HAL, AIRCRAFT-DIVISON,BANGLORE,SUMMER TRAINING REPORT

i
HINDUSTAN AERONAUTICS LIMITED
A dissertation submitted to
FACULTY OF SCIENCE & TECHNOLOGY,
THE ICFAI UNIVERSITY, DEHRADUN
Towards The Partial Fulfillment of The Requirement For
The Award of the Degree of
BACHELOR OF TECHNOLOGY
IN
MECHANICAL ENGINEERING
Submitted By
PRANJUL PAL
131MC00219
Under The Guidance of
MR. P. JAGAN MOHAN, FACULTY MEMBER
FACULTY OF SCIENCE & TECHNOLOGY

ii
A REPORT
ON
COMPARISON OF AIRCRAFT IN AIRCRAFT DIVISION
AT
HAL, BANGALORE
BY
PRANJUL PAL 131MC00219
AT
IP-1 STATION: AIRCRAFT DIVISION HAL, BANGLORE
An Internship Program-I station of
The ICFAI University, Dehradun
(July, 2015)

iii
A REPORT
ON
COMPARISON OF AIRCRAFT IN AIRCRAFT DIVISION
AT
HAL, BANGALORE
BY
PRANJUL PAL 131MC00219 MECHANICAL
Prepared in partial fulfillment of the
IP 201 Internship Program –I Course
AT
AIRCRAFT DIVISION HAL, BANGLORE
An Internship Program-I station of
The ICFAI University, Dehradun
(July, 2015)

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ICFAI INSTITUTE OF SCIENCE AND TECHNOLOGY
Internship Program Division
Station: AIRCRAFT DIVISION Center: HAL, BANGLORE
Duration: 45 days Date of Start: 8th
JUNE
Date of Submission: 31st
JULY
Title of the Project: COMPARISON OF AIRCRAFT
ID No./Name/ 131MC00219/ PRANJUL PAL/ MECHANICAL
Discipline/of
the student:
Name and
Designation Mr. Vandan Kumar
of the expert: Deputy Manager in Sheet Metal Department
Name of the
IP Faculty: Mr. P. Jagan Mohan
Project Areas: Aircraft Division HAL, Bangalore
Signature of Student Signature of IP Faculty
Date: Date:

v
CERTIFICATE
This is to certify that the project work entitled on COMPARISON OF AIRCRAFT
in AIRCRAFT DIVISION at HAL, Bangalore has been carried out by
Mr.PRANJUL PAL(I.D. No. 131MC00219), during the Internship Program 1
which was commenced for the period of June 8th
to July 31st
of the year 2015. It is
certified that all corrections / suggestions indicated have been incorporated in the
report. The project has been approved as it satisfies the academic requirements in
respect of Internship Program I.
Signature of project Guide Signature of IP Faculty

vi
ACKNOWLEDGEMENT
I would like to thank the entire HAL, BANGLORE team to give me an opportunity to
work with them in the organization for the training of two months.
I sincerely would like to thank our Deputy Manager Mr. VANDAN KUMAR along with
them to the company H.R. Mrs. ARTI He always took out time from his busy schedule to
guide me in not only technical matters but also in behavioral matters too.
I would like to express my gratitude towards Mr. P. JAGAN MOHAN, faculty member
of IP-I at HAL, BANGLORE who reviewed the manuscript and provided valuable
suggestions for improvement.
Last but not the least I would like to thank those numerous employees of the company
whose clarity of concepts and ability to solve problems is proverbial. Their unflinching
encouragement shall ever remain as a treasure in my memory.
Thanks to my parents who gave me the logistic support and moral encouragement day
over day.
PRANJUL PAL

vii
PREFACE
Technology has rapidly grown in past two-three decades. An engineer without practical
knowledge and skills cannot survive in this technical era. Theoretical knowledge does
matter as it is the practical knowledge that creates the difference between the batter and
the best. Organizations also prefer experienced engineers than fresher ones due to
practical knowledge and industrial exposure of the former. So it can be said the industrial
exposure has to be very much mandatory for engineers nowadays. The practical training
is highly conductive for solid foundation for:
 Solid foundation of knowledge and personality.
 Exposure to industrial environment.
 Confidence building.

