PROFESSIONAL TRAINING

Hindustan Aeronautics Limited

Helicopter Division, Bangalore-560017

Submitted to

BY:-

KAMAL KUMAR
ENROLLMENT NO:- 118526393
BTAE
HINDUSTAN AVIATION ACADEMY
I would like to offer my sincerest thanks and deepest appreciation to all those who
helped me to complete my training with a bunch of useful knowledge. I also offer a
very special thanks to “HAL, HELICOPTER DIVISION” for giving me such a
golden opportunity of grateful stay in its industry as a trainee. I also thank my
department HOD “Mr. Ramakrishna Reddy” for his time to time suggestions about
the fields we can opt for in our future interest as an Aerospace Engineer. I also pay
my sincere thanks to my lecturer (Aircraft Safety And Maintenance) “Mr.
MUKHARJEE” for being my soul inspiration towards my training in helicopter
division as he continuously monitored me with all the available suggestions about
how good and exciting once career can be in the field of rotary wing mechanism
and that helped me a lot in setting my approach towards this professional training.
I will also greet my special thanks to all colleague trainees and staff members, who
treated me as their junior and helped me on every aspect.

It was a pleasure stay at HAL under the guidance of our division manager, who
always had time for me and other trainee.
INTRODUCTION:

This report entails the industrial work experience scheme carried out by me as the
purpose of partial fulfillment of the requirements given by SCHOOL OF
ENGINEERING AND TECHNOLOGY, INDIRA GANDHI NATIONAL OPEN
UNIVERSITY for obtaining a B. Tech. degree in Aerospace Engineering. The
primary objective of the scheme is detailed comprehension of the theoretical
approach to learning in the university and the practical understanding of what is
obtained in the industry. The industry here in particular is the “HAL
HELICOPTER DIVISION” and I have been trained under the helicopter BLADE
MANUFACTURING DEPARTMENT & ALH final assembly.

Blade manufacturing department undertakes the repairing and manufacturing of

helicopter blade series 30 & 85.Helicopter blade series 30 & Helicopter blade
series 85 are widely used in helicopter like Chetak & Cheetah. The designs of this
are performed in multiple stages involving detailed calculations and complex
analysis to provide maximum safety & best efficient airflow over it to give the best
performance possible in the air. HAL manufactures these blades for Chetak &
cheetah Helicopters, which is used for civil and military operations. BLADE SHOP
manufactures these blade series after passing through various processes and then
after various checks like static and dynamic balancing, it is delivered to Chetak &
cheetah Helicopter assembly.

ALH Final Assembly looks after the assembling & equipping of ALH (Advanced
Light Helicopter).
HAL is engaged in design, development, manufacture, repair and overhaul of ALH
named 'DHRUV'. DHRUV is a light 5.5 tonne class, multi-role, multi-mission
helicopter, fitted with two Turbomeca TM333 2B2 engines.
The advanced technologies incorporated in the ALH design include
 Automatic Flight Control (AFC)
 Anti-Resonance Vibration Isolation System (ARIS)
 Full Authority Digital Electronic Control (FADEC)
 Hinge Less Main Rotor
 Bearing Less Tail Rotor
 Integrated Dynamic System (IDS)
ORGANISATION
ABOUT ORGANISATION

Hindustan Aeronautics Limited (HAL) established as Hindustan Aircraft in 1940,

based in Bangalore, India, is one of Asia's largest aerospace companies. The
primary engineering divisions that this industry possess are manufacturing,
assembling & Diagnosis. HAL built the first military aircraft in South Asia. The
primary engineering divisions that HAL currently possess are designing,
fabrication and assembly of aircraft, jet engines, and helicopters, as well as their
components and spares.

Hindustan Aeronautics Limited (HAL) was formed on 1 October 1964 when

Hindustan Aircraft Limited joined the consortium formed in June by the IAF
Aircraft Manufacturing Depot, Kanpur and the group recently set up to
manufacture Mig-21 under license . Though HAL was not used actively for
developing newer models of fighter jets, the company has played a crucial role in
modernization of the Indian Air Force. In 1957 company started
manufacturing Bristol Siddeley Orpheus jet engines under license at new factory
located in Bangalore.
During the 1980s, HAL's operations saw a rapid increase which resulted in the
development of new indigenous aircraft such as the HAL Tejas and HAL Dhruv.
HAL also developed an advanced version of the MiG-21, known as MiG-21 Bison,
which increased its life-span by more than 20 years.
TRAINING PERIOD (27th june2014 -16th july2013)

A brief discussion on the assignments given and training undergone during this
period follows.

