Last One PDF

VISVESVARAYA TECHNOLOGICAL UNIVERSITY
Jnana Sangama, Belagavi – 590 018.
Internship Report on
“HELICOPTER MRO DIVISION”

Submitted in partial fulfilment for the award of Degree of
Bachelor of Engineering
in
Mechanical Engineering
Submitted By
HEMANTH M(1VK15ME012)
Internship carried out at
HINDUSTAN AERONAUTICS LIMITED

HELICOPTER MRO Division, Bengaluru
Internal Guide External Guide

Mr. ADESH K Mr VASANTH KUMAR
Assistant Professor Deputy Manager
Department of Mechanical Engineering, helicopter MRO Division
VKIT, HAL, Bengaluru
Department of Mechanical Engineering

VIVEKANANDA INSTITUTE OF TECHNOLOGY
GUDIMAVU, KENGERI HOB LI, KUMB ALAGODU, B ENGALURU -560074
VIVEKANANDA INSTITUTE OF TECHNOLOGY
Gudimavu ,kengeri hobli, Kumbalagodu post, Bengaluru-560074
DEPARTMENT OF MECHANICAL ENGINEERING
CERTIFICATE
This is to certify that the Internship work prescribed by the Visvesvaraya

Technological University, Belagavi entitled “HELICOPTER MRO DIVISION ”was carried
out by HEMANTH M(1VK15ME012) is a bonafide student of VIII Semester, Mechanical
Engineering, Vivekananda Institute Of Technology. This is in partial fulfillment for the award
of Bachelor of Engineering in the Visvesvaraya Technological University, Belagavi during
the academic year 2018-2019. It is certified that all corrections/suggestions indicated for
internship work internal assessment have been incorporated in the report.
The internship report has been approved as it satisfies the academic requirements in the
respect of internship work prescribed for the said degree.
Signature of the Guide Signature of the HOD Signature of the Principal

Mr. ADESH K Mr.B SRINIVASMURTHY Dr.KUMAR KENCHEGOWDA
Name of Examiners Signature with date
1.___________________________
2.___________________________
ACKNOWLEDGEMENT
My most sincere and grateful thanks to VIVEKANANDA INSTITUTE OF TECHNOLOGY,