viii
TABLE OF CONTENTS
1. INTRODUCTION............................................................................................................1
1.1 COMPANY PROFILE:..........................................................................................1
1.2 CERTIFICATION:.................................................................................................2
1.3 MISSION:.............................................................................................................. 2
1.4 OBJECTIVES........................................................................................................ 2
1.4.1 Major objectives:.........................................................................................2
1.4.2 Minor objectives:........................................................................................ 2
2. PRODUCTS OF HAL......................................................................................................4
2.1 FIGHTER AIRCRAFTS........................................................................................4
2.1.1 SU-30 MKI..................................................................................................4
2.1.2 JAGUAR.....................................................................................................5
2.2 PASSENGER AIRCRAFT.....................................................................................5
2.3 HELICOPTERS.....................................................................................................6
2.3.1 DHRUV.......................................................................................................6
2.4.2 CHETAK.....................................................................................................7
2.4 LIGHT TRAINER AIRCRAFT.............................................................................8
2.4.1 TEJAS....................................................................................................... 10
2.5 SATELLITE LAUNCH VEHICLES................................................................... 10
3. COMPARISON OF AIRCRAFT................................................................................... 11
4. COMPARISON OF HELICOPTER.............................................................................. 13
5. AIRCRAFT DIVISION................................................................................................. 14
6. HAWK MACHINE SHOP.............................................................................................16
7. HONEYCOMB SHOP...................................................................................................17
8. HEAT TREATMENT & PLASTICS DEPARTMENT..................................................18
9. DROP TANK................................................................................................................. 20
10. NC SHOP & NC PROGRAMING DEPARTMENT................................................... 21
11. METHODS & PROGRAMING ENGINEERING......................................................21
12. HAWK WING ASSEMBLY........................................................................................21
13. HAWK EQUIPPING LOOM SHOP........................................................................... 23
14. HAWK STRUCTURE AND FINAL ASSEMBLY..................................................... 24
14.1 BOEING 777 UPLOCK BOX COMPONENTS.......................................25
14.2 BOEING 737-300 CARGO CONVERSION DOOR & KIT.................... 25
14.3 A320 FORWARD PASSENGER DOORS.................................................26
15. DESIGN LIAISON ENGINEERING..........................................................................26
16. TOOL ROOM & TOOL ENGINEERING...................................................................27
17. PROCESS SHOP & WORK TEST LAB.....................................................................28
17.1 ANODIZING..............................................................................................28
18. EXTERNAL SOURCES..............................................................................................29
19. NC PIPE BENDING SHOP.........................................................................................29
20. HUMAN RESOURCE DEPARTMENT..................................................................... 30
21. CONCLUSION............................................................................................................31
22. BIBLOGRAPHY......................................................................................................... 32

ix
TABLE OF FIG.
FIG 1.................................................................................................................................... 4
FIG 2.................................................................................................................................... 5
FIG 3.................................................................................................................................... 6
FIG 4.................................................................................................................................... 7
FIG 5.................................................................................................................................... 8
FIG 6.................................................................................................................................... 9
FIG 7.................................................................................................................................. 10
FIG 8.................................................................................................................................. 16
FIG 9.................................................................................................................................. 17
FIG 10................................................................................................................................ 18
FIG 11................................................................................................................................ 19
FIG 12................................................................................................................................ 21
FIG 13................................................................................................................................ 22
FIG 14................................................................................................................................ 23
FIG 15................................................................................................................................ 24
FIG 16................................................................................................................................ 26
FIG 17................................................................................................................................ 27
FIG 18................................................................................................................................ 28
FIG 19................................................................................................................................ 29
FIG 20................................................................................................................................ 30