Assignments carried out & completed Section where assignment

Dates was carried out

27th june  Introduction to helicopter & Blade Shop

importance of MRB & TRB in its
functioning
 Explanation about Types & Anatomy of
Helicopter Blades

28th june  Basic study of anatomy of Helicopter Blade Shop

Blade used in Chetak & cheetah
Helicopters
 A brief inspection & introduction about
machines, materials, chemicals,
composites and instruments to be used
in manufacturing of Helicopter Blade
series 30 & 85
th
29 june- Manufacturing stages (Main Rotor Blade) : Blade Shop
st
1 july  De-greasing of metallic sheet
 Soaking
 Folding(by skin folding machine)
 Stretching(manually and by skin stretch
press machine)
 1st stage Pickling (in sulpho-chromic
solution & then in cold water)
 Bonding
 1st stage Heat treatment
 Trimming stage
 Tip & Ribs attaching
 2nd stage burning
 Filling of home material (i.e. composite
material)
 2nd stage bonding
  Trimming of Trim Tabs
 Twist check
 Static Balancing
 Weighing
 Dynamic Balancing
 Deliver for assembly section of
helicopter

2nd July  Structural analysis of Tail Rotor Blade Blade Shop

 Manufacturing process of Tail Rotor
Blade
3rd July Observation of spar manufacturing process in Machine shop
machining shop

4th July Observation of steps involved in ribs Machine Shop

manufacturing in machining shop
5th July Transmission assembly of Chetak Cheetah Transmission Assembly
helicopters
6th July Blades installation on CHETAK & Chetak Cheetah final
CHEETAH HELICOPTER in final assembly assembly
hanger

7th July Transmission Assembly of ALH (IDS) ALH transmission

8th July Bringing together of subassembly of ALH like ALH Final Assembly
 Transmission equipment deck
 Tail boom structure
 Bottom structure
 Etc….
9th July Fitting together of subassembly on jig ALH Final Assembly

10th July Performing remaining activities of ALH Final Assembly

assembling the subassemblies off the jig
th
11 July – Equipping of helicopter ALH Final Assembly
14th July

15th July Rain water test & Flight test

16th July Report submission, viva & certificate issue

Brief Training Exposure:

ALH Final Assembly

ALH Final Assembly looks after the assembling & equipping of ALH (Advanced
Light Helicopter). In particular I was trained to the ALH hanger which is engaged
in development & manufacture of ALH named 'DHRUV'
DHRUV is a light 5.5 tonne class, multi-role, multi-mission helicopter, fitted with
two Turbomeca TM333 2B2 engines. The advanced technologies incorporated in
the ALH design includes:
 Automatic Flight Control System (AFCS)
 Anti-Resonance Vibration Isolation System (ARIS)
 Active Vibration Control System (AVCS)
 Full Authority Digital Engine Control (FADEC)
 Hinge Less Main Rotor & Bearing Less Tail Rotor
 Integrated Dynamic System (IDS)

Automatic Flight Control System(AFCS)

An AFC system is a system which augments the stability, improves handling and
provides automatic flying thus relieving the pilot’s workload and also freeing him
for other mission related activity by providing auto pilot functions such as velocity
hold, altitude hold, heading hold etc.
Control system comprises of:
1. Collective control (using collective stick)
2. Cyclic longitudinal control (using cyclic stick)
3. Cyclic lateral control (using cyclic stick)
4. Directional controls or Tail Rotor Control (using rudder pedals)
5. Control rod Vibration Isolation System
6. Force Feel and Trim System (FFS)
7. Push Pull rods and Bell cranks

Need for AFCS:

 Achieve adequate stability. (Stability augmentation)
 Achieve required level of controllability and maneuverability. (Control
augmentation)
 Provide good gust response.
 Provide auto pilot modes.
 Reduce pilot workload
Anti-Resonance Vibration Isolation System (ARIS)

The Anti-Resonance Isolation System (ARIS) is a six-degree of freedom vibration

isolation system. ARIS isolates the fuselage from the rotor-induced vibrations.
Four units of ARIS are installed between the main gearbox (MGB) and fuselage. It
is placed at ± 45°position to the fuselage centerline. This results in each unit being
subjected to reaction forces generated by main rotor forces.
An ARIS unit consists of a spring mass system and it transmits low frequency loads
due to flight conditions and absorbs high frequency loads due to vibration caused
by rotation of the main rotor. The ARIS units, each of 2 degree of freedom, which
are interposed between rotor and fuselage system, isolate vibratory loads
pertaining to 3 forces and 3 moments arising from the rotor and hence ARIS is
effective in all 6 degree of freedom.

Function and capabilities of ARIS:

1. It reduces the transmissibility of 4/rev contents of all rotor hub forces and
moments from the rotor/gearbox unit to the fuselage.
2. In case of the total failure of the spring of ARIS the system ensures transfer
of static loads to the fuselage.
3. It is functional in maneuvers at typical load factors.
4. It significantly reduces the vibration in the continuous power-on at an rpm
range of 98-102%, Where 100% is 32.88 rad / sec.

