain finishing machines (such as vibratory tumblers) can be

expensive, but may compensate for their price by delivering faster cycle rates
 Metal hardness: Harder metals usually require more intense finishing techniques, like
grinding, or may need tougher abrasives than those used on those used on softer
materials

17 | P a g e
WELDING & SHEET METAL SHOP
Welding
Welding is a fabrication process that joins materials, usually metals or thermoplastics, by
causing fusion. In addition to melting the base metal, a filler material is typically added to the
joint to form a pool of molten material (the weld pool) that cools to form a joint that is usually
stronger than the base material. Pressure may also be used in conjunction with heat, or by itself,
to produce a weld.
Manufacturing nearly any modern product involves joining various separate components.
When a permanent joint is required welding is commonly used.
Different types of energy sources can be used for welding includes gas flames, electric arc,
laser, electron beam, friction & ultrasound.

Figure : Electric Arc welding Figure : welding symbols

There are two categories of welding process:
Fusion welding: The surface of two components to be joined are cleaned placed close together
and heated, forming a pool of molten metal that connects the components. A filler rod may be
used to add metal to the joint.
Pressure welding: A pressure welding process in which macro deformation of the base
material to produce coalescence results from the application of heat and pressure. Pressure
welding usually involves heating the surfaces to a plastic state and then forcing the metal
together. The heating can be by electric current of by friction resulting from moving one surface
relative to the other.

Types of welding
Types of welding which are available in HAL are:
 Gas welding
 Electric Arc Welding
 TIG (Tungsten Inert Gas ) Welding
 Spot Welding

18 | P a g e
Gas Welding:
Oxy-fuel welding (commonly called oxyacetylene welding, oxy welding, or gas welding in the
U.S.) and oxy-fuel cutting are processes that use fuel gases and oxygen to weld and cut metals.

In oxy-fuel welding, a welding torch is used to weld metals. Welding metal results when two
pieces are heated to a temperature that produces a shared pool of molten metal. The molten
pool is generally supplied with additional metal called filler. Filler material depends upon
metals to be welded. Oxy-fuel processes may use a variety of fuel gases, the most common
being acetylene.

Figure : Gas welding

Other gases that may be used are propylene, liquefied petroleum gas (LPG), propane, natural
gas, hydrogen, and MAPP gas. Many brands use different kinds of gases in their mixes.

Electric Arc Welding:

Arc welding is a process that is used to join metal to metal by using electricity to create enough
heat to melt metal, and the melted metals when cool result in a binding of the metals. It is a
type of welding that uses a welding power supply to create an electric arc between an electrode
and the base material to melt the metals at the welding point. They can use either direct (DC)
or alternating (AC) current, and consumable or non-consumable electrodes.
TIG Welding:
Tungsten Inert Gas (TIG) welding, is an arc welding process that uses a non-consumable
tungsten electrode to produce the weld. The weld area and electrode is protected from oxidation
or other atmospheric contamination by an inert shielding gas. A constant-current welding
power supply produces electrical energy, which is conducted across the arc through a column
of highly ionized gas and metal vapours known as a plasma.

19 | P a g e
 Figure : T.I.G welding

Spot welding:
Resistance spot welding (RSW) is a process in which contacting metal surfaces are joined by
the heat obtained from resistance to electric current. Work-pieces are held together under
pressure exerted by electrodes. The process uses two shaped copper alloy electrodes to
concentrate welding current into a small "spot" and to simultaneously clamp the sheets
together. Forcing a large current through the spot will melt the metal and form the welded

Figure : Spot welding method Figure : Spot welding process

Sheet Metal
Sheet metal is metal formed by an industrial process into thin, flat pieces. It is one of the fundamental
forms used in metalworking and it can be cut and bent into a variety of shapes. Countless everyday
objects are fabricated from sheet metal. Thicknesses can vary significantly; extremely thin thicknesses
are considered foil or leaf, and pieces thicker than 6 mm (0.25 in) are considered plate.
There are different types of sheet metal processes available in HAL Bangalore are: -

Bending:

20 | P a g e
Bending is a manufacturing process that produces a V-shape, U-shape, or
channel shape along a straight axis in ductile materials.
Punching:
Punching is performed by placing the sheet of metal stock between a punch and a die mounted in a
press. The punch and die are made of hardened steel and are the same shape. The punch is sized to be
a very close fit in the die. The press pushes the punch against and into the die with enough force to cut
a hole in the stock

Figure : Bending Machine Figure : Punching Machine

21 | P a g e
 STRUCTRAL ASSEMBLY
Types of Helicopter Construction
It can be divided into 3 categories such as
1) Tubular construction
2) Stressed construction
3) Bonded construction
Tubular Construction
This type of structure is still in use in many lightweight aircraft using welded steel tube trusses.
A box truss fuselage structure can also be built out of wood—often covered with plywood.
Simple box structures may be rounded by the addition of supported lightweight stringers,
allowing the fabric covering to form a more aerodynamic shape, or one more pleasing to the
eye. Eg. Cheetah, Cheetal.

