Industrial Training presentation At Hal

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Presentation on industrial training :

Presentation o n industrial training Hindustan Aeronautical Limited Bangalore At Presented by: Aasan Depart of Mechanical engineering, Final year, SLBS engineering college Jodhpur. Thursday, October 09, 2014 Industrial training at HAL 1

Presentation overview :

Presentation overview About HAL (Hindustan Aeronautical Limited ) History Today HAL HAL Bangalore complex (Aircraft division) Current manufacturing project Repairs Manufacturing Design and manufacturing Department wise visit of HAL. Industrial training at HAL 2

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About HAL:- Asia’s largest aerospace company Under the management of ministry of defense Design of various cargo and combat aircraft , manufacturing, assembly, repairing , jet engines manufacturing, rudders , aviation equipment, spare parts of aircraft and helicopters and space vehicles also. Manufacturing of helicopters, gliders . History of HAL:- HAL was established as Hindustan Aircraft in 1940. Seth Watchband Hirachand was owner of HA. Production of aircrafts for the Royal Indian air Force. Initiative was actively encouraged by Kingdom of Mysore Industrial training at HAL 3

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Today HAL:- HAL is Navratna company and also the largest d efense public s ector undertaking under the department of defense. It has 19 production division . It has 9 co-located research and development centers are located at 7 locations in country. 12 types of aircraft manufactured with in-house R & D and 14 types produced under license. HAL has over the years manufactured nearly 3550 aircrafts, 3600 engines and overhauled over 8150 aircrafts and 27300 engines . Industrial training at HAL 4

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Bangalore Complex Aircraft Division Engine Division Industrial & Marine Gas Turbine Division Overhaul Division Aerospace Division Foundry & Forge Division Airport Service center LCA/LSP IJT/LSP Central Materials and processes Laboratory Industrial training at HAL 5

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3. HAL Bangalore complex (Aircraft division Bangalore):- In aircraft division manufacturing of variety of aircraft both under license as well as indigenously designed and developed. Division now the work on new project HAWK Mk132 by contract with I ndian Air force . HAL Bangalore complex have 2179 highly skilled workers and 511 officers . It’s area about 2,2500 sq. m. Industrial training at HAL 6

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4. Current manufacturing at HAL:- Hawk- Advanced Jet Trainer The Hawk is a tandem-seat Aircraft for ground attack, flying training and weapon training. It has a low wing and an all-metal structure and is powered by an Adour Mk 871 turbofan engine. The Aircraft has an integrated navigation /attack system and radio and inertial navigation systems. The Aircraft is cleared for instrument (IFR) flying and for Solo Instrument flying from the front cockpit only. Industrial training at HAL 7

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Basic Data Length:- 12.43 m Area (Gross ):- 16.70 m2 Wing Span :- 9.940 m Height:- 3.98 m Wing Aspect Ratio :- 5.29 Maximum Take Off weight:-9100 kg Basic Mass (Empty ):- 4,440 Kg Fuel capacity Sweep:- Internal:- 360 Imp Galls Ext . Drop Tanks :- 2 x 130 Imp Galls Engine type :- Rolls Royce Adour MK 871 Turbofan Static Thrust at sea level: 1 x 25.5 kN (5730 lbf ) at sea level ISA Industrial training at HAL 8

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6. Repairs :- Composite Repairs Structural Repairs Welding Repairs Parts Fabrications 7. Manufacture of :- Structural sub-assemblies such as Doors, Pylons, Fairings, Drop Tanks, Control Structures, etc. Precision sheet metal forming (Cold or Hot Forming) of Aircraft components out of Light alloys, Steel and Titanium. Precision machined components. Honeycomb Sandwich bonded structures, metal-to-metal bonded components, Composite components in carbon , Kevlar etc. Glass Fiber Reinforced Plastic components like Fairings, Ducts, Pipes etc . Aircraft Transparencies like Windshields, Canopies, Helicopters Panel, etc Electrical Cable Looms (Harnesses) Landing Gears. Industrial training at HAL 9

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8. Design and Manufacture of : Jigs Fixtures and Templates Press Tools Composite Molding Tools Forming Tools for Transparencies Acceptance Gauges / Jigs Tooling Masters except MTG‘S Structural Assembly Jigs Ground Support Equipment for Aircraft Weld Jigs Pressure Test Fixtures Sheet Metal Tools (Stretch Forming Blocks) Industrial training at HAL 10

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Department wise visit of HAL Bangalore complex:- Industrial training at HAL 11

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1. NC shop & NC programing Department:- Numerical control (NC) is the automation of machine tools that are operated by precisely programmed commands encoded on a storage medium, as opposed to controlled manually via hand wheels or levers, or mechanically automated via cams alone. Most NC today is computer numerical control (CNC), in which computers play an integral part of the control.   Industrial training at HAL 12

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2. Methods & Programing Eng.:- 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 . Industrial training at HAL 13

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3 . Export machine shop:- Export machine shop is a work place where our side jet aircrafts various part are machined. In this shop, International airbus and jet fighters small and big parts manufactured. HAL is manufacture aircraft parts and export following counters 1.USA 2.FRANCE 3.Russia 4.Switzerland 5.Israel Industrial training at HAL 14

