A REPORT ON INDUSTRIAL TRAINING

IN

MANUFAUCTURING SHOP

AT

HINDUSTAN AERONAUTICS LIMITED

KORWA

SUBMITTED TO SUBMITTED BY

Er. AWADHESH KUMAR PRASHUN JAISWAL

MECHANICAL ENGINEERING Roll No:213449

DEPARTMENT B.Tech 4th year (ME)

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ACKNOWLEDGEMENT

It gives us an immense pleasure to present the report of the Project undertaken by me during summer

training. We owe special debt of gratitude to N. K. NISHAD Manager (Training) at Hindustan

Aeronautics Limited, KORWA for his constant support and guidance throughout the course of my

work. His sincerity, thoroughness and perseverance have been a constant source of inspiration for us.

It is only his cognizant efforts that our endeavours have seen light of the day.

We also take the opportunity to acknowledge the contribution of all the staff members at HAL

KORWA for their full support and assistance during the development of the project.

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CONTENTS

1. INTRODUCTION TO HAL

2. ABOUT HAL KORWA

3. FACILITY

4. PRODUCTS BY HAL

5. PRODUCTS BY HAL KORWA

6. REPAIR ,MAJOR SERVICING, SUPPLY OF SPARES

7. MANUFACTURING SHOP

Jig Boring

Electric Discharge Machine

Wire Cut EDM Machine

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INTRODUCTION TO HAL

HAL was established as Hindustan Aircraft in Bangalore in 1940 by Seth Walchand Hirachand to

produce military aircraft for the Royal Indian Air Force. The initiative was actively encouraged by

the Kingdom of Mysore, especially by the Diwan, Sir Mirza Ismail and it also had financial help

from the Indian Government. Mysore was favoured because of the availability of cheap electricity.

The organisation and equipment for the factory at Bangalore was set up by William D. Pawley of the

Intercontinental Aircraft Corporation of New York, an exporter of American aircraft to the region.

Pawley managed to obtain a large number of machine-tools and equipment from the United States.

The Indian Government bought a one-third stake in the company and by April 1941 as it believed

this to be a strategic imperative. The decision by the government was primarily motivated to boost

British military hardware supplies in Asia to counter the increasing threat posed by Imperial Japan

during Second World War. The Kingdom of Mysore supplied two directors, Air Marshal John

Higgins was resident director. The first aircraft built was a Harlow PC-5[3] On 2 April 1942, the

government announced that the company had been nationalised when it had bought out the stakes of

Seth Walchand Hirachand and other promoters so that it could act freely. The Mysore Kingdom

refused to sell its stake in the company but yielded the management control over to the Indian

Government.

In 1943 the Bangalore factory was handed over to the United States Army Air Forces but still using

Hindustan Aircraft management. The factory expanded rapidly and became the centre for major

overhaul and repairs of American aircraft and was known as the 84th Air Depot. The first aircraft to

be overhauled was a Consolidated PBY Catalina followed by every type of aircraft operated in India

and Burma. When returned to Indian control two-years later the factory had become one of the

largest overhaul and repair organisations in the East. In the post war reorganization the company

built railway carriages as an interim activity.

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After India gained independence in 1947, the management of the company was passed over to the

Government of India.Hindustan Aeronautics Limited (HAL) was formed on 1 October 1964 when

Hindustan Aircraft Limited joined the consortium formed in June by the IAF Aircraft Manufacturing

Depot, Kanpur (at the time manufacturing HS.748 under license) and the group recently set up to

manufacture Mig-21 under license (with its new factories planned in Koraput, Nasik and

Hyderabad). Though HAL was not used actively for developing newer models of fighter jets, the

company has played a crucial role in modernization of the Indian Air Force. In 1957 company

started manufacturing Bristol Siddeley Orpheusjet engines under license at new factory located in

Bangalore.

ABOUT HAL KORWA

Welcome to the Avionics Division, Korwa of Hindustan Aeronautics Limited. Avionics Division

Korwa was established in the year 1982, to take up the production of Display Attack Ranging and

Inertial Navigation (DARIN) system for Jaguar International aircraft for Indian Air Force. Since,

1987 Korwa Division has also been manufacturing and supplying similar avionic systems for MiG-

27 aircraft to IAF. All the facilities required for manufacture of such advanced airborne avionic

systems are available under one roof. The Division of HAL, has been built in a pollution free

environment sprawling over approximately 1 million sq.mts. of lush green area including complete

amenities for a residential complex. The total covered area for manufacturing is around 38000 sq.

mts. The Division has got a highly skilled work force of approximately 1100 including 200 highly

qualified engineers.

