DAYANANDA SAGAR COLLEGE OF ENGINEERING

SHAVIGE MALLESHWARA HILLS, KUMARASWAMY LAYOUT, BANGALORE-560078

(AN AUTONOMOUS INSTITUTE AFFILIATED TO VTU, APPROVED BY AICTE &ISO 9001: 2008 CERTIFIED)
ACCREDITED BY NATIONAL ASSESSMENT & ACCREDITATION COUNCIL (NAAC) WITH ‘A’ GRADE
DEPARTMENT OF AERONAUTICAL ENGINEERING
(ACCREDITED BY NBA)

INTERNSHIP PRESENTATION-2024

Title: “Hindustan Aeronautics Limited (HAL) Aircraft Division”

UNDER THE GUIDANCE OF

Dr. JAYARAM R POTHNIS

Associate Professor
Submitted BY :
KAVYA H R
1DS20AE012
CONTENTSts

 COMPANY DESCRIPTION
 OVERVIEW OF AIRCRAFT
 ONGOING PROJECTS AT THE AIRCRAFT
DIVISION
 DEPARTMENT COLLABARATION
 CONCLUSION
 CERTIFICATE
 COMPANY DESCRIPTION

• Established in 1940, Hindustan Aeronautics Limited (HAL) stands as

India's leading aerospace company, founded by Shri Walchand
Hirachand.
• Over the years, HAL has evolved into a comprehensive aerospace
conglomerate, serving both military and civil sectors.
• With a skilled workforce and state-of-the-art infrastructure, the
Aircraft Division continues to deliver cutting-edge solutions,
contributing significantly to India's aerospace ambitions and global
competitiveness.
 OVERVIEW OF THE AIRCRAFT:

1. JAGUAR(TRAINER AND STRIKER):

• The jaguar is an orthodox single-seat, swept-wing, twin-engine monoplane design with tall tricycle-type
retractable landing gear.
• This had a maximum take-off weight in the 15-tonne class with a combat radius on internal fuel of 850 km.
• This aircraft had hard points fitted for external weapons loads of up to 10,000lb(4,500kg)
2. HAWK:

• The British hawk is an advanced training aircraft with a single-jet engine.

• It has been used as a training tool and a cheap combat aircraft.
• Currently, IAF’s fleet now consists of 123 hawk advanced jet trainers.
• The Bidar air force station, one of the IAF’s top centers for flying instruction.
3. TEJAS:
• HAL and ADA collaborated to create the single-engine, delta-wing, light multirole fighter known
as HAL tejas for the indian air force and indian navy.
• It was created as a result of the LCA program, which was first started in 1980s to replace outdated
mig-21 fighters.
• The LCA was given the official name “tejas” in 2003.
4. MIRAGE-2000:
• The dassault mirage 2000 is a french multirole, single-engine, fourth-generation jet fighter
manufactured by dassault aviation.
• It was designed in the late 1970s as a lightweight fighter to replace the mirage 2000 and evolved
into a multirole aircraft with several variants developed.
• Over 600 aircrafts were built and it has been in service with nine nations.
 ONGOING PROJECTS AT AIRCRAFT
DIVISION
1. DORNIER LANDING GEAR:

• The hydraulically operated landing gear consists of a forward retracting twin wheel. Nose leg
and sideways retracting single-wheel main legs.

• The main landing gear consists of two oleo-pneumatic shock absorbents which are integrated
into the gear structure.

• The landing gear actuators are secured by an internal mechanical lock at the extended position.
2.HTT(Hindustan Turbo Trainer) order of 70
Aircrafts:
• HTT is one of the major projects handled by HAL.
• It is a tandem-seat trainer aircraft powered by a 100-hp turbo engine.
• Due to a few complications, it was rejected by the IAF.
• Once the HTT-40 started flying, the Indian Air Force Commander publicly
stated that the IAF would buy the HTT-40 in large numbers.

3. LCA (LIGHT COMBAT AIRCRAFT) order of 83

aircraft:
• The LCA Tejas is a multi-user, all-weather fighter aircraft.
• The plane is made to be a multi-role weapon that can be easily perform in ground
assault, close combat, and offensive air support mission.
4. CANOPY IN THE PLASTICS DEPARTMENT:
• An aircraft canopy is a transparent enclosure over the cockpit of some types of
aircraft.