Components of ARIS:-
The hardware of ARIS, mainly consists of casing ring, support tube, R glass spring,
Composite diaphragm, composite pendulum and the elastomeric bearings
Active Vibration Control System (AVCS)

Dhruv (ALH) helicopter incorporates a highly advanced hinge less main rotor.
This rotor configuration induces high dynamic loads on the airframe, particularly
at the blade passing frequency 4/rev (21 Hz), which is equal to the number of
blades 4 multiplied by the rotor speed of 314 rpm. The 4/rev main rotor vibration
is a cause of discomfort for passengers and crew, reduces fatigue life, cause
damage to on-board sensitive equipment and increase maintenance cost.
The Active Vibration Control System (Frahm Damper system) developed by M/s
Lord Corporation , USA have been employed on the helicopter to augment the
existing ARIS system for further reduction in vibration level over the flight
envelope for different helicopter configurations.
The AVCS along with ARIS will enhance the crew and passenger comfort and
attenuate the 4/rev main rotor vibration to acceptable levels.

Full Authority Digital Engine Control (FADEC)

The TM333-2B2 engine is controlled by the Full Authority Digital Engine Control
(FADEC). The heart of this system is a computer, which is provided in avionics
bay / hinged panel. The FADEC receives the input signal from the sensors
mounted on engine and pilot orders and control switches. FADEC functions and
operations are explained latter.
Hinge Less Main Rotor & Bearing Less Tail Rotor
The technological advancement in material science especially composites, has lead
to the elimination of physical hinges in the rotor system. The main rotor blades of
Dhruv (ALH -Advanced Light Helicopter), uses the flexibility of fiber reinforced
composites in order to eliminate the need for hinges. The flap and lead-lag
articulations are provided by the flexing of the soft neck area of the rotor blades.
This type rotor without mechanical hinges is called Hinge less Rotor. The pitch
change bearings have been replaced by elastomeric bearings which do not need
any lubrication.
In tail rotor of Dhruv, all the three articulations (flap, lead-lag and pitch) are
obtained through flexing and twisting of flex beam. Such rotors are called
Bearingless Rotors.

Specifications of main rotor:-

Rotor type :- Hingeless, Fiber-elastomeric

Number of blades :- 4 (composite material)
Rotor speed :-314 rpm.
Direction of rotation :- Clockwise (as seen from top)
Rotor diameter :- 13.2 m (43.3 feet)
Blade plan form :- Rectangular with Parabolic tip.
Blade chord :- 0.5 m up to 0.9242R, 0.167 m at the tip
Airfoil :- DMH 4 up to 0.8R (STA 5280)
DMH3 from 0.9242R (STA 6100) to 1R (STA 6600)
Advantages of main rotor system:-
1. Reduced number of parts
2. Ease of maintenance (No greasing points)
3. High Fatigue life for rotor hub and blades.
4. Fast control response suitable for superior nap of earth flying and
maneuvers.
Special features of main rotor:-
1. Glass and carbon composite rotor blades.
2. Carbon composite rotor hub.
3. Upper controls located inside the main gearbox and stub shaft.
4. Rotor blade attachment to the hub through radial and conical

Materials used for the manufacture of main rotor blade:-

1. Carbon fibers
2. Glass fibers
3. Copper mesh
4. Epoxy resin
5. Foam for the core
6. Lead mass
7. Stainless steel tube for trim chamber
8. Stainless steel sheet and nickel shield for erosion protection
9. Teflon film at the spoon
10.Paint (polyurethane based)

Integrated Dynamic System (IDS)

Integrated Dynamic System (IDS) is the advanced system in ALH , which combines
several key rotor control functions into a single module carrying the engine power
to the rotors.
Fig :- IDS of DHRUV

TURBOMECA 333-2B2 ENGINE SPECIFICATION:

Model : TM–333 M/s TurboMeca (France)
Version : 2B2
Power Output : 801 kW (1073 Shp) at SL ISA
Length : 1045 mm
Breadth : 450 mm
Width : 745 mm
Weight : 166.5 Kg.
Output shaft speed : 6000 rpm (CW view from rear)
Gas Generator Speed : 45000rpm (100%) (CCW view from rear)
Power Turbine Speed : 37562 rpm (100%) (CW view from rear)
Operating altitude : -500 m to 7000m
Operating temperature : -50 °C to +50 °C
Fuel used : ATF K-50
Oil Used : MIL–L–23699(JET OIL II)
Assembling & Equipping of ALH
ALH final assembly assembles the DHRUV helicopter in four specific stages
carried out at 4 different work stations under the same hanger consisting of 37
equipping stages. After the helicopter is assembled, the various functional tests are
carried out for each system under differing atmospheric conditions, it includes:-

o Functional testing of Hydraulic system

o Functional testing of PP & FUEL system
o Functional testing of electrical AFCS & Avionic system
o Rain water testing
o Break out force Measurement testing

Then in next stage “Optional equipment” is installed to the helicopter.