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FACILITY

For the manufacture of advanced avionic systems, Korwa Division has well equipped laboratories,

modern test facilities and advanced high accuracy automatic production equipment and machines as

mentioned

High precision of CNC Machining Centres, Lathes, Milling machines

High precision Jig Borers & Jig Grinders

CNC Tool & Cutter Grinder, EDM, Electron Beam Welding machines

Precision Tool Room/Process Shop with Heat Treatment and Plating facilities.

Optical Component fabrication facilities

Automatic Test Equipment for testing of Electronic modules

Laser Trimming & Dynamic Balancing of Gyroscopes

General Purpose ATE for Repair & Testing of Multilayer PCBs having VLSI/Hybrid components

Super Clean and Controlled environment rooms (upto Class 100)

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PRODUCTS BY HAL

Su 30 MKI - Twin-seater, Multi-role, Long range Fighter / Bomber / Air Superiority Aircraft

MiG-27 M - Single-seater Tactical Fighter / Bomber with variable sweep wings

MiG-21 VARIANTS - Single-seater Front line Tactical Interceptor / Fighter Aircraft

METALLIC DROP TANKS - The Division manufactures different types of metallic drop

(Jettisonable) tanks with capacity of 490 and 800 litres

UNDERCARRIAGE - The Division has facilities and expertise in the manufacture and

overhaul of Undercarriages of both MiG-27M and MiG-21 variants. The landing gears are of

a conventional tricycle type and consist of one steerable Nose wheel leg and two Main wheel

legs to roll the aircraft in motion, on the ground, during take-off run and landing run. The

Landing Gear legs have Pneumatic shock absorbers.

EJECTION SEAT - The Ejection Seat is installed to provide safe escape to the Pilot from

the Aircraft while catapuling is effected with the help of a combined Ejection Gun. The

Division has the facilities and expertise in the manufacture and overhaul of ejection seats for

both MiG-27M and MiG-21 variants.

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CANOPY -The Division manufactures and overhauls canopies of MiG-21 variants and MiG-

27M Aircraft.

FLEXIBLE RUBBER FUEL TANKS - The Division manufactures and supplies all types of

Rubber Fuel Tanks required for MiG-21 Variants. The Rubber Fuel Tanks are provided with

special protection coating against Ozone/heat and adverse climatic conditions.

PRECISION COMPONENTS- The Division also produces precision components like: total

gamut of Blades ranging from Compressor Rotors and Stators to Turbine Blades and Nozzle

Guide Vanes, intricate Cored Magnesium Alloy Gear Casings, Compressor and Turbine Discs

and Shafts, JIS class-l/DlN 5 Spur, Helical Gears and DIN 6 straight and Hypoid / Spiral

Bevel Gears ranging from module 1 to 6.

HYDRAULIC SYSTEM AND POWER CONTROL- Hydraulic Pumps, Accumulators,

Actuators, Electro-selectors, Bootstrap Reservoirs and various types of valves

ENVIRONMENTAL CONTROL SYSTEM- Cold Air Unit, Water Extractors, Non

Return Valves and Venturies

ENGINE FUEL CONTROL SYSTEM- Fuel after Burner regulator and distributor, Main

Fuel Distributor, Regulator and After Burner Pump, Plunger Pumps, Fuel Metering Device

INSTRUMENTS- Electrical Indicators, Fuel quantity and flow metering instruments, Flight

instruments, Sensors and Switches

ELECTRICAL POWER GENERATION AND CONTROL SYSTEM-AC/DC

Generator, Control and Protection Units, AC and DC Master Box, Inverters, Transformer

Rectifier Unit, Actuators

UNDERCARRIAGE, WHEELS AND BRAKES -Main and Nose Undercarriage, Main

and Nose Wheel, Brake System LRUs

TEST RIGS -Dedicated Test Rigs, custom-built Fuel/Hydraulic Test Rigs and Electrical

Test Rigs

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PRODUCTS BY HAL KORWA

Currently korwa Division is manufacturing the Navigation, Ranging, Display and Attack Systems for

both jaguar and MiG-27 aircraft.