• An aircraft canopy provides a controlled and sometimes pressurized environment for

the aircraft's occupants and allows for a greater field of view over a traditional flight
deck.

• HEAT(HIGH-SPEED EXPANDABLE AERIAL TARGET) developed by the

ADE (Aeronautical Development Establishment) of the DRDO order of 12
aircraft.
 DEPARTMENT COLLABARATION:
Honeycomb and Bonding Shop
Honeycomb and Bonding Shop at HAL Aircraft Division specializes in crafting lightweight yet robust honeycomb structures, crucial for
aircraft construction. From canopies to enclosures, these components enhance aircraft performance and safety.

Manufacturing Process
 Core Selection: Engineers choose honeycomb core material based on
weight, strength, and fire resistance.
 Facing Sheet Preparation: Thin sheets undergo precision cutting and
surface treatment for optimal bonding.
 Adhesive Application: High-strength epoxy resin-based adhesives are
applied to the core using precision dispensing equipment.
 Panel Assembly: Skilled technicians use machinery for precise
alignment and bonding.
 Curing: Panels undergo controlled curing in Special machine store in -
18 deg,cec and pressures of 1 to 5 bar.
 Machining and Finishing: Advanced CNC machining and laser
cutting shape panels to specifications.
Drop Tank Department
Within the HAL Aircraft Division, the Drop Tanks Department specializes in the design and production of supplemental fuel containers
known as drop tanks. These essential components enhance aircraft range and performance, contributing significantly to the division's
mission of advancing aviation capabilities

Assembly Process for Drop Tanks

 Riveting: Metal components are joined with rivets for structural integrity.
 Buffel Plate Installation: Buffel plates are installed for reinforcement and load
distribution.
 Welding: Sealing of joints and seams using welding, suitable for aluminum materials.
Machine Shop Department
Hindustan Aeronautics Limited (HAL) Aircraft Division encompasses essential departments vital for aircraft production. Among these,
Machine Shop-2 holds significant importance, serving as a specialized facility dedicated to the manufacturing of landing gear and piston
shafts for LCA Tejas aircraft.

Manufacturing Process
 Turning: Raw materials transformed into cylindrical shapes using CNC turning
machines.
 Boring: Creates or enlarges precise holes within machined components.
 Heat Treatment: Components undergo controlled heat treatment to modify mechanical
properties.
 Grinding: CNC grinding machines achieve final desired dimensions and surface
finishes accurately.
 Inspection: Rigorous inspections ensure components meet dimensional and surface
finish requirements.
 Plating: Chromium coating or other plating processes applied for corrosion resistance,
if necessary.

Materials
Steel, Aluminum.
Sheet Metal Shop
The Sheet Metal Shop specializes in the creation of various aircraft components using sheet metal fabrication techniques. These
components are crucial for the structural integrity, aerodynamics, and overall functionality of the aircraft.

Materials Used
Commonly utilized materials include Aluminum alloys, Titanium alloys, and Stainless
Steel.

Manufacturing Process
 Cutting: CNC punching, shearing, or laser cutting machines cut sheet metal to
required dimensions.
 Forming: CNC press brakes bend and shape components to achieve desired shapes
and angles.
 Joining: Sheet metal components are securely joined using welding processes like
MIG, TIG, or resistance welding.
 Finishing: Surface treatment processes such as painting, anodizing, or coating
enhance corrosion resistance and aesthetics.
 CONCLUSION:

• My HAL Aircraft Division internship provided invaluable insights into the practical application of mechanical engineering principles
in aerospace manufacturing. Witnessing the transformation of raw materials into intricate components of fighter jets and cargo
airbuses was a real-world education. It was a hands-on opportunity to grasp how theory translates into reality.
• Overall, our internship at HAL's aircraft division has been a rewarding and enriching experience, allowing me to immerse myself in
the fascinating world of aerospace manufacturing and contribute to the advancement of aviation technology. I can carry forward the
lessons learned and the experiences gained from my internship as embark on my professional journey in the aerospace industry.
CERTIFICATE
THANK YOU