1
INTRODUCTION
COMPANY PROFILE:
Hindustan Aeronautics Limited is an Indian state-owned aerospace an Defense
company based in Bangalore, Karnataka. It is governed under the management of
the Indian Ministry of Defense.
Hindustan Aircraft Company was incorporated on 23 Dec 1940 at Bangalore by Shri
Walchand Hirachand with the aim of manufacturing aircraft in India.The Indian
Government bought a one-third stake in the company and by April 1941 by investing 25
lakhs as it believed this to be a strategic imperative.The first aircraft built was a Harlow
PC-5 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.After India gained independence in 1947, the
management of the company was passed over to the Government of India.
HAL is the One of the largest aerospace companies in Asia, HAL has annual turnover of
over US$2 billion. More than 40% of HAL's revenues come from international deals to
manufacture aircraft engines, spare parts, and other aircraft materials.It is currently
involved in the design, fabrication and assembly of aircraft jet engines helicopters and
their spare parts.
It has several facilities spread across India. The locations where the manufacturing plants
are operated by HAL include Nasik, Korwa, Kanpur, Koraput, Lucknow, Banglore and
Hyderabad. The German engineer Kurt Tank designed the HF-24 Marut fighter-bomber,
the first fighter aircraft made in India.

2
CERTIFICATION:
The ISO 9001 for entire range of products and services.
ISO 14001 for Environmental Management System.
Approval for Research and Design Center by Department of Science and Technology,
Govt. of India.
Approval of Director General Aeronautical Quality Assurance for Military Aviation
Products and Services.
VISION:
" To become a significant global player in the aerospace industry. “
MISSION:
“To become a globally competitive aerospace industry while working as an instrument for
achieving self-reliance in design manufacture, maintainence of aerospace defense
equipment and managing the business on commercial lines in a climate of growing
professional competence.”
OBJECTIVES
Major objectives:
To analyze the existing training practices, its effectiveness and recommend measures to
improve the training practices in HAL.
Minor objectives:
1.To study the frequency of training methods and their effects on the trainees and
recommend certain measures for improvement.
2.To understand the present practices enforced in respect of training at the personnel
department and recommend any changes if necessary.

3
DIVISION OF HAL
 ENGINE DIVISION, BANGALORE
 AIRCRAFT DIVISION, BANGALORE
 AEROSPACE DIVISION, BANGALORE
 HELICOPTER DIVISION, BANGALORE
 INDUSTRIAL & MARINE GAS TURBINE DIVISION, BANGALORE
 OVERHAUL DIVISION, BANGALORE
 FOUNDRYAND FORGE DIVISION, BANGALORE
 ENGINE DIVISION, KORAPUT
 AVIONICS DIVISION, HYDERABAD
 AIRCRAFT DIVISION, NASIK
 TRANSPORT AIRCRAFT DIVISION, KANPUR
 ACCESSORIES DIVISION, LUCKNOW
 AVIONICS DIVISION, KORWA
COLLABORATIONS WITH COMPANIES
 Airbus
 Boeing
 Sukhoi Aviation Corporation
 Israel Aircraft Industries
 RSK MiG
 BAE Systems
 Rolls-Royce plc
 Dassault Aviation
 Dornier Flugzeugwerke
 Indian Aeronautical Development Agency
 Indian Space Research Organization.