Figure : Truss-Type design

Stressed Skin construction:

It can be used under semi-monocoque or monocoque.
High strength to weight ratio than tubular construction.
 Semi-monocoque: It consists of frameworks of vertical and horizontal members
covered with metal skin. Vertical members are called bulkhead and formers provide the
shape of fuselage

Figure : Semi-Monocouque

22 | P a g e
  Monocouque: Its construction involves the construction of tubes and
cones without internal structural members. It’s is necessary to have formers to maintain
the shape but it’s the stressed skin that carries the principle stress imposed upon the
structure. Eg.-Chetak, Chetaal.

Figure : Monocouque

Bonded construction:-
In this type of construction the structural parts are joined together by the chemical methods.
Fibre glass, honeycombs and other composite materials that are used in the structure by the use
of adhesive, heat and pressure. Eg. - Dhruv, LCH

Different sections of helicopter structure

Different sections of helicopter structure are as follows

Figure : Helicopter Structural parts

 Body structure: It is the main structural member of the fuselage. It does not only
carries the load and thrust but also the landing load. It support all other member directly

23 | P a g e
 or indirectly. Transmission assembly main rotor is also support by this.
In the middle of this structure fuel tank is placed.
 Bottom structure: It’s made up of two cantilevered beam extending from the box to
the cross members of the box. The two beam carry the weight of the cabin and transmit
it to the box. The cabin section is directly attached to the floor.
 Cabin section: It’s made almost entirely from synthetic material. It’s heat moulded and
assembled by ultra-sonic spot welding or riveted to the cabin floor and bulkhead.
 Rear section: Connects to the body section. It’s made up of 3 frames connected by the
beam to the body section. This frame covered with firewall material and act as an
attachment point of the engine. Tail boom section is also bolted to the rear section.
 Tail boom section: It consists of tail rotor which provides both the anti-torque and
direction. It also includes the drive shaft, tail gear box, vertical fins, horizontal
stabilizers, and tail skid. It’s of conventional design-circular frames, longerons and
outer skins.

Figure : Tail Boom Section

 Vertical and Horizontal Stabilizers: Fin is bolted to the tail boom at leading edge and
spar of section of the fin. It is protected by the tail rotor guard. Horizontal stabilizers
produces downward forces to keep the helicopter level in forward flight. It passes
through slot and in the tail boom and bolted on each side.

24 | P a g e
 BLADE SHOP
Blade shop consist of the following: -
 Manufacturing of MRB and TRB
 Repairing of MRB and TRB
 Static balancing tests for MRB and TRB

Procedure for Blade Manufacturing

The MRB & TGB for Cheetah and Cheetal (further modification of Cheetah Helicopter) are
been manufactured and repaired for these Aircrafts. The process of manufacturing of MRB is
described in steps below:-
 0.4 mm thick sheet of Aluminium alloy (having ASTM B289)
 Vapour Blasting with air, water, sand.
 Sulfochromic pickling to remove excess water, sand, oil or grease.
 Folding the sheet into desired shape (symmetric airfoil-NACA0012) with the help of
jigs and a mechanical press (using dead weight).
 Adding steel cuff and spar with the help of adhesive filling and heating it at 60°C for
15 min.
 Filling the inner space with moltoprenefoam material.
 Applying liquid araldite at the opening and let it heat at 165°C for 2 hours in oven for
bonding,
 Let it cool and get riveted and for providing the twist angle (6°) again heat it at 60°C
for 5 hours with the help of UV bulbs in a specific mould.
 Paint will be done after letting the blade cool.
 After paint static balancing will be done and some weight will be added at the tips of
the blades (4gm to 40gm each).
 Protective casing will be added and all the screws and rivets are applied and sent for
the dynamic test.
 For dynamic test the blade will be mounted on the transmission test unit and vibration
tests will be performed and some free weight will be added on the certain points.
 Now the last part of blade manufacturing the necessary markings will be done to denote
the blade type and design year and manufacturer logo.

Figure : Cross-section of blade

25 | P a g e
Servicing
The ideal life of a single blade is about 6000 hours or 20 years but need to check after 4-5
years. In repairing of the blades static and dynamic test takes place if the blades are been having
any inner problems the disassembly of the blades takes place and the whole procedure
mentioned above is repeated

26 | P a g e
 TRANSMISSION ASSEMBLY
The transmission system transfers power from the engine to the main rotor, tail rotor, and other
accessories. The main components of the transmission system are the main rotor transmission,
tail rotor drive system, clutch, and freewheeling unit. Helicopter transmissions are normally
lubricated and cooled with their own oil supply. A sight gauge is provided to check the oil
level. Some transmissions have chip detectors located in the sump. These detectors are wired
to warning lights located on the pilot’s instrument panel that illuminate in the event of an metal
shavings are detected, indicating an internal problem.