Brief details of the avionic system are as under:

Jaguar avionics

Jaguar avionicsInternational Navigation System

Stabilized Inertial Platform with Dry-tuned Gyroscopes and Accelerometers

Digital Nav-Attack Computer

Interface Unit and Cockpit Control Panels

Head-Up Display & Weapon Aiming Computer (HUDWAC)

Microprocessor based head-up Display & Sighting System

Scan and Cursive modes of display

Weapon Aiming Computations in Reversionary modes in the event of failure of INS Computer

Combined Map and Electronic Display (COMED)

Head Down Navigation & Map Display

Soft key Selectable Display Modes

Integrated with INS and HUDWAC on MIL-STD 1553B Digital Data bus

Flight Data Recorder (FDR)

Crash protected Flight Data Recording System with Data Acquisition unit

Simultaneous recording of Data and Audio tracks

Recording Duration of 90 minutes in endless loop

Laser Ranger and Marked Target Seeker (LRMTS)

Operates both in Ranging and Target Seeking modes

Target Range Computation

Neodymium Doped YAG Laser

Autostabliser System (AUTOSTAB)

Computer Based System for Control of Tailplane, Rudder and Spoiler Movements

Incorporate BITE Facility

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MiG-27M Avionics

MiG-27M AvionicsIntegrated Navigation And sighting Complex (44 LK System)

Inertial Navigation System

Centralized Digital Computer

Radio and Doppler Navigation

Stabilised Sight

Air Data Computer

Laser Ranging System

Flight Data Recorder (UZL TESTER)

Recording Duration of 3 Hours

Crash Protected Recording System

Records 38 Analogue and 32 Discrete Parameters

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REPAIRS, MAJOR SERVICING, SUPPLY OF SPARES

This Division undertakes the repair and overhaul of the airborne avionic systems of Jaguar, MiG-27

and Mirage-2000 aircraft throughout the lifecycle of the product.

The Division also provides the comprehensive customer services and support to Indian Air Force

(IAF). The broad spectrum of customer services provided by the division comprises of the following.

Supply of spares to Indian Air Force

Quick response and fast turnaround servicing of avionic systems and LRUs

Regular workshops both at in-house training school and at Air Force bases to the IAF personnel

Updation of the avionic systems to cater to the needs of the customers for the induction of new

armaments and weapon systems.

Design, manufacture and supply of the computer based dedicated, special to Type test Equipment to

IAF.

Apart from the above, Korwa division provides similar services to other customers e.g. indian Navy,

Army and other defence organisations for the products akin to our production range.

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MANUFACTURING SHOP

JIG BORING MACHINE

• Jig borers are vertical boring machines with high precision bearings.

• It was developed primarily for accurately locating and producing holes in precise locations.

They are also called precision co-ordinate measuring machines. It’s used for making

numerous holes necessary for jigs, fixtures, gauges and other precision parts.

• The most important tool used in jig borers is: single- point boring bar. Other tools like drills,

reamers, and counter borers are also used.

• Very important tool before age of computer-controlled machining centers.

• Jig boring is used to accurately enlarge existing holes and make their diameters highly

accurate. Jig boring is used for holes that need to have diameter and total runout controlled to

a high degree. Typically, a part has holes machined on regular equipment and then the part is

transferred to a dedicated jig boring machine for final operations on the especially accurate

holes.

• Jig boring can also maintain high accuracy between multiple holes or holes and surfaces.

Tolerances can be held readily within ±.005 mm (±0.0002 inches). Dedicated jig boring

machines are designed to machine holes with the tightest tolerances possible with a machine

tool.

• When designing a part with holes, it is important to determine what holes must be jig bored.

The reason for this is that jig boring requires extra time and attention. Jig boring can therefore

have a big impact on the lead time of a part. A cross section of a hole being jig bored is

shown below.

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• Standard boring can be carried out on a mill fitted with a boring head or on a lathe. Boring is

accurate on a lathe since a lathe is dedicated to solids of revolution (axially symmetric parts).

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DESCRIPTION:

A jig borer is built lower to the floor & is much more rigid and of highly accurate

construction.

On the base of it a saddle is supported which move in and out from the operator to the

column. A table is provided to supplement the saddle movement which can move to right or

left.

Third position adjustment is achieved by the movement of a massive column which support

the spindle housing which is capable of moving up and down the column ways.

The spindle moves inside the quill, and the quill moves up-down inside housing, thus giving

Telescopic mechanism.

For purpose of high accuracy & precision, the spindle, quill and housing are manufactured

under careful conditions. The spindle and spindle bearing are constructed with very high

accuracy.

To minimise the errors due to thermal expansion, the housing is made of Invar Cast Iron.

Driving mechanism provides speeds ranging from 30 to 1500 r.p.m. so that best cutting speed

is there for each size holes.

It is very important for the proper use of jig borer that it is kept in a temperature controlled

room.

In jig boring only soft material up to a certain hardness can be machined like aluminium,

brass and steel.

Single point boring tool consist of a round shaft with one insert pocket designed to reach into a part hole

or cavity to remove internal stock in one or several machine passes.

