COMPANY PROFILE

Hindustan Aeronautics Limited (HAL) came in to 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.

The Company traces its routes to the pioneering efforts of an industrialist with extraordinary vision, the late
Seth Walchand Hirachand, who set up Hindustan Aeronautics Limited at Bangalore in association with
erstwhile princely State of Mysore in December 1940. The Government of India became a shareholder in March
1941 and overtook the Management in 1942.

Today, HAL has 16 Production Units and 9 Research and Design Centers in 7 locations in India. The Company
has an impressive product track record – 12 types of aircrafts manufactured within –house R&D 14 types
produced under license.

HAL has manufactured 3550 aircrafts (which includes 11 types designed indigenously), 3600 engines and
overhauled over 8150 aircrafts and 27300 engines.

HAL has been successful in numerous R&D programs developed for both Defence and Civil Aviation sectors.
HAL has made substantial progress in its current projects:

• Dhruv , which is Advanced Light Helicopter (ALH)

• Tejas – Light Combat Aircraft (LCA)

• Various military and civil upgrades.

HAL has played a significant role for India’s space programs by participating in the manufacture of structures
for Satellite Launch Vehicles like

• PSLV (Polar Satellite Launch Vehicle)

• GSLV (Geostationary Satellite launch vehicle)
• IRS (Indian Remote Satellite)
• INSAT (Indian National Satellite)
There are 3 joint venture companies with HAL:

• BAe HAL Software Limited

• Indo-Russian Aviation Limited (IRAL)
• Snecma HAL Aerospace Private Limited.

Apart from these three, other major diversification projects are Industrial Marine Gas Turbine and Airport
Services. Several Co-production and Joint Ventures with international participation are under consideration.

HAL has won several International & National Awards for achievements in R&D, Technology, and Managerial
performance, Exports, Energy Conservation, Quality and Fulfillment of Social Responsibilities.

HAL was awarded the “ INTERNATIONAL GOLD MEDAL AWARD “ for Corporate Achievement in
Quality and Efficiency at the International Summit (Global Rating Leaders 2003) , London ,UK by M/S Global
Rating , UK in conjunction with the International Information and Marketing Center (IIMC).

HAL was presented the International – “ARCH OF EUROPE “Award in Gold Category in recognition for its
commitment to Quality, Leadership, Technology and Innovation.

At the national level, won the “GOLD TROPHY”, for excellence in Public Sector Management, instituted by
Standing Conference of Public Enterprises (SCOPE).
P ro d u 0

1. LITERATURE SURVEY
1.1. The Tool Designer
LITERATURE SURVEY

THE AIRCRAFT DIVISION

Aircraft Division was established in the year 1940. Since inception, the
Division has manufactured a variety of Aircraft both under licence as well
as indigenously designed and developed.

Currently, the Division is manufacturing the HAWK MK-132

International Aircraft under licence from BAE,UK.

The Division is equipped with modern infrastructure in Plant and Equipment like CAD- CAM Manufacturing
Engineering, Quality Assurance and Customer support System with 2121 highly skilled personnel including more than
500 engineers working in a covered area of 2,25,000 sq.m.

In a major diversification initiative, the division is now manufacturing and exporting high precision Aircraft Components
and sub-assemblies for commercial aircraft.

The Division has so far manufactured over 1,500 aircraft of various types. With experience and capabilities built over the
past six decades, the Aircraft Division is bidding for substantial share in the International Aeronautical market.

INTERNATIONAL CO-OPERATION

AIRCRAFT DIVISION, HAL IS AN ESTABLISHED EXPORTER TO

• BOEING, USA
o Up lock box assy. for Boeing 777
o Over wing exit doors for Boeing 757
• AIRBUS, FRANCE
o Forward passenger doors for Airbus A320
• BAE SYSTEMS, UK
o Jaguar Aircraft
• ROYAL AIRFORCE OF OMAN
o Jaguar airframe spares
 ACKNOWLEDGEMENT

The successful completion of our project has left us in debt of a lot of people. We would like to take this
opportunity to thank everyone who have helped us explicitly, but there are persons, without whom our success probably
might not have been realized.