Figure : Helicopter Parts

Main Rotor Transmission

The primary purpose of the main rotor transmission is to reduce engine output RPM to optimum
rotor RPM. Suppose the engine speed of a specific helicopter is 2,700 RPM. Achieving a rotor
speed of 450 RPM would require a 6 to 1 reduction. A 9 to 1 reduction would mean the rotor
would turn at 300 RPM. Most helicopters use a dual-needle tachometer to show both engine
and rotor RPM or a percentage of engine and rotor RPM. The rotor RPM needle normally is
used mostly during clutch engagement to monitor rotor acceleration and in autorotation to
maintain RPM within prescribed limits. See figure 3-1. In helicopters with horizontally
mounted engines, another purpose of the main rotor transmission is to change the axis of
rotation from the horizontal axis of the engine to the vertical axis of the rotor shaft. The primary
purpose of the main rotor transmission is to reduce engine output RPM to optimum rotor RPM.
Suppose the engine speed of a specific helicopter is 2,700 RPM. Achieving a rotor speed of
450 RPM would require a 6 to 1 reduction. A 9 to 1 reduction would mean the rotor would turn
at 300 RPM. Most helicopters use a dual-needle tachometer to show both engine and rotor
RPM or a percentage of engine and rotor RPM. The rotor RPM needle normally is used mostly
during clutch engagement to monitor rotor acceleration and in autorotation to maintain RPM
within prescribed limits. In helicopters with horizontally mounted engines, another purpose of
the main rotor transmission is to change the axis of rotation from the horizontal axis of the
engine to the vertical axis of the rotor shaft.

27 | P a g e
 Figure : Main rotor system

Tail Rotor Drive System

The tail rotor drive system consists of a tail rotor drive shaft powered from the main
transmission and a tail rotor transmission mounted at the end of the tail boom. The drive shaft
may consist of one long shaft or a series of shorter shafts connected at both ends with flexible
couplings. This allows the drive shaft to flex with the tail boom. The tail rotor transmission
provides a right angle drive for the tail rotor and may also include gearing to adjust the output
to optimum tail rotor RPM

Figure : Tail rotor system

Clutch
Owing to the greater weight of a rotor in relation to the power of the engine, as compared to
the weight of a propeller and the power in an airplane, the rotor must be disconnected from the

28 | P a g e
engine when you engage the starter. A clutch allows the engine to be started and
then gradually pick up the load of the rotor. On free turbine engines, no clutch
is required, as the gas producer turbine is essentially disconnected from the power turbine.
When the engine is started, there is little resistance from the power turbine. This enables the
gas producer turbine to accelerate to normal idle speed without the load of the transmission and
rotor system dragging it down. As the gas pressure increases through the power turbine, the
rotor blades begin to turn, slowly at first and then gradually accelerate to normal operating
RPM. On reciprocating helicopters, the two main types of clutches are the centrifugal clutch
and the belt drive clutch.
 Centrifugal Clutch: The centrifugal clutch is made up of an inner assembly and an
outer drum. The inner assembly, which is connected to the engine driveshaft, consists
of shoes lined with material similar to automotive brake linings. At low engine speeds,
springs hold the shoes in, so there is no contact with the outer drum, which is attached
to the transmission input shaft. As engine speed increases, centrifugal force causes the
clutch shoes to move outward and begin sliding against the outer drum. The
transmission input shaft begins to rotate, causing the rotor to turn, slowly at first, but
increases as the friction between the clutch shoes and transmission drum increases. As
rotor speed increases, the rotor tachometer needle shows an increase by moving toward
the engine tachometer needle. When the two needles are superimposed, the engine and
the rotor are synchronized, indicating the clutch is fully engaged and there is no further
slippage of the clutch shoes.
 Belt Drive Clutch: Some helicopters utilize a belt drive to transmit power from the
engine to the transmission. A belt drive consists of a lower pulley attached to the engine,
an upper pulley attached to the transmission input shaft, a belt or a series of V-belts,
and some means of applying tension to the belts. The belts fit loosely over the upper
and lower pulley when there is no tension on the belts. This allows the engine to be
started without any load from the transmission. Once the engine is running, tension on
the belts is gradually increased. When the rotor and engine tachometer needles are
superimposed, the rotor and the engine are synchronized, and the clutch is then fully
engaged. Advantages of this system include vibration isolation, simple maintenance,
and the ability to start and warm up the engine without engaging the rotor.