for giving us an opportunity to pursue the B.E in Mechanical Engineering and thus helping us to
share our career.
First and foremost, I would like to express our gratitude to Dr.KUMAR KENCHEGOWDA,
Principal VKIT Bengaluru for his support in bringing this internship to completion.
I would like to extend our sincere thanks to Mr SRINIVASMURTHY, HOD & Prof,
Department of Mechanical Engineering, VKIT Bangalore, for his suggestions which helped ME
to complete the internship.
I would like to express my sincere thanks to internal guide Mr. ADESH K Asst. prof,
Department of Mechanical Engineering, VKIT Bengaluru, for guidance & support in bringing
this internship to completion.
It is our radiant sentiment to place on record our best regards, deepest sense of gratitude to Mr.
VASANTH KUMAR (Structures), Mr NIKHIL (FCS), Mr.MOHAN RAJ (Hydraulic and ECS),
who gave me system specific, in-depth knowledge and helped me to understand the aircraft
systems and for their careful and precious guidance which were extremely valuable for my study
I wish to thank whole HAL group for their help and support without that support and
cooperation this internship program would not have been such a great learning experience.
Table of Contents
1 - INTRODUCTION ___________________________________________________________ 1
1.1 About HAL ______________________________________________________________ 1
1.2 History__________________________________________________________________ 2
2. ALH TRAINING ____________________________________________________________ 4
2.1 Role of Helicopters ________________________________________________________ 4
2.2 Advanced Light Helicopter (ALH- DHRUV) ___________________________________ 4
2.3 Features of ALH __________________________________________________________ 4
2.4 Role of ALH Training ______________________________________________________ 4
2.5 Customers _______________________________________________________________ 5
2.6 ALH Training Classification _________________________________________________ 5
3. MACHINE SHOP ___________________________________________________________ 6
3.1 Operations in Machine Shop _________________________________________________ 6
3.2 Turning _________________________________________________________________ 6
3.3 Grinding ________________________________________________________________ 7
3.4 Taper Turning ____________________________________________________________ 7
3.5 Gear Cutting _____________________________________________________________ 7
3.6 Milling __________________________________________________________________ 7
3.7 Drilling _________________________________________________________________ 8
3.8 Boring __________________________________________________________________ 8
4 - METHODS AND TOOLING __________________________________________________ 9
4.1 Methods _________________________________________________________________ 9
4.2 Tooling ________________________________________________________________ 10
4.2.1 Tooling planning______________________________________________________ 10
4.2.2 Tool design __________________________________________________________ 10
5. HEAT TREATMENT SHOP __________________________________________________ 11
5.1 Heat Treatment __________________________________________________________ 11
5.2 Heat treatment techniques __________________________________________________ 11
5.3 Furnace Types ___________________________________________________________ 12
6. PROCESS SHOP ___________________________________________________________ 15
6.1 Surface finishing processes _________________________________________________ 15
6.2 Choosing a Metal Finishing Process __________________________________________ 17
7. WELDING & SHEET METAL SHOP __________________________________________ 18
7.1 Welding ________________________________________________________________ 18
7.1.1 Types of welding _____________________________________________________ 19
7.2 Sheet Metal _____________________________________________________________ 21
8. BLADE SHOP _____________________________________________________________ 22
8.1 Procedure for Blade Manufacturing __________________________________________ 22
8.2 Servicing _______________________________________________________________ 23
9 - STRUCTRAL ASSEMBLY __________________________________________________ 24
9.1 Types of Helicopter Construction ____________________________________________ 24
9.1.1 Tubular Construction __________________________________________________ 24
9.1.2 Stressed Skin Construction ______________________________________________ 24
9.1.3 Bonded construction:- __________________________________________________ 25
9.2 Different sections of helicopter structure ______________________________________ 26
10. TRANSMISSION ASSEMBLY ______________________________________________ 23
10.1 Main Rotor Transmission _________________________________________________ 28
10.2 Tail Rotor Drive System __________________________________________________ 29
10.3 Clutch ________________________________________________________________ 30
10.4 Freewheeling Unit _______________________________________________________ 31
11. QUALITY & PROGRAMME ENGINEERING __________________________________ 32
11.1 Quality________________________________________________________________ 32
11.2 Programme Engineering __________________________________________________ 33
12. DLE_____________________________________________________________________ 34
13. FINAL ASSEMBLY _______________________________________________________ 36
13.1 Electrical System________________________________________________________ 36
13.2 Avionics ______________________________________________________________ 37
13.3 AFCS (automatic flight control system) ______________________________________ 37
13.4 MSI (mission system integration) ___________________________________________ 38
13.5 WSI (weapon system integration) ___________________________________________ 38
14. CIVIL HELICOPTERS _____________________________________________________ 39
15. CONCLUSION____________________________________________________________ 41
BIBLIOGRAPHY_____________________________________________________________ 42
List of Figures
Figure 1: HAL corporate 2
Figure 2: Process chart of Method Department 9
Figure 3: Box-type furnace 12
Figure 4: Pit Furnace 12
Figure 5: Salt-bath furnace 13
Figure 6: Vacuum furnaces 13
Figure 7: Muffle furnace 14
Figure 8: Electric Arc Welding 18
Figure 9: Welding symbol 18
Figure 10: Gas Welding 19
Figure 11: T.I.G. Welding 20
Figure 12: Spot Welding Process 21
Figure 13: Spot Welding Machine 21
Figure 14: Bending Machine 21
Figure 15: Punching Machine 21
Figure 16: Cross Section of typical Blade 23
Figure 17: Cross Section of Cheetah Blade 23
Figure 18: Truss type design 24
Figure 19: Semi-monocouque 25
Figure 20: Monocouque 25
Figure 21: Helicopter structural parts 26
Figure 22: Tail Boom Section 27
Figure 23: Helicopter Parts 28
Figure 24: Main rotor system 29
Figure 25: Tail Rotor Drive System 30
Chapter 1
INTRODUCTION
1.1 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 USD 2 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 fulfilment 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).
DEPARTMENT OF ME,VKIT 2018-19 Page 1