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PRODUCTS OF HAL
FIGHTER AIRCRAFT
SU-30 MKI
The Sukhoi Su-30MKI is a twin jet Multi role Air superiority fighter developed by
Russia’s Sukhoi and built under licence by India’s Hindustan Aeronautics Limited for the
Indian Air Force. A variant of the Sukhoi Su-30, it is a heavy, all-weather, long-range
fighter. The Su-30MKI is a highly integrated twin-finned aircraft. The air frame is
constructed of titanium and high strength aluminum alloys.Su-30MKI aerodynamic
configuration is a longitudinal tri-plane with relaxed stability. The aeronautics increases
the aircraft lift ability and deflects automatically to allow high angle of attack flights
allowing it to perform Pugachev’s Cobra. The Su-30MKI is powered by the two Al-31FP
turbofans, eachratedat12,500kgf(27,550lbf) of full after-burning thrust, which enable
speeds of up to mach two in horizontal flight (about2450km/hat ground-level) and a rate
of climbof230m/s. The mean time between overhaul is reportedly 1,000 hours with a
full-lifespanof3,000hours; the titanium nozzle has a mean time between overhaul of 500
hours.
FIG 1

5
JAGUAR
The Jaguar is an ortho dox single-seat, swept-wing, twin engine monoplane design, with
tall tricycle-type retractable landing gear. In its original configuration, it had a maximum
take-offweight in the15 tonne class and could manage a combat radius on internal fuel
alone of 850 km (530 mi), giving the Jaguar a greater operational range than competitor
aircraft such as the Mikoyan MiG-27. The aircraft had hard points fitted for an external
weapons load of up to 10,000 lb (4,500 kg).The SEPECAT Jaguar is powered by the
Rolls-Royce Turbomeca Adour turbofan engine.
FIG 2
Jaguar Aircraft in final assembly shop at HAL, Bangalore
PASSENGER AIRCRAFT
 Dornier
 Indian Regional Jet

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HELICOPTERS
DHRUV
The HAL Dhruv ("Polaris")is a utility helicopter developed and manufactured by India's
Hindustan Aeronautics Limited (HAL). The development of the Dhruv was ﬁrst
announced in November 1984, and it was subsequently designed with assistance from
MBB in German.The HAL Dhruv is of conventional design about 29 percent of its empty
weight (constituting 60 percent of the Air frame’s surface area) is composite materials. It
has been reported that the unique carbon ﬁbre composite developed by HAL reduced the
helicopter’s weight by 50 percent. The high tail boom allows easy access to the rear
doors.
FIG 3
Dhruv Helicopter at HAL Airport, Bangalore

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CHETAK
Chetak is a single-engine, light utility helicopter developed by Sud Aviation. It was
manufactured by Aérospatiale of France, and under licence by Hindustan Aeronautics
Limited in India as Hal Chetak. Over 500 units were manufactured underlicence in
Romania, India and Switzerland. Hindustan Aeronautics Limited (HAL) obtained a
licence to build Alouette IIIs as the HAL Chetak in India. Hindustan Aeronautics Limited
built over 300 units of the helicopter underlicence as the HAL Chetak. They were
primarily in service with the Indian Armed Forces in training, transport, communications
and liaison roles. The Chetak is being replaced by HAL Dhruv in the armed forces. An
option to re-engine the HAL Chetak with the Turbomeca TM333-2B engine for
high-altitude operations in the Himalayas was considered, but not pursued.
FIG 4
Chetak Helicopter

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LIGHT TRAINER AIRCRAFT
KIRAN
The HAL HJT-16 Kiran (Ray of Light) is an Indian two seat intermediate jet trainer built
by Hindustan Aeronautics. Used by the Indian Air Force for intermediate training for
pilots trained on the HPT-32 Deepak. It is used by the Indian Air Force aerobatic team
Surya Kiran and Indian naval aerobatic team Sagar Pawans.
The Kiran was designed to meet an Indian air force requirement for an intermediate jet
trainer. The first aircraft powered by the Rolls Royce Viper Mk11 was flown for the first
time on 4 September 1964. The production aircraft was designated the Kiran I, and first
pre-production deliveries were made to the Indian Air Force in March 1968. Later
production aircraft were fitted with hard points under each wing for weapon training and
re-designated as the Kiran IA. A total of 190MkI and 1A aircraft were built.
FIG 5
Kiran Aircraft at Aircraft Division, Bangalore