Freewheeling Unit
Since lift in a helicopter is provided by rotating airfoils, these airfoils must be free to
rotate if the engine fails. The freewheeling unit automatically disengages the engine
from the main rotor when engine RPM is less than main rotor RPM. This allows the
main rotor to continue turning at normal in-flight speeds. The most common
freewheeling unit assembly consists of a one-
way “sprag” clutch located between the engine and main rotor transmission. This is
usually in
the upper pulley in a piston helicopter or mounted on the engine gearbox in a turbine
helicopter. When the engine is driving the rotor, inclined surfaces in the sprag clutch
force rollers against an outer drum. This prevents the engine from exceeding
transmission RPM. If the engine fails, the rollers move inward, allowing the outer drum
to exceed the speed of the inner portion. The transmission can then exceed the speed of

29 | P a g e
the engine. In this condition, engine speed is less than that of the drive
system, and the helicopter is in an autorotative state.

30 | P a g e
 HEAT TREATMENT SHOP
Heat Treatment
Heat treating is a group of industrial and metal working processes used to alter the physical
and sometimes chemical, properties of a material. The most common application metallurgical.
Heat treatments are also used in the manufacture of many other materials such as glass. Heat
treatment involves the use of heating or chilling, normally to extreme temperatures, to achieve
a desired result such as hardening or softening of a material.

Heat treatment techniques

 Annealing: Annealing is the process by which the properties of steel are enhanced to
meet machinability requirements. Annealing is a process of heating the steel slightly
above the critical temperature of steel (723 degrees Centigrade) and allowing it to cool
down very slowly.
 Case hardening(Carburizing): Case-hardening or surface hardening is the process of
hardening the surface of a metal object while allowing the metal deeper underneath to
remain soft, thus forming a thin layer of hard metal (called the “case”) at the surface.
 Precipitation strengthening: Precipitation hardening, also called age hardening, is a
heat treatment technique used to increase the yield strength of malleable materials,
including most structural alloys of aluminium, magnesium, nickel, titanium, and some
steels and stainless steels. In super alloys, it is known to cause yield strength anomaly
providing excellent high-temperature strength.
 Tempering: Tempering is a process of heat treating, which is used to increase the
toughness of the iron-based alloys. Tempering is usually performed after hardening, to
reduce some of the excess hardness and is done by heating the metal to some
temperature below the critical point for a certain period of time, then allowing it to cool
in still air.
 Normalizing: Normalization is a process that relieves stress on steel this improves
ductility and toughness in steels that may harden after the cold working process.
 Quenching: Quenching is the rapid cooling of a workpiece to obtain certain material
properties. A type of heat treating, quenching prevents undesired low-temperature
processes, such as phase transformations, from occurring.

Furnace Types
 Box-type furnace: Many basic box type furnaces have been upgraded to a semi-
continuous batch furnaces are a very commonly used piece of equipment for heat-
treating

Figure : Box-type furnace

31 | P a g e
 Pit furnaces: Furnaces which are constructed in a pit and extend to
floor level or slightly above are called pit furnaces. Workpieces can be suspended from
fixtures, held in baskets or placed on bases in the furnace. Pit furnaces are suited to
heating long tubes, shafts and rods by holding them in a vertical position

Figure : Pit furnace

 Salt bath furnaces: Salt bath are used in a wide variety of heat treatment processes
including neutral hardening, liquid carburizing, liquid nitriding, austempering,
martempering, tempering. Parts are loaded into a pot of molten salt where they are
heated by conduction, giving a very readily available source of heat. The core
temperature of the part rises in temperature at approximately the same rate as its surface
in a salt bath.

Figure : Salt bath furnace

 Vacuum furnaces: A vacuum furnace is type of furnace in which the product in the
furnace is surrounded by a vacuum during processing. The absence of air or other gases
Prevents oxidation, heat loss from the product through convection and removes a source
of contamination. This enables the furnace to heat materials to temperature as high as
3,000 degree Celsius with select materials.

32 | P a g e
 Figure : vacuum furnace

 Muffle Furnace: A muffle furnace (sometimes retort furnace in historical usage ) is a

furnace in which the subject material is isolated from the fuel and all the products of
combustion, including gases and flying ash.

Figure : Muffle furnace

33 | P a g e
 LRU
1. AHRS: An attitude and heading reference system (AHRS) consists of sensors on
three axes that provide attitude information for aircraft, including roll, pitch and yaw.

2. APIRS: The APIRS is an attitude and heading reference system and the first link in
an integrated flight control chain.

3. Annunciator panel: An annunciator panel, also known in some aircraft as the

Centralized Warning Panel (CWP), is a group of lights used as a central indicator of
status of equipment or systems in an aircraft, industrial process, building or other
installation.

4. Automatic Flight Control System (AFCS): An aircraft autopilot with many

features and various autopilot related systems integrated into a single system is called
an automatic flight control system (AFCS). These were formerly found only on high-
performance aircraft. Currently, due to advances in digital technology for aircraft,
modern aircraft of any size may have AFCS.