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Aircraft division, HAL is an established exporter to Boeing, usa . Boeing 777 Up lock Box F/A 18 Gun Bay Door F/A 18 Wire Harness P-8I Weapon Bay Door B777 Flaperon P8I Tail Cone Chinook- Aft Pylon & Ramp Door Leading Edge Extension F/A 18 P-8I APU Door Fairing Assembly D ornier landing gears Industrial training at HAL 15

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4. Management Services Department function responsibility and authority main function:- The main function of management services department are to asses the management and machine required in the various production shops for achieve the planned production targets. To function as the central agency for control of new forms and formats . To assess and monitor the standard hours require for manufacturing assembly and testing of various products. In the factory three type employs 1. Skilled 2.Unskilled 3.Semi-skilled Industrial training at HAL 16

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5. Hawk Machine shop:-   The Hawk machine shop is main machining shop where various parts of different fighter jets in addition, airbuses parts are done. Hawk machine shop has following units:- Boring CNC Drilling Grinding Lathe Milling   Industrial training at HAL 17

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6 . Honeycomb workshop :- Honeycomb structures are natural or man-made structures that have the geometry of a honeycomb to allow the minimization of the amount of used material to reach minimal weight and minimal material cost. The geometry of honeycomb structures can vary widely but the common feature of all such structures is an array of hollow cells formed between thin vertical walls. The cells are often columnar and hexagonal in shape. A honeycomb shaped structure provides a material with minimal density and relative high out-of plane compression properties and out-of-plane shear properties . Industrial training at HAL 18

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Industrial training at HAL 19

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Structure of honeycomb Industrial training at HAL 20

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7. Process shop   Chemical Processing of Aluminum: Chemical Conversion Coatings: Many times called chem -film or Anodyne, this treatment involves a pretreatment de-oxidizing etch, rinse, and immersion into a chromate based solution to effect the conversion coat or film. In addition to the enhanced corrosion benefits, improved adhesion of prime-paint is also seen compared to bare aluminum Anodizing: This electro chemical treatment radically improves the corrosion resistance of the aluminum alloy. It is an electrolytic oxidation process where the surface is made the anode in an electrolyte bath with a metal or carbon cathode, and electrical current is passed through the cell. The aluminum surface is converted to aluminum oxide, Al 2 O 3 . The oxide coating is integral to the base aluminum, i.e. it does not simply sit on the surface but is part of, or integral to the base aluminum alloy. As formed, it is porous and capable of being dyed or tinted different colors. Industrial training at HAL 21

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Industrial training at HAL 22

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Anodizing of aircraft parts Industrial training at HAL 23

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8. Information & finance department :- IT management is all about understanding the technology and aligning technology to the business goals which are to be achieved. This involves strategies, tactics and policy creation . IT management creates guidelines for the rest of the department, guidelines which are as rigid or as flexible as the business requires. Finance department :- The finance department is also responsible for management of the organization’s cash flow and ensuring there are enough funds available to meet the day-to-day payments. This area also encompasses the credit and collections policies for the company’s customers, to ensure the organization is paid on time, and that there is a payment policy for the company’s suppliers. Industrial training at HAL 24

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Information department functions Industrial training at HAL 25

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Industrial training at HAL 26

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9. Design Liaison Engineering:- 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. Industrial training at HAL 27

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Design liaison department Industrial training at HAL 28

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10. Heat treatment and Plastic department: Its purpose is to change a mechanical property or combination of mechanical properties so that the metal will be more useful, serviceable, and safe for a definite purpose. By heat-treating, a metal can be made harder, stronger, and more resistant to impact. Heat-treating can also make a metal softer and more ductile. Normalizing Heat treatment of nonferrous metals :- In the wrought form, commercially pure aluminum is known as 1100. Annealing Solution heat treatment Precipitation hardening Stress reliving Industrial training at HAL 29

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Plastic department :- Plastics are used in many applications throughout modern aircraft. These applications range from structural components of thermosetting plastics reinforced with fiberglass to decorative trim of thermoplastic materials to windows. Transparent Plastics Thermosetting plastics Reinforced plastic Acrylic plastic Industrial training at HAL 30

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11. NC pipe bending Tube bending is the umbrella term for metal forming processes used to permanently form pipes or tubing. One has to differentiate between form-bound and freeform-bending procedures, as well as between heat supported and cold forming procedures Press bending Rotary draw bending Roll bending Tree roll push bending Industrial training at HAL 31

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12. Sheet metal and welding :- 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 constructed with sheet metal. Forming processes:- Bending Curling DE cambering Deep drawing Expanding Incremental sheet forming (stretching ) Ironing Laser cutting Perforating Press brake forming Punching Roll forming Rolling Spinning Stamping Water jet cutting Wheeling Fasteners Industrial training at HAL 32

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Welding:- Types of welding use in aircraft industry are followings:- 1. Gas welding 2. Electric arc welding 3. Gas tungsten arc welding 4. Gas metal arc welding ( metal inert gas welding) 5. Spot welding Industrial training at HAL 33