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HAWK
Hawk is a British single engine, jet powered advanced trainer aircraft. It has been used in
a training capacity and as a low-cost combat aircraft. Operators of the Hawk include the
Royal Air Force (notably the Red Arrows display team) and a considerable number of
foreign military operators. The Hawk is still in production in the UK and under licence in
India by Hindustan Aeronautics Limited (HAL) with over 900 Hawks sold to 18
operators around the world.
The Hawk is an advanced trainer with a two-man tandem cockpit, a low-mounted
cantilever wing and is powered by a single turbo fan engine. Unlike many of the previous
trainers in RAF service, the Hawk was speciﬁcally designed for training. Hawker had
developed the aircraft to have a high level of service ability, as well as lower purchasing
and operating cost than previous trainers like the Jet Provost. The Hawk has been praised
by pilots for its agility, in particular its roll and turn handling.
FIG 6
Hawk Trainer Aircraft in production line at HAL, Bangalore

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TEJAS
The HAL Tejas is an Indian single-seat, single-jet engine, muti-role light fighter
developed by Hindustan Aeronautics Limited. It is a tail less, compound delta wing
design powered by a single engine. It came from the Light Combat Aircraft programme,
which began in the 1980s to replace MiG-21 fighters.
FIG 7
Tejas Trainer Aircraft at under construction
SATELLITE LAUNCH VEHICLES
 PSLV
 GSLV
 IRS
 INSAT

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COMPARISON OF AIRCRAFT
SU-30 MKI Crew: 1
Length: 21.935m(72.97ft)
Wingspan: 14.7m(48.2ft)
Height: 6.36m(20.85ft)
Wing area: 62.0m²(667ft²)
Empty weight: 18,400kg
Loaded weight: 26,090kg
Max. Take offweight: 38,800kg
Power plant: 2 × Lyulka AL-31FP thrust
vectoring turbo fans, 123kN with after
burner (27,560lbf) each
Maximum speed: Mach 2.0[91] (2,100
km/h or 1,300mph)at altitude; 1,350km/h,
839mph near ground level.
HAWK Crew: 2: student, instructor
Length: 12.43m(40ft9in)
Wingspan: 9.94m(32ft7in)
Height: 3.98m(13ft1in)
Wing area: 16.70m2 (179.64ft2)
Empty weight: 4,480kg(9,880lb)
Useful load: 3,000kg(6,600lb)
Max take offweight: 9,100kg(20,000lb)
Power plant: 1× Rolls-Royce Adour Mk.
951 turbo fan with FADEC, 29kN
(6,500lbf) 29kN
Maximum speed: Mach 0.84 (1,028 km/h,
638 mph) at altitude
TEJAS Crew: 1
Wing area: 38.4m²(413ft²)
Empty weight: 6,500kg
Loaded weight: 9,500kg
Max. Take offweight: 13,200kg
Power plant: 1×F404-GE-IN20turbofan
Internal fuel capacity: 2,458kg
External fuel capacity: 2 x 1,200litre

12
JAGUAR Crew: One.
Length: 16.83m(55ft2½in)
Height: 4.89m(16ft0½in)
Wing area: 24.18m²(260.27ft²)
Loaded weight: 10,954kg(24,149lb)
Max. Take oﬀweight: 15,700kg(34,612lb)
Power plant: 2 × Rolls-Royce/Turbomeca
Adour Mk102 turbo fans
Maximum speed: Mach 1.6 (1,699 km/h,
917 knots,1,056mph) at 11,000m.
MIRAGE -2000 Crew: 1
Wingspan: 9.13m(29ft)
Height: 5.20m(17ft)
Wing area: 41m²(441.3ft²)
Loaded weight: 13,800kg(30,420lb)
Power plant: 1 × SNECMA M53-P2 after
burning turbofan.
Maximum speed: Mach 2.2
(2,530+km/h,1,500+ mph) at high
altitude/1,110km/h(690mph) at low
altitude
KIRAN Crew: 2
Wingspan: 10.70m(35ft1¼in)
Wing area: 19.00m²(204.5ft²)
Power plant: 1×Rolls-Royce Viper
turbojet,11.12 kN(2,500lbf)
Maximum speed: 695km/h
(375knots,432mph)