5. BACARA: BACARA is portable Solution to coordinate and control field artillery

fire ground -ground, for battery - powered equipped. Used at the battery command
level, it figures out the best firing solution from a fire request by computing the firing
data for each gun of the battery. It may also be used at the battalion command level,
in order to figure out the best available means for the mission, among deployed units.

6. Magnetometer: A magnetometer is an instrument that measures magnetism either

the magnetization of a magnetic material like a ferromagnet, or the direction,
strength, or relative change of a magnetic field at a particular location. A compass is
a simple type of magnetometer, one that measures the direction of an ambient
magnetic field.

7. Pilot Control Unit: It is usually located between the pilot's legs, but on some
helicopters, it is a central pillar that either pilot can manipulate. The control is called
the cyclic because it changes the pitch angle of the rotor blades cyclically.

8. RMM: Remote monitoring and management (RMM), also known as network

management or remote monitoring software, is a type of software designed to help
managed IT service providers (msps) remotely and proactively monitor client
endpoints, networks and computers.

9. Trim Actuators: Four rotary Trim Actuators provide full control of Pitch, Roll,
Yaw and Collective axis for automatic flight. The Trim Actuators are connected in

34 | P a g e
 parallel with pilot flight control input (cyclic stick, collective Lever
and pedals) and have the full travel authority on the flight control lines.

10. Control and Display System (CDS): Full glass cockpit with 4 or 5 multi-
function displays and stand-by instruments. Compatible with NVG (Night Vision
Goggles) and helmet mounted display system. Inter-seat and overhead console. The
cockpit is an integrated workstation for the pilot/co-pilot.

11. Data Interface Unit: The Data Interface Unit (DIU) is a rack mounted device
that collects multiple analog signals from the aircraft engines and converts them to
digital format. Our DIU has the ability to processes other aircraft signals such as
flight surface position, fuel quantity, autopilot drive, proximity sensors, plus several
others. It outputs data over an industry standard data bus that interfaces to a
multifunctional cockpit display. Data is also outputted directly to the Flight Data
Recorder via analog or data bus signals. The DIU features redundant signal
processing to provide reliable data gathering and is capable of storing engine
parameter data to aid in trend monitoring and exceedance tracking.

12. Display and Mission Computer (DMU): General Dynamics Display

Mission Computer (DMC) is the nerve center of the helicopter. The mission
computers provide pilots with the ability to see and control the battlefield with the
advanced situational awareness and combat systems control that is necessary to
complete their missions. The DMC is a high-performance, COTS-based, open
systems architecture product, and is configurable to any operating environment.

13. Multi Function Display (MFD): A MFD is a small-screen (CRT or LCD)

surrounded by multiple soft keys (configurable buttons) that can be used to display
information to the user in numerous configurable ways. Mfds originated in aviation,
first in military aircraft, and later were adopted by commercial aircraft, general
aviation, automotive use, and shipboard use. The advantage of an MFD over analog
display is that an MFD does not consume much space in the cockpit, as data can be
presented in multiple pages, rather than always being present at once.

14. AC Monitor Box: The AC-Monitor (ACM) shows all interesting values of the
AC voltage supply on board. When the AC voltage is detected by the transducer unit,
the current voltage, frequency and the power will be displayed. The integrated
monitoring function constantly monitors the values of current and voltage. Using the
built-in buzzer, the AC-Monitor alarms when one of the monitored values goes out
of the range. The required supply voltage for operation of the transducer comes
directly from the measured line.

35 | P a g e
15. Static Inverter: Static Inverters are supplied at power levels
ranging from 20VA single phase to 37.5kva three phase. Lightweight, small size and
high reliability are achieved with the use of high frequency switching circuitry.
Inverters are designed to operate in the most stringent environments. Units are
qualified to meet FAA and military standards for mission critical equipment.
Applications range from large-scale commercial air transport, corporate and private
aircraft to ground mobile shelters and forward area military back-up power.

16. Battery Junction Box: It is useful for locating frequently accessed wires to an
easily accessible location. Also great for use with relocated batteries. It has one red,
one black stud.

17. AC Master Box: It performs data acquisition system of NI make. It has mounted
Voltmeters, Ammeters, Frequency meters and Transducer.

18. DC Master Box: DC master box can be designed to customer’s requirements in a

modular concept. Integrated control boards will manage reconfiguration and
interface with external avionics. Special SSPC solutions can be part of the design for
28V secondary power distribution systems, procuring weight savings, reliable power
control and optimized cost.

19. Centralized Warning Panel: The Centralized Warning Panel (CWP) is a

group of lights used as a central indicator of status of equipment or systems in
an aircraft, industrial process, building or other installation.