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Advantages of boring over reaming: Better finish is obtained. Boring can be done for all sizes while

in reamers only standard sizes available. Reamer have a tendency to run away from central axis

hence reamers do not give excellent surface finish.

COMPARISON OF BORING ON A BORING MACHINE AND LATHE

LATHE JIG BORER

For a normal boring operation on a

lathe, the work revolves mounted in the

chuck or on the faceplate, and the

single-point boring tool is set to cut and

feed.

For the corresponding operation on a jig-borer, the work

is stationary on the machine table, while the single-point

boring tool revolves and is fed.

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On a lathe, however, it would mean

loosening and resetting the work, a

longer and more difficult job.

The table of the jig-borer can be moved by accurate feed

screws in two directions at right angles, the position of a

hole can be located on the feed screw micro meter

collars. The positions of other holes can be obtained by

using end gauges against stops.

ELECTRIC DISCHARGE MACHINE (EDM)

EDM is a thermo electrical material removal process, in which the tool electrode shape is

formed as mirror image on work piece surface.

The machine tool holds an electrode, which advances into the work material and produces a

high frequency series of electrical spark discharges.

The EDM phenomenon can be divided into three stages namely application of adequate

electrical energy, dielectric breakdown, sparking and expulsions (erosion) of work material.

The control of erosion of the material is achieved by rapidly recurring spark discharges

produced between the electrode and work piece.

Localised extreme rise in temperature of 10,000o

C leads to material removal due to instant

vaporization of the material as well as due to melting. However, the heat affected zone is

limited to only 2 – 4 μm of the spark crater as there is not enough time for the heat to diffuse

towards work piece.

The metal removal rates and surface finish are controlled by the frequency and intensity of

the spark. With high sparking frequencies the spark erosion gives substantial metal removal

rates. It has been found that high frequency and low amperage settings give the best surface

finish.

The higher amount of erosion occurs at the positive electrode, therefore, to have maximum

material removal from work piece and have minimum wear on tool, the tool is made cathode

and work piece as anode.

Material removal depends on mainly thermal properties of the work material rather than its

strength, hardness etc.

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Functions of the Dielectric are as follows:

Insulation: One important function of the dielectric is to insulate the work piece from the

electrode. The disruptive discharge (a sudden large increase in current through an insulating

medium resulting from failure of the medium to withstand an applied electric field) must take

place across a spark gap which is as narrow as possible. In this way efficiency and accuracy

are improved.

Ionization: After the impulse the spark path must be de-ionized quickly so that the next

discharge can be made. The dielectric ought to constrict the spark path as much as possible,

so that high energy density is achieved, which increases discharge efficiency at the same

time.

Cooling: The spark has a temperature of 8,000-12,000° C when it punctures the work piece

and so the dielectric must cool both the electrode and the work piece. Overheating of the

electrode must be avoided, so that excessively high electrode wear cannot occur. It must be

possible for the metal gases which develop during spark erosion to condense in the liquid.

ADVANTAGES

1. EDM has no contact and no cutting force process, and therefore does not makes direct contact

between tool electrode and the work material. This eliminates the chances of mechanical

stress, chatter and vibration problems, as is prominent in traditional machining.

2. No complicated fixtures are needed for holding the job.

3. Material of any hardness can be cut.

4. High accuracy and good surface finish are possible.

5. Intricate-shaped cavities can be cut with modest tooling costs.

6. Holes completed in one “pass”

7. The EDM process is burr-free.

8. Thin fragile sections such as webs or fins can be easily machined without deforming the part.

DISADVANTAGES

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1. Electrode wear takes place during the EDM operation when the electrode (i.e. the tool) gets

eroded due to the sparking action.

2. Limited to electrically conductive materials.

3. Slow process, particularly if good surface finish and high accuracy are required

4. Dielectric vapour can be dangerous.

5. Tool life is limited.

6. There is a possibility of taper and overcut in EDM.

CHARACTERISTICS OF EDM:

PARAMETERS VALUES

Spark gap 0.005 mm - .125 mm

Spark frequency 100-500 KHz

Peak voltage

across gap

30-250 V

MRR 5000 mm3/min.

Dielectric fluid EDM synthetic hydrocarbon

Tool material Do not know ( maybe copper )

Wire Cut Electric Discharge Machining

The Wire Electric Discharge Machining (WEDM) is a variation of EDM and is commonly known as

wire-cut EDM or wire cutting. In this process, a thin metallic wire is fed on-to the work piece, which

is submerged in a tank of dielectric fluid such as de-ionized water. This process can also cut plates as

thick as 300mm and is used for making punches, tools and dies from hard metals that are difficult to

machine with other methods. The wire, which is constantly fed from a spool, is held between upper

and lower diamond guides. The guides are usually CNC-controlled and move in the x–y plane. The

wire-cut EDM is every useful used for cutting very intricate and delicate shapes.