13
COMPARISON OF HELICOPTER
DHRUV Crew: 1 or 2 pilots
Capacity:12-14 passenger or 4stretchers
Length: 15.87m(52ft0.8in)
Rotor diameter: 13.20m(43ft3.7in)
Height: 4.98m(16ft4.06in)
Disc area: 137m²(1,472ft²)
Power plant: 2×Shakti turbo
shafts,1,000kWeach (1,400shp[139])
Alternate engine: 2 x Turbomeca TM
333-2B2 turbo shaft,746kW(1,000shp)
CHETAH Crew: 1
Capacity: 4 passengers or1,135kg load
Length: 10.24m(33ft7¼in)
Main rotor diameter: 11.02m(36ft1¾in)
Height: 3.09m(10ft1¾in)
Main rotor area: 95.38m2 (1,026ft2)
Power plant: 1 × Turbomeca Artouste IIIB
turbo shaft, 649 kW (870 hp) derated to
410 kW (550hp)each
Maximum speed: 192km/h(119mph)
RUDRA Crew: 1 or 2 pilots
Capacity:12-14 passengers or 4stretchers
Length: 15.87m(52ft0.8in)
Rotor diameter: 13.20m(43ft3.7in)
Height: 4.98m(16ft4.06in)
Disc area: 137m²(1,472ft²)
Power plant: 2 × HAL/Turbomeca Shakti
turbo shafts,1,000kW(1,400shp[17])
Alternate engine: 2 x Turbomeca TM
333-2B2 turbo shaft,746kW(1,000shp)

14
AIRCRAFT DIVISION
Aircraft Division works on manufacturing and maintenance of fighter aircraft and trainer
aircraft. Aircraft Division was established in the year 1940. Since inception, the Division
has manufactured a variety of Aircraft both under licence as well as indigenously
designed and developed.
Apart from 1st order of Hawk Mk132 Aircraft (66 Nos.), the division has signed contract
with Indian Air Force and Indian Navy to supply additional 57 Hawk Aircrafts (40 Nos.
Hawk for Indian Airforce and 17 Nos. Hawk for Indian Navy).
Currently, the Division is manufacturing The Hawk Mk.132, a transonic tandem-seat
ground attack / trainer, powered by a single Rolls Royce Adour Mk.871 turbo fan under
licence from BAE SYSTEMS, UK .
The Division is equipped with modern infrastructure in Plant and Equipment like CAD -
CAM Manufacturing Engineering, Quality Assurance and Customer support System with
2179 highly skilled personnel including more than 511officers working in a covered area
of 2,25,000 sq.m.
The Division has so far manufactured over 2010 aircrafts of various types. With
experience and capabilities built over the past seven decades, the Aircraft Division is
bidding for substantial share in the International Aeronautical market.
The Pilot Project for the implementation of Enterprise Resource Planning (ERP) was
launched in the Division in July 2004. The ERP system was made operational from
Nov-2006. Apart from the existing system, many additional ERP facilities being
integrated.

15
There are more than 25 departments who work together to maintain the production.
These departments are-
 Hawk Machine Shop
 Export Machine Shop
 NC Shop & NC Programming
 Process Shop
 Honeycomb Shop
 Work Test Lab
 Customer Service
 Design Liaison Engineering
 Management Service Department
 Human Resources
 Tool Room & Tool Engineering
 Hawk Structure and Final Assembly
 Hawk Wing Assembly
 Maintenance & Safety
 NC Pipe Bending
 Stores & Inventory
 External Sources
 Methods & Programming Engineering
 IT Department & Finance
 Export Assembly / Marketing
 Sheet Metal / Welding
 Drop Tank
 Heat treatment & Plastics
 Hawk Equipping Loom Shop.