20. Engine Fail Warning Unit: A red engine warning light tells the pilot that the
aircraft have a potentially serious problem, possibly a complete failure of one or
more things that can result in damage to your engine if he continue to drive.

21. Fuel Tank Probes: The capacitance transmitted by all of the probes in a tank is
totaled and compared in a bridge circuit by a microchip computer in
the tank's digital fuel quantity indicator in the cockpit. As the aircraft maneuvers,
some probes are in more fuel than others due to the attitude of the aircraft.

22. Fire Detection Unit: In the most advanced applications, the detection
system circuitry controls all aircraft fire protection functions, including fire
detection and extinguishing for engines, apus, cargo bays, and bleed-air systems.
Some smaller turboprop aircraft are outfitted with pneumatic single point detectors.

23. Fuel Dumping: Fuel dumping (or a fuel jettison) is a procedure used by aircraft in
certain emergency situations before a return to the airport shortly after takeoff, or

36 | P a g e
 before landing short of its intended destination (emergency landing)
to reduce the aircraft's weight.

24. On Board Inert Gases Generation System (OBIGGS): The OBIGGS is a

system composed of well-proven equipment generating directly Nitrogen on board to
fully protect the aircraft tanks against explosion. Autonomous, it does not require any
logistics.

25. Hydraulic Pressure: Hydraulic systems are commonly used to raise and lower
landing gear, operate flight controls, apply brakes, and more. Sufficient pressure in
the hydraulic system developed by the hydraulic pump is instruments, causing the
gyroscopes to spin.

26. Engine Limit Indicator: The processing resource associated with

the indicator determines a ratio of the manifold pressure of the engine to the
currently available maximum five-minute MP limit or to the maximum available MP,
whichever is most limiting, and displays the ratio to the pilot.

27. Engine Oil Temperature and Pressure Indicator: The oil pressure and
temperature sensor OPS+T is used to measure the absolute oil pressure and the oil
temperature directly in the main oil channel behind the oil filter. It uses the pressure
value to properly control mechanical or electrical oil pumps.

28. GYRO HORIZON: A gyro -

operated flight instrument that shows the pitching and banking attitudes of an aircraft
or spacecraft with respect toa reference line horizon, within limited degrees of move
ment, by means of the relative position of lines or marks on theface of the instrument
representing the aircraft and the horizon. Also known as automatic horizon.A device
, such as a spirit level or pendulum, that establishes a horizontal reference in a naviga
tion instrument.

29. Instruments:

 AC ammeter
 AC voltmeter
 Aircraft clock
 Cyclic neutral indicator
 DC ammeter
 DC voltmeter
 Dual tachometer
 Fuel display unit
 ISIS

37 | P a g e
30. Warnings:
 Audio warning generator
 Rotor warning indicator
 Standby CWD

31. Lighting System:

 Dual filament landing light
 Retractable landing light
 Search light

32. Navigation and RADAR System:

 ADF (Automatic Direction Finder)
 FDR/CVR (Flight Data Recorder/ Cockpit Voice Recorder)
 RADAR (Radio Detection and Ranging)
 RADIO (Remote Audio Discrete Integrated Oscillations)

33. Radio Communication:

 HFSSB- Power Amplifier /Antenna coupler
 INTERCOM system
 Radio

34. Transmission System:

 MGB (Main Gear Box)
 TGB (Tail Gear Box)
 IGB (Intermediate Gear Box)

35. Windshield System:

 Wind wiper system
 Wiper head

38 | P a g e
 QUALITY & PROGRAMME ENGINEERING
Quality
Engineers and test operators commonly use data acquisition hardware and software to verify
functionality and ensure the quality of finished goods. This may include a wide range of
manual or automated electrical, mechanical, or environmental tests. The following case
studies illustrate the reliability, accuracy, and flexibility provided by data acquisition
hardware and LabVIEW software for manufacturing and quality test. The challenge is of
ensuring high quality of manufacturing increases when the manufacturing of your products
are been done in other locations of your company or by a subcontractor. In both cases, your
control over quality of process is limited. Product testing seeks to ensure that consumers can
understand what products will do for them and which products are the best value. Product
testing is a strategy to increase consumer protection. Quality assurance (QA) is a way of
preventing mistakes or defects in manufactured products and avoiding problems when
delivering solutions or services to customers; which ISO 9000 defines as "part of quality
management focused on providing confidence that quality requirements will be fulfilled"
Quality assurance comprises administrative and procedural activities implemented in a
quality system so that requirements and goals for a product, service or activity will be
fulfilled. It is the systematic measurement, comparison with a standard, monitoring of
processes and an associated feedback loop that confers error prevention. This can be
contrasted with quality control, which is focused on process output. Quality assurance
includes two principles: "Fit for purpose" (the product should be suitable for the intended
purpose); and "right first time" (mistakes should be eliminated). A includes management of
the quality of raw materials, assemblies, products and components, services related to
production, and management, production and inspection processes. The two principles also
manifest before the background of developing (engineering) a novel technical product: The
task of engineering is to make it work once, while the task of quality assurance is to make it
work all the time.