HAL Corporate
BENGALURU MiG HELICOPTER ACCESSORIES DESIGN

COMPLEX COMPLEX COMPLEX COMPLEX COMPLEX
Figure : 1 HAL
corporate
HAL has its five complex (refer figure 1) and several divisions in Bengaluru, Nasik,
Hyderabad, Kasargod, Lucknow, Kanpur, Korwa, Barrackpore, 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,
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.
1.2 History
With the objective of promoting aviation industry for assembly and overhaul of aircraft,
engines and accessories under license, Hindustan Aircraft Factory was setup by the late
Walchand Hirachand on 24th December 1940. The Government of India became a
shareholder in March 1941 and took over the Management in 1942. Helicopter Division was
established in July 1970. The division manufactures single engine as well as twin engine
helicopters to cater the growing needs of the market.
Helicopter Division manufactures Rudra, Dhruv, Cheetah, Chetak, Cheetal, Lancer,

LUH & LCH helicopters.The division is supported by the co-located R&D center – Rotary
Wing Research & Design Centre (RWR&DC).
The MRO division caters to the Maintenance, Repair & Overhaul activities of
helicopters. The Rotary Wing Academy focuses on training of pilots.

HAL started manufacturing of helicopters in 1962, by entering an agreement with M/s

SUDAVIATION (Presently M/s EUROCOPTER, France) for production of Aloutte III
helicopters.(Chetak). The first Chetak (Aloutte III) in ‗Fly Away‘ condition delivered in
1965.
License agreement for production of Cheetah (LAMA SA 315-B) signed with M/s
SNIAS (presently M/s, Eurocopter) in 1970. First Cheetah manufactured from raw materials
was delivered in 1976-77.
In 1990s, HAL has developed a light attack helicopter ―Lancer‖. The basic structure
of the lancer is derived from reliable and proven Cheetah helicopter. The helicopter has bullet
proof front panels. Gun cum Rocket pod one each (70 mm Rocket+12.5 mm Gun) fitted on
either side. An optical sight has been fitted for accurate firing.
The Cheetal helicopter is a re-engined variant of Cheetah helicopter. The Cheetal

helicopter set the world record of world‘s highest landing at ‗Saser Kangri‘ of Himalayas in
2006. HAL Helicopter division has successfully manufactured 600 Single Engine helicopters.
HAL achieved self-reliance in design, developing & manufacturing of twin engine Advanced
Light Helicopter ―Dhruv‖. Dhruv is a multi-role, multi mission all weather helicopter in the
5.5 ton category. The indigenously designed twin engine helicopter started series production
during 2001-2002.
The division is accredited with AS 9100 C & ISO 14001:2004 certifications. The
division is also approved by Directorate General of Civil Aviation (DGCA) for CAR 21,
CAR 145 & CAR M certifications.
HAL with the proven track record of manufacturing more than 700 helicopters, the
helicopter division has expand its design, developing & production range by manufacturing
new helicopters like Weapon System Integrated (WSI) version of Dhruv (Christened as
―Rudra‖), Light Combat Helicopter (LCH) and Light Utility Helicopter (LUH).

Chapter 2
ALH TRAINING
2.1 Role of Helicopters
Few roles of helicopter are as follows:-
• Patrolling
• Army troops transportation
• Warfare
• Air Ambulance
• Rescue operations
2.2 Advanced Light Helicopter (ALH- DHRUV)

The Advanced Light Helicopter (ALH-DHRUV) is a twin engine, multi-role, 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 Military Airworthiness Certification (CEMILAC) and civil operations by the
Directorate General of Civil Aviation (DGCA).
2.3 Features of ALH

Features of ALH are as follows:-
• 4-Axis digital Automatic Flight Control System

• Advanced Cockpit
• Hinge less main motor
• 6-Axis freedom
• Anti-resonance isolation system
• Bearing less rear motor
2.4 Role of ALH Training

Roles of ALH training are as follows:-
• Training to newly inducted training personnel