We would like to take this opportunity to express our gratitude to the management of M/S Hindustan Aeronautics
Limited, Bangalore for facilitating all available resources at our disposal, which were necessary for the completion of this
project.

It gives us great pleasure to thank Sri. ABHAY SINGH, E n g i n e e r , External Sourcing Dept., for guiding us
ably thought the project, regardless of his busy schedules.

A special mention of gratitude to our guide Mr. FRANCIS AUGUSTINE Department of Mechanical
Engineering, SAINTGITS College of Engineering for his meticulous guidance right from the start of our project to its
successful completion.

Our sincere thanks to Sri. ABDUL SALAM, Chief Manager, External Sourcing Dept. for his help and
encouragement for the project.

The project report will not be complete without mentioning the names of Sri. Jagadish, (Deputy Manager,
external sourcing Dept) & Sri. Sashikanth (Senior Manager, Export assembly shop).

We would also like to thank all the teaching & non-teaching staff of the Department of Mechanical Engineering,
SAINTGITS for their kind support and co-operation.

Finally many thanks to our parents whose consistent encouragement, blessings and undivided support have paid
dividends in the form of our project.
 ABSTRACT

From the past some time, engineering industries have expanded enormously and this trend will continue in the future too.
There has been widespread increase in the production of products. The concept of mass production is being employed in
every industry. Mass production aims at interchangeability and high productivity to reduce unit cost and facilitate easy
assembly and inspection. This requires increase in the rate of manufacture and inspection. It is in the context of
inspection that jigs and fixtures have assumed a paramount importance and are becoming indispensable in engineering
industries.

The door arm support of the Airbus A320 is a very important and critical part of the aircraft. It supports the whole weight
of the door single-handedly and hence is built to be very strong and durable. It also works as a hinge and is fitted with
locks, sensors and safety devices to prevent accidental opening or closing of the door.

The component is manufactured in large quantities and fast inspection of the machined component is necessary to ensure
early assembly with the door. Inspection is a very important process as any and all defects should be detected at this stage,
failing which the component may malfunction. Currently, inspection of the component is done manually using
instruments such as height gauges and vernier calipers. This takes a lot of time and very few components are inspected per
day. We will be designing an inspection fixture that will potentially reduce inspection time to a fraction of what it
currently is, and will also eliminate the use of measuring instruments, relying on go-no go gauges and pins instead. It will
also reduce setup times and fatigue experienced by the inspector during continuous inspection.
 CONTENTS

1. LITERATURE SURVEY
1.1 Introduction 2
1.2 The Design Procedure 2

2. JIGS AND FIXTURES

2.1 Introduction 6
2.2 Jigs 6
2.3 Fixtures 7
2.4 Advantages of Jigs and Fixtures 9
2.5 Applications 9

3. DESIGN CONSIDERATIONS FOR FIXTURE

3.1 Principle of Fixture Design and Considerations 12

4. LOCATING DEVICES
4.1 Basic Principles of Locating 15
4.2 The Mechanics of Locating 15
4.3 Forms of Location 16
4.4 Locating from External Surfaces 17
4.5 Locating from Internal Surfaces 20
4.6 Locating Guidelines 21

5. COMPONENT STUDY AND PROCESS PLANNING

5.1 Component Study 25
5.2 Next Assembly 27
5.3 Process Planning
5.3.1 Casting and Forging 28
5.3.2 Machining Operations 29

6. INSPECTION WITHOUT FIXTURE

6.1 Introduction 37
6.2 Measuring Instruments 37
6.3 Inspection Setups 41

7. PART DETAILS OF FIXTURE

7.1 Design of Fixture Parts
 7.1.1 Side Plates 46
7.1.2 Bearing 48
7.1.3 Stiffener 50
7.1.4 Checking Plate (Type 1) 52
7.1.5 L-angle 54
7.1.6 Checking Plate (Type 2) 56
7.1.7 Checking Plate (Type 3) 58
7.1.8 U-Channel 60
7.1.9 Trolley 62

8. FIXTURE ASSEMBLY 65

9. COST ESTIMATION OF FIXTURE 70

CONCLUSION 75

BIBLIOGRAPHY 77