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Gas welding setup Spot welding thin sheet metal Industrial training at HAL 34

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Electric arc welding set up Industrial training at HAL 35

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Metal inert gas (MIG) welding Industrial training at HAL 36

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Metal inert gas (MIG) welding process Industrial training at HAL 37

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Tungsten inert gas (TIG) welding process Industrial training at HAL 38

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Typical setup for TIG welding Industrial training at HAL 39

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13. Tool room and tool engineering:- The tools required for the production of an aircraft are generally manufactured in a tool room comprising of different types of machine tools and associated production equipment. A typical aircraft tool room generally consists of the following types of machine tools and associated production and inspection equipment: Industrial training at HAL 40

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The following tools are manufacture in HAL:- Assembly jigs Drill jigs Milling fixtures Copy mill fixtures Copy mill model Drilling and route templates Form hocks Stretch forming tools Copy forming tools Annealing jigs Malty point and single point Industrial training at HAL 41

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14. Maintenance and safety department:- Maintenance dept.:- The objectives that govern the existence of the maintenance organization should also guide the functional activities of the department. Safety:- Safety and maintenance go hand in hand because in order for items of equipment in a facility to be operated safely, they have to have any hazardous conditions fixed. Industrial training at HAL 42

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M aintenance department objectives Industrial training at HAL 43

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M aintenance department functions:- Repairs Engineering Preventive maintenance Safety Planning and scheduling Estimating Stores control Work management Plant operations Quality Assurance Employee relations Training Record keeping Energy management Regulatory compliance Data base management Budgeting Reports and analysis Financial planning Construction and remodeling Industrial training at HAL 44

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15. Export Assembly / Marketing:- HAL’s cost-effective and widespread skills are available to the International Aerospace Community. HAL has proven capabilities and offers collaborative arrangements in the areas of manufacturing of machine components, sheet metals, assemblies, subassemblies and design and development tasks (Structural analysis, 3D modeling and testing). Some of the work packages for renowned international aerospace leaders include Airbus A320 Forward Passenger Doors Boeing 757 over Wing Exit Doors Boeing 777 Up lock Box Assembly Boeing 767 Bulk Cargo Doors Boeing 737 Freighter Conversion Kits Boeing F/A 18 Gun Bay Door Boeing P-8 I Weapon Doors & Tail cone Euro copter Ecureuil composites Boeing -3D-Modelling / Digitization of Drawings Industrial training at HAL 45

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B oeing 737 cargo door Dornier landing gear & Up lock box Industrial training at HAL 46

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f/a-18 gun bay door p-8i weapon bay door Industrial training at HAL 47

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16. Drop tank :- In aviation, a drop tank (external tank, wing tank, or belly tank) is used to describe auxiliary fuel tanks externally carried by aircraft. A drop tank is expendable and often jettison able. External tanks are commonplace on modern military aircraft and occasionally found in civilian ones, although the latter are less likely to be discarded except in the event of emergency. The primary disadvantage with drop tanks is that they impose a drag penalty on the aircraft carrying them. Industrial training at HAL 48

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17. S tore and integrated materials management:- Materials Management strives to ensure that the material cost component of the total product cost be the least. In order to achieve this, the control is exercised in the following fields . Materials planning. Purchasing. Store keeping. Inventory control. Receiving, inspection and dispatching. Value analysis, standardization and variety Reduction. Materials handling & traffic. Disposal of scrap and surplus, material Preservation. Industrial training at HAL 49

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18. Hawk Wing assembly:- The wing design depends on many parameters such as selection of aspect ratio, taper ratio, sweepback angle, thickness ratio, section profile, washout and dihedral. The cross-sectional shape of the wing is its airfoil. The construction of the wing starts with the rib which defines the airfoil shape. Ribs can be made of wood, metal, plastic or even composites. Industrial training at HAL 50

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19. Hawk Equipping loom shop :- In the HAL the hawk equipping loom shop in which electronic equipment are install in the hawk. In the hawk equipping loom assembly in which following equipping are install :- 1.Pizo static 2.DITCO ( continuity test) 9000 points 3.Oxygen system ( 2 cylinder ) 4.PRB ( pressure measuring device) 5.Power check ( A.C or D.C ) 6.Fuel system check (900 liter fuel) 7.Low and high level device 8.Hydraulic for flight control a)7 flight control Industrial training at HAL 51

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b)Primer (redder tell stock, ailerons c)Secondary (air brake, flaps, jacks) 9.Ground surface a)Under carriage system b)2nd under carriage 10.Wheel brake system 11.Engine driven pump 12.Aileron and tell plan 13.ACS (airmen center system) a)Heat condition and moisture b)Pressure control jacket 14.Cabin pressure check Industrial training at HAL 52

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20.Hawk structural & final assembly:- The whole parts of Hawk are manifested then work is remaining the final assembly. This position is responsible for the structural installation of parts and major components in the manufacturing of the aircraft for the final assembly line. Industrial training at HAL 53

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Industrial training at HAL 54

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Nomenclature of Fighter jet Industrial training at HAL 55

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21. Human resources depart main functions Industrial training at HAL 56

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Thanks for all you Please ask any question. Industrial training at HAL 57

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