• Familiarization of maintenance
• Pre-flight and ground training to pilots

2.5 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,
Suriname and Ecuador
2.6 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.
• Power plant: Two types of power plants used in ALH are following:-
1. TM 333-2B2 (for DHRUV MK-I and MK-II)& ARDIDEN 1H1 SHAKTI (for
DHRUV MK-III & MK-IV)
2. Max power is 801 KW
• Electrical: ALH is equipped with two electrical systems both DC and AC
1. DC: The DC power specifications is 28A, The DC generator also charges a 24V
generator also charges a 24V battery that provides a stand by time of 30min.
2. AC: 115/200V, 3-phase, 400Hz, AC power is generated by an alternator coupled to
the main gear box.
• Instruments: There are two types of instruments system:-
1. DIRECT SENSING TYPE: The measured data reaches the system directly from the
sensor module.
2. REMOTE SENSING TYPE: the measured data from sensor is stored and converted
in a sub system and then further retried.
• 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

Chapter 3
MACHINE SHOP
A machine shop is a room or building where machining is done. In a machine shop,
machinists use machine tools and cutting tools to make parts, usually of metal or plastic (but
sometimes of other materials such as glass or wood). The parts produced can be the end
product of the factory, to be sold to customers in the machine industry, the car industry, the
aircraft industry, or others. In other cases, companies in those fields 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 centers,
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 stock for machining) and an inventory of finished parts. These items
are often stored in a warehouse.
3.1 Operations in Machine Shop

Various types of operations performed in machine shop are following:-
• Turning
• Grinding
• Taper Turning
• Gear Cutting
• Milling
• Drilling
• Boring
3.2 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 (in the non-mathematical sense). The cutting
of faces on the workpiece (that is, surfaces perpendicular to its rotating axis), whether with a
turning tool, is called "facing", and may be lumped into either category as a subset.

3.3 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-cranked 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 basements
3.4 Taper Turning

When the diameter of a piece 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 in diameter
from one part of a cylindrical workpiece to another part. Tapers can be either external or
internal.
3.5 Gear Cutting

Gear cutting is any machining process for creating a gear. The most common gear-cutting
processes include hobbing, 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.
3.6 Milling
Milling is the machining process of using rotary cutters to remove material from a workpiece
by advancing (or feeding) 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

3.7 Drilling
Drilling is a 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 (swarf) from the
hole as it is drilled.
3.8 Boring
In machining, boring is the process of enlarging a hole that has already been drilled (or cast)
by means of a single-point cutting tool (or of a boring head containing several such tools),
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 diameters.

Chapter 4
METHODS AND TOOLING
4.1 Methods
This department is basically a support department that is concerned with providing the most
feasible and the best applicable methods for manufacturing. Alternatively it can be described
as the design of the productive process in which a person is involved, the task of the methods
engineer is to decide where humans will be utilized in the process of converting raw material
to finished product. The terms operation analysis work design and simplifying and corporate
re-engineering frequency used interchangeability over cost increase in reliability and
productivity of methods of engineering. Figure 2 describes the work of methods department.
Design from Study of drawing Initial methods

RWRDC and standards.
No
Design through Production Feasiblity check
DLE Queries
Yes
Instruction set
Product
structure and
routing in
software
Product structure
and routing in Process freezing Process proving
software
Figure 2 Process
: chart of Method Department

4.2 Tooling
The tooling department plays an important role in manufacturing of tools like jigs and
fixtures which are non-standardized in market. The tools are selected for the requirement in
manufacturing the project.
4.2.1 Tooling planning
The process request is received from the methods department. The raw material and sequence
tool manufacturing is decided. Reusability of existing tools to carry the new process will also
be studied.
4.2.2 Tool design
The tools is designed in specific orientation and demand. The utility of raw material is
selected for tool to ensure the durability, mass and defined properties. The tools design
department also tries to reverse engineer tools for reducing in house cost of spare parts
cutting tools harness are designed by this section.