In the wire-cut EDM process, deionized water is commonly used as the dielectric fluid.

Wires made of brass are generally preferred with diameter between 0.02 and 0.30 mm.

The deionized water helps in flushing away the debris from the cutting zone. The flushing

also helps to determine the feed rates to be given for different thickness of the materials. The

schematic of wire cut EDM is shown in Figure.

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The WEDM process requires lower cutting forces in material removal. Hence it is generally used

when lower residual stresses in work piece are desired (as in case of aircraft parts).

If the energy/power per pulse is relatively low (as in finishing operations), little changes in the

mechanical properties of the material are expected due to the low residual stresses. The materials

which are not stress-relieved earlier can get distorted in the machining process.

PROCESS OF MATERIAL REMOVAL IN WEDM

In the WEDM process, the motion of wire is slow. It is fed in the programmed path and material is

cut/ removed from the work piece accordingly. Electrically conductive materials are cut by the

WEDM process by the electro-thermal mechanisms. Material removal takes place by a series of

discrete discharges between the wire electrode and work piece in the presence of a dielectric fluid.

The dielectric fluid gets ionized in between the tool-electrode gap thereby creating a path for each

discharge. The area wherein discharge takes place gets heated to very high temperatures such that the

surface gets melted and removed. The cut particles (debris) get flushed away by the continuously

flowing dielectric fluid.

WEDM is a non-conventional process and is very widely used in tool steels for pattern and die

making industries. The process is also used for cutting intricate shapes in components used for the

electric and aerospace industries.

Applications of Wire-Cut EDM

Wire EDM is used for cutting aluminium, brass, copper, carbides, graphite, steels and

titanium. The wire material varies with the application requirements. Example: for quicker

cutting action, zinc-coated brass wires are used while for more accurate applications,

molybdenum wires are used.

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In aerospace industry, WEDM is used to manufacture parts including engine, fuel system,

and landing- gear components, as well as other high-stress, high-temperature parts.

Virtually all commercial, scientific, and military aeronautical and aerospace hardware has

used parts manufactured partially or in whole by WEDM.

The aerospace industry needs the WEDM process to make many of the components used in

aircraft because of the intricate shapes, tough alloys, and very tight tolerances involved.

Subsystems of wire EDM

Power supply.

Dielectric system.

Wire feeding system.

Positioning system.

The power supply and di-electric system used in WEDM is very similar to that of the

conventional EDM. The main difference lies only in the type of dielectric used. In wire cut EDM, a

moving wire electrode is used to cut complex outlines and fine details in the required work piece.

The wire is wound on a spool and is kept in constant tension. The drive system continuously delivers

the fresh wire on-to the work area. New wire is continuously exposed to the work piece hence the

wear of the wire (tool) is not the major issue in WEDM process. The wire feeding system consists of

a large spool of wire and rollers which direct the wire through the machine. The presence of metal

contact provides power to the wire and guides it further in-order to keep it straight throughout the

cutting process. The other parts are the pinch rollers which provide drive and wire tension.

Process Parameters in WEDM

The process parameters that can affect the quality of machining or cutting or drilling in WEDM

process are as follows:

Electrical parameters: Peak current, pulse on time, pulse off time and supply voltage and

polarity.

Non-electrical parameters: Wire speed; work feed rate, machining time, gain and rate of

flushing.

Electrode based parameters: Material and size of the wire.

Dielectric System: Type, viscosity, and other flow characteristics.

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CONCLUSION

The joy of flying has fascinated the human race for centuries. Defense avionics major & Navratana

PSU Hindustan Aeronautics Limited ( H A L) is in the business of building a w hole range of

aircraft , helicopters and jet trainers .Besides , the company manufactures aircraft components,

overhauls fighter planes and trains future pilot’s . its success in the design and development of light

combat aircraft Tejas and advanced light helicopter Dhruv has won admiration. HAL is the backbone

of India’s air defense and continues to occupy the strategic importance reflecting a new pace of

growth.Today the faster growing sector is the aviation sector & is likely to be a boon for the entire

job market . It deals with the manufacture, design & development of aircrafts.The project is based on

the instruments that are used in the manufacture of the various aircrafts. A deep knowledge of these

instruments is crucial in the perfect design & manufacture of the air crafts. The project will benefit

those who have interest in the instrument & will provide the reader with the deeper knowledge of the

topic.