Once helicopter is ready with all the required equipment as per customer demand,
it is taken for final inspection followed by FOD check & CRI. After these all, the
helicopter is ready for ground run.
A flow chart showing the stages of DHRUV assembly is shown below:
List of Final Assembly Equipment Activity:-
1. Internal painting of helicopter structure
2. Fuel tank installation & finalization of floor board
3. MGB deck clearance
4. ARIS & torque plate installation
5. Engine deck preparation from STAR & EQUIPMENT
6. Preparation for LOOM installation
7. LOOM installation
8. Preparation for NLG & MLG installation
9. Finalization of LG
10.Tail Boom installation
11.Wind shield glass finalization
12.Continuity & MEGGAR checks of LOOM
13.DOOR Finalization
14.FCS BELL CRANK & Control rod installation
15.IDS installation
16.AGB, IGB, TGB installation
17.Gear box alignment
18.TDS bracket riveting
19.Engine Installation & Alignment
20.Cowling Finalization
21.Hydraulic system finalization
22.MRB installation
23.MIP & center console finalization
24.Electrical OH & CB panel installation
25.Electrical / AFCS /Avionics LRU installation
26.Power ON
27.Rigging
28.AIR condition installation
29.Functional testing of Hydraulic system
30.Functional testing of PP & FUEL system
31.Functional testing of electrical AFCS & Avionic system
32.Optional equipment
33.Rain water testing
34.Finalization of AC & oxygen system
35.Break out force Measurement
36.Final inspection , FOD check & CRI
37.GROUND RUN
GUIDENCE:

Mr. Mahadev (Senior Manager, Blade shop)

Mr. Murgasamy (Senior Manager Quality, Blade shop)

Mr. Kishor Sami Reddy (D.M., ALH Final Assembly)

Mr. Gaurav Kumar (D.M., ALH Final Assembly)

Mr. Vara Prasad (D.M., ALH Transmission)

OBJECTIVES OF TRAINING

This full training was oriented towards a big positive on the exposure to the works
carried out in an aviation industry and hence learnt a good deal from them. It was
a major step towards the practical things going outside our syllabus, which was
like a really different world and the environment we usually get in our college
under the umbrella of our university syllabus.

The base aim of the training was to know about how and in how many stages a
helicopter blade is manufactured. It was also towards the learning of how
complicated a helicopter’s working mechanism can be and what are the ways our
engineers have found to bring it of simplest mechanism, better safety and more
efficiency. The advancement in helicopter since it was first built in any Indian
industry to presently an armed ALH has been a great example of advancement and
of premier example set upon for me and all the upcoming engineers in future.

METHODOLOGY

My training consisted of three sessions;

In first session I did attained an industrial environment where I observed the

process and procedure going on in the industry about how machines are used and
how to use the instruments with a comprehensive explanation. In this I observed
the working of all the staff and how they operated the machines with great care,
taking all the possible precautions.

In second session we were given a manual about the instruments which included
all the details about the parts to be manufactured and how to use all these
instruments under the guidance of my seniors in industry. And then my guide
explained all the machine parts with a great sincerity.

Later in the last session I observed all the product produced on day and observed
the final assembly obtained from that whole day. It also included observing and
comparing the product with the master sample product available and checking for
if any deviation had occurred from master piece data and how that was
compensated, followed by a doubt clearance and questionnaire session on the
topics we covered on that day.

BENEFIT OF THE TRAINING

As the training was fully concentrated towards our approach in any industry, it
was a dare time to face our future in present scenario as a student. This training
will work up as a boost for me in future, when I step up in the shoes of an engineer
in coming years. This training will also be helpful to me in future at the time of my
project along with all the theoretical knowledge I gain in my college, as now I can
be more confident with my approach towards the machining, stressing, stretching
and other processes going on any of the materials I have worked on in my short
stay with the industry. This short stay at HAL HELICOPTER DIVISION will be of
uttermost utility at the time when I will be supposed to put my visual experience
along with my imagination, as said:-

“Invention is the place where poetry and engineering come together”.

REMARKS OF THE INCHARGE ON THE PERFORMANCE OF THE

STUDENT:
Mr. Kamal Kumar has been continuous & disciplinary throughout his training
period. His continuity and punctuality has been of well appreciation as well. We
appreciate his enthusiasm for learning in the industry and wish him a great career
ahead.

------------------------------
Senior manager
(Blade Shop, HAL,
Helicopter division)