Programme 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 customers’
requirement & organizational guidelines. It is responsible for project progress, central
scheduling, availability of machines and raw material.

39 | P a g e
 DLE
It applies knowledge of design principles to assess and resolve product/process issues through
the product lifecycle. Analysis, conducts root cause analysis and develops dispositions for
design non-conformances. Applies engineering principles to research technical, operational
and quality issues that cannot be resolved by customer and designs interim and final
engineering solutions. Identifies documents, analyses reported problems and communicates
deviations that could impact design intent and safety; recommends and manages resolution.
Develops and implements product/process improvements. Supports Integrated Product Teams
(IPT) and participates in design reviews. Represents the engineering community in the build
through post production environment. Ensures supplier and build partner compliance with
standards. Develops customer correspondence for continued safe operation and maintenance
of equipment. Participates in on-site disabled product repair teams and accident investigation
or support team. Analysis damage repair or structural modification to determine appropriate
jacking and shoring, prevent collateral damage and assure a safe work environment. Designs
interim structural repairs and conducts static strength analysis. Develops non-destructive test
procedures, tools and standards. Conducts simple static strength analysis.
 Coordinates activities to evaluate and resolve engineering-related production
problems encountered in assigned area of aircraft manufacturing facility: Reviews
production schedules, engineering specifications, orders, and related information to
maintain current knowledge of manufacturing methods, procedures, and activities in
assigned area.
 Confers with quality control, material, manufacturing, and other department personnel
to provide technical support.
 Interprets engineering drawings and facilitates correction of errors on drawings and
documents identified during manufacturing operations.
 Investigates reports of defective, damaged, or malfunctioning parts, assemblies,
equipment, or systems to determine nature and scope of problem.
 Examines, measures, inspects, or tests defective part for conformance to engineering
design drawings or blueprint specifications, using precision measuring and testing
instruments, devices, and equipment.
 Consults with project engineers to obtain specialized information.
 Evaluates findings to formulate corrective action plan and coordinates implementation
of plan.
 Maintains records or oversees recording of information by others to ensure
engineering drawings and documents are current and that engineering-related
production problems and resolutions are documented

40 | P a g e
 CIVIL HELICOPTERS
To exploit the national and international market potential in the 4 to 5 ton weight class, Civil
Variant of ALH was taken up. It is mainly intended to be used in the transport role,
commuter, offshore as well as VIP roles. Additional roles such as emergency medical service,
rescue, utility, law enforcement are also envisaged. First flight of ALH civil variant was
carried out successfully on 6th Mar’2002 & demonstrated at Aero-India 2003 and 2005.
Certification for Civil wheel version was obtained in Oct.’03 and for civil Skid Version
obtained in Jul.’04. PT-2 basic version was converted to Air Ambulance version and
demonstrated during Aero India 2001. Further, ALH capabilities were successfully
demonstrated in Chile with IAI-LAHAV’s centralized avionics package. After the successful
Type certification of ALH civil variant upto five ALH civil helicopters are in service with
various operators like ONGC, IAI, BSF, GSI and Govt. of Jharkhand. The revalidation of
ALH civil variant Type Certificate with DGAC, Chile has been completed in April 2007.
This is the first re-validation accorded by any foreign airworthiness authority to an Indian
Aircraft.
The certification with EASA is under progress and FAA is being pursued

MK-I
It is a Utility Version with Conventional Cockpit & 2B2 Engine, its specifications are
described below:
 Max take-off Weight: 5500 Kg
 Fuel Capacity: 1055 Kg
 Useful Load: 2490 Kg
 Never exceed speed: 295 km/h
 Service Ceiling: 6500 m
 Under Slung: 1500 Kg

Mk-II
It is a Utility Version with Glass Cockpit & 2B2 Engine, its specifications are described
below:
 Max take-off Weight: 5500 Kg
 Fuel Capacity: 1055 Kg
 Never exceed speed: 292 km/h
 Useful Load: 2100 Kg
 Service Ceiling: 6500 m
 Under Slung: 1500 Kg

Civil variants
Dhruv (C): Also known as ALH-Civil, a Turbomeca TM333-2B2-powered 12-seat
helicopter, type certificate issued on 31 October 2003.

41 | P a g e
Dhruv (CFW): A Turbomeca TM333-2B2-powered 12-seat helicopter fitted
with wheels, type certificate issued on 20 April 2005. Dhruv (CS): A
Turbomeca TM333-2B2-powered 12-seat helicopter fitted with skids, type certificate issued
on 30 July 2004. Garuda Vasudha: A Dhruv outfitted with a heliborne geophysical survey
system (HGSS).