Chapter 5
HEAT TREATMENT SHOP
5.1 Heat Treatment
Heat treating is a group of industrial and metalworking processes used to alter the physical,
and sometimes chemical, properties of a material. The most common application is
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.
5.2 Heat treatment techniques

The heat treatment techniques are as follows:-
• Annealing: Annealing is a 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 harder metal (called the "case") at the surface.
• Precipitation strengthening: Precipitation hardening, also called age hardening or
particle 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 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 of heat treatment 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.
5.3 Furnace Types

Furnaces used in heat treatment process are following
• Box-type furnace: Many basic box type furnaces have been upgraded to a semi-
continuous batch furnace with the addition of integrated quench tanks and slow-cool
chambers. These upgraded furnaces are a very commonly used piece of equipment for
heat-treating.
Figure 3: Box-type furnace
• 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 4: Pit Furnace

• Salt bath furnaces: Salt baths are used in a wide variety of heat treatment processes
including neutral hardening, liquid carburizing, liquid nitriding, austempering,
martempering and 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 a part rises in temperature at approximately the same rate as its surface in a salt bath.
Figure 5: Salt-bath furnace
• Vacuum furnaces: A vacuum furnace is a 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 temperatures as high as
3,000 °C with select materials.
Figure 6: Vacuum furnaces
• 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 of the products of
combustion, including gases and flying ash.

Figure 7: Muffle furnace

Chapter 6
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.
6.1 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, 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. Super finishing, unlike polishing which produces a mirror finish, creates a
cross-hatch pattern on the workpiece.

6.2 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 softer materials.

Chapter 7
WELDING & SHEET METAL SHOP

7.1 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 8: Electric Arc Welding Figure 9: 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.

7.1.1 Types of welding
Types of welding which are available in HAL are:
• Gas welding
• Electric Arc Welding
• TIG(Tungsten Inert Gas ) Welding
• Spot Welding
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 the
metals to be welded.
Figure 10: Gas Welding
Oxy-fuel processes may use a variety of fuel gases, the most common being acetylene. 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 nonconsumable electrodes.
TIG Welding: Tungsten Inert Gas (TIG) welding, is an arc welding process that uses a
nonconsumable 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.
Figure 11: 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
weld.

Figure 12: Spot Welding Process Figure 13: Spot Welding Machine
7.2 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: Bending is a manufacturing process that produces a V-shape, U-shape, or channel
shape along a straight axis in ductile materials. (Refer figure 14)
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. (Refer figure 15)
Figure 14: Bending Machine Figure 15: Punching Machine

Chapter 8
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
8.1 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 moltoprene foam 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 16: Cross Section of typical Blade
Leading
Trailing edge
Spar Honeycom
b
structure
Figure 17: Cross Section of Cheetah Blade
8.2 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.

Chapter 9
STRUCTRAL ASSEMBLY
9.1 Types of Helicopter Construction
It can be divided into 3 categories such as
1) Tubular construction
2) Stressed construction
3) Bonded construction
9.1.1 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 18: Truss type design
9.1.2 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. Longerons provide the primary strength while Stiffeners gives mean of
attaching and stiffening the skin.

Figure 19: Semi-monocouque
• Monocoque: 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,
Chetan. (Refer figure 20)
Figure 20: Monocouque
9.1.3 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

9.2 Different sections of helicopter structure

Different sections of helicopter structure are as follows (Refer figure 21):
Figure 21: 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 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 22: 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.

Chapter 10
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 23: Helicopter Parts
10.1 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. See
figure 24. 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.
Figure 24: Main rotor system
10.2 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. (Refer figure 25)

Figure 2 5: Tail Rotor Drive System
10.3 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 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.
10.4 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 oneway ―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 the engine. In this
condition, engine speed is less than that of the drive system, and the helicopter is in an
autorotative state.

Chapter 11
QUALITY & PROGRAMME ENGINEERING

11.1 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.
11.2 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.

Chapter 12
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.

Chapter13
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.
13.1 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.
13.2 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.
13.3 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.

13.4 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.
• 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.
13.5 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.

Chapter 14
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. PT2 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.
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).

Chapter 15
CONCLUSION
In summary , it has been a reality fulfilling internship experience here at HAL not only I have
gained practical knowledge and real-life experience of branding and dealing with real clients,
I have also managed to develop relationships with my colleagues and honed my social skills.
Besides, a lot of independence was given to me despite the fact that I am only an intern. It
also helps that my supervisor seldom directs me or oversees my work after the few days
because I had to learn to deal with other colleagues and clients by myself and I am not
protected or shielded from the reality of the working world. Sometimes, it also feels as if I
am actually one of the staff here rather than an intern because of the level; of trust they have
in me and the responsibilities they delegate to me. HAL has given me much room to explore
and discover the perks and difficulties of client servicing.
I believe that the knowledge and experience gained through this time at HAL would
come in handy and be able to put to good use upon my graduation, as it has opened up
another possible carrier route for me.

BIBLIOGRAPHY
[1] www.hal-india.com/Product_Details.aspx?Mkey=54&lKey=&CKey=24
[2] http://www.hal-india.com/Helicopter%20Complex/M__124
[3] http://www.hal-india.com/Rotary%20Wing/M__147
[4] https://www.faasafety.gov/gslac/ALC/course_content.aspx?cID=105&sID=461&prev
iew=true

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VISVESVARAYA TECHNOLOGICAL UNIVERSITY

Jnana Sangama, Belagavi – 590 018.

“HELICOPTER MRO DIVISION”

HINDUSTAN AERONAUTICS LIMITED

Internal Guide External Guide

Department of Mechanical Engineering

This is to certify that the Internship work prescribed by the Visvesvaraya

Signature of the Guide Signature of the HOD Signature of the Principal

Name of Examiners Signature with date

My most sincere and grateful thanks to VIVEKANANDA INSTITUTE OF TECHNOLOGY,

The Indian Aerospace Industry is witnessing an unprecedented growth. Hindustan

HAL has 20 production divisions for manufacture and overhaul of aircraft,

DEPARTMENT OF ME,VKIT 2018-19 Page 1

BENGALURU MiG HELICOPTER ACCESSORIES DESIGN

Helicopter Division manufactures Rudra, Dhruv, Cheetah, Chetak, Cheetal, Lancer,

DEPARTMENT OF ME,VKIT 2018-19 Page 2

HAL started manufacturing of helicopters in 1962, by entering an agreement with M/s

The Cheetal helicopter is a re-engined variant of Cheetah helicopter. The Cheetal

DEPARTMENT OF ME,VKIT 2018-19 Page 3

2.2 Advanced Light Helicopter (ALH- DHRUV)

2.3 Features of ALH

• 4-Axis digital Automatic Flight Control System

2.4 Role of ALH Training

• Training to newly inducted training personnel

DEPARTMENT OF ME,VKIT 2018-19 Page 4

2.6 ALH Training Classification

DEPARTMENT OF ME,VKIT 2018-19 Page 5

3.1 Operations in Machine Shop

DEPARTMENT OF ME,VKIT 2018-19 Page 6

• Hand-cranked knife-sharpening stones (grindstones)

3.4 Taper Turning

3.5 Gear Cutting

1. Horizontal Milling Machine

DEPARTMENT OF ME,VKIT 2018-19 Page 7

DEPARTMENT OF ME,VKIT 2018-19 Page 8

Design from Study of drawing Initial methods

DEPARTMENT OF ME,VKIT 2018-19 Page 9

4.2.1 Tooling planning

4.2.2 Tool design

DEPARTMENT OF ME,VKIT 2018-19 Page 10

5.2 Heat treatment techniques

DEPARTMENT OF ME,VKIT 2018-19 Page 11

• Quenching: Quenching is the rapid cooling of a workpiece to obtain certain material

5.3 Furnace Types

Figure 3: Box-type furnace

Figure 4: Pit Furnace

DEPARTMENT OF ME,VKIT 2018-19 Page 12

Figure 5: Salt-bath furnace

Figure 6: Vacuum furnaces

• Muffle Furnace- A muffle furnace (sometimes retort furnace in historical usage) is a

DEPARTMENT OF ME,VKIT 2018-19 Page 13

Figure 7: Muffle furnace

DEPARTMENT OF ME,VKIT 2018-19 Page 14

6.1 Surface finishing processes

DEPARTMENT OF ME,VKIT 2018-19 Page 15

• Sandblasting: Sand-blasting machines are typically employed in projects requiring a

DEPARTMENT OF ME,VKIT 2018-19 Page 16

6.2 Choosing a Metal Finishing Process

• Production speed & Process speed.

DEPARTMENT OF ME,VKIT 2018-19 Page 17

WELDING & SHEET METAL SHOP

Figure 8: Electric Arc Welding Figure 9: Welding symbols