Figure : MK-I

Figure : MK -II

42 | P a g e
 Figure : MK-III

Figure – MK-IV

43 | P a g e
Figure : DHRUV

Figure : LUH

44 | P a g e
Figure : LCH

45 | P a g e
CHEETAH, CHETAK, CHEETAL HELICOPTERS
 CHEETAH HELICOPTER
HAL signed license agreement for Cheetah with M/s SNIAS in 1970. First Cheetah
manufactured from raw materials was delivered in 1976-77.
The Cheetah Helicopter (identical to LAMA SA 315B Helicopter of Euro copter, France) is a
high performance helicopter designed for operation over a very wide range of weight, centre
of gravity and altitude conditions. The five seated Cheetah helicopter is versatile, multi role,
multipurpose, highly maneuverable and rugged in construction. It holds the world record in
high altitude flying among all categories of Helicopters.
The helicopter is powered by Artouste - III B turbo shaft engine.
The helicopter is suitable for commuting, observation, surveillance, logistics support, rescue
operations and high altitude missions.
Till date, HAL has produced and sold more than 275 of these versatile Helicopters which are
in service both in India and abroad. Recently, HAL has received orders for Cheetah
helicopters from mod Namibia.

 CHETAK HELICOPTERS
HAL, Helicopter Division started manufacturing of helicopters in 1962, by entering an
agreement with M/s SUD-AVIATION (Presently M/s AIRBUS (Former EUROCOPTER),
France) for production of Aloutte III helicopters (Chetak). The first Chetak (Aloutte III) in
‘Fly Away’ condition delivered in 1965.

The Chetak Helicopter is a two ton class helicopter. The seven seated Chetak helicopter is
versatile, multi role, multipurpose, and spacious.

The helicopter is powered by Artouste - III B turbo shaft engine.

The helicopter is suitable for commuting, cargo / material transport, casualty evacuation,
Search & Rescue (SAR), Aerial Survey & Patrolling, Emergency Medical Services, Off-
shore operations and under slung operations.

Till date, HAL has produced and sold more than 350 of these versatile Helicopters which are

46 | P a g e
 in service both in India and abroad. Recently, HAL has received orders for
Chetak helicopters from MOD Namibia & mod Suriname.

 CHEETAL HELICOPTERS
Cheetal is the re-engined version of the Cheetah helicopter. The project initiated during 2002
and aimed to enhance high altitude operational capabilities and maintainability as well as to
provide a mid-life upgrade for safe & reliable operations.

Artouste-IIIB engine of Cheetah was replaced with the modern fuel efficient TM333–2M2
engine with FADEC for better performance. In addition, an automatic Backup Engine
Control system (EBCB) is equipped with engine.

Salient features:

 Quicker start-up and easier re-light procedure.

 Improved reliability and easier handling of engine.
 Higher thermal margins resulting in better climb performance at high altitudes.
 Lower noise levels.
 Lower specific fuel consumption (SFC) provides - Higher payload, Better range and
Increased Endurance
 Cheetal has been designed to incorporate upgraded features such as light weight electrically
driven Artificial Horizon, Directional Gyro, Flight Monitoring System (FMS), Cockpit Voice
Recorder (CVR), Modular Warning Lights, Master Flasher Warning and modern electrical
system.
HAL has delivered 1st production batch of 10 Cheetal helicopters and in operation by Indian
Air Force at LEH region. Helicopter is in production for other operators.

47 | P a g e
48 | P a g e
 CONCLUSION
During training period, a lot of experience, knowledge and exposure. All disclosures were
awakening us in a boost of self-confidence to face life more challenging now. Practical is a
complement to the science or theory learned. This is clearly the concept of science and
technology, where they have learned without practice will be lost and will not give anything -
what effect. So if we do without the knowledge of course there will be problems in terms of
grip and stance ever - changing.

During our industrial training, there are many changes from the point of learning
environments and discussion among colleagues. It can directly increase the dedication and
rational attitude .

However, there are still some weaknesses that can be improved in the future. Therefore we
conclude that the industrial training program has provided many benefits to students even if
there are minor flaws that are somewhat disfiguring condition , so that this weakness can be
rectified in the future.

The training gives a very deep knowledge about manufacturing of Helicopter. Various
branches of engineering merge to manufacture structurally/ technologically advanced
helicopters.

49 | P a g e
 REFERENCES
 www.hal-india.com/Product_Details.aspx?Mkey=54&lKey=&CKey=24
 https://en.wikipedia.org/wiki/HAL_Dhruv
 http://www.hal-india.com/Helicopter%20Complex/M__124
 http://www.hal-india.com/Rotary%20Wing/M__147
 https://www.faasafety.gov/gslac/ALC/course_content.aspx?cID=105&sID=461&prev
iew=true

50 | P a g e