16
HAWK MACHINE SHOP
In Hawk Machine Shop they manufacture the spare parts of Hawk Trainer Aircraft such
as wings panel, wing sheet, ribs of wings, fuel tank, connecting rods, wing frame, pistons,
landing gear parts, flaps etc.
FIG 8
Layout of this hawk machine shop is in the form of Process Layout and continuous
production.
Parts manufactured include the landing gear unit, the flaps, the ailerons, parts of the air
frame, the wing frame, hydraulic pistons used in opening the canopy etc.
These parts manufactured by lathe machine through various operation such as cutting,
boring, grooving, turning, drilling, milling etc.

17
HONEYCOMB SHOP
FIG 9
Honey Comb structure
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 honeycomb sandwich structure was manufactured at HAL using aluminum
honeycomb core and aluminum reverse plate.
We use honeycomb structure to get light weight and more compressive strength in aircraft
and helicopter. Honeycomb structure used in bottom surface and roof of the aircraft and
helicopter.

18
HEAT TREATMENT & PLASTICS DEPARTMENT
The heat treatment and plastics shop mainly deals with the manufacture of the canopies
for the Hawk Mk 132 aircraft.
The canopies were made of either Mono Acrylic Sheets or Poly Acrylic sheets.
FIG 10
Acrylic sheet
The canopies are made through forming process such as-
Vacuum forming
Non Greece forming
Greece Forming
Glow Forming
Wrap Forming
Formula Used for Heating of Sheets
T=10+80x
Where,
x= Thickness of sheet
T= Time in min.

19
For making of canopies we heat the acrylic sheets in the oven at a particular time, after
heating the sheet is like a rubber then we give any shape to this acrylic sheet. If we over
heat this sheet then it melts.
FIG 11
Minimum Thickness of sheet 2.5mm
Maximum Thickness of Sheet 19mm
Vacuum forming process

20
DROP TANK
A drop tank is used to describe auxiliary fuel tanks externally carried by aircraft.
A drop tank is expendable and often jettisonable.
The drop tanks are made by aluminum. Firstly a drop tank framework is made of
aluminum and the sheet metal is used as the skin for the tank.
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
jettisonable. 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.

21
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.
FIG 12
METHODS & PROGRAMING 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.

22
HAWK WING ASSEMBLY
A fixed position layout wherein personnel, supplies, and equipment are brought to the
specially designed jigs which are helpful in hoisting the wing frame and the riveting the
aluminum sheets on to this frame.
In the Hawk aircraft both the wings are joined at the wing assembly and then added onto
the fuselage in final assembly.
Wings are two types these are-
 Rotatary wings
 Fixed wings
Rotatary wings are used in helicopter and fixed wings are used in aircraft, airbus.
FIG 13
Wing Panel of Hawk Aircraft

23
HAWK EQUIPPING LOOM SHOP
Hawk equipping loom shop is responsible for fitting electrical and hydraulics into the
airplane.
The first step in equipping is that the technicians sort out the entire wiring on a table
based on the design specifications and code them accordingly.
Cockpit gauges and controls, hydraulics, fuel tank connections, aileron, rudder and flap
are also connected at this stage.
FIG 14

24
HAWK STRUCTURE AND FINAL ASSEMBLY
In this stage all the components of the aircraft are brought to one place.
The parts are held with the help of specially designed fixtures.
The aircraft is brought here from the equipping and loom shop and the wings are brought
from the wing assembly and finally assembled here.
FIG 15

25
EXPORT MACHINE SHOP
Export machine shop is a work place where our side jet aircraft various part are machined.
In this shop, International airbus and jet fighters small and big parts manufactured and the
layout configuration like the HAWK machine shop and the parts that are being
manufactured are-
 Dornier landing gear
 Boeing 777 Uplock Box components
 A320 Forward Passenger Doors
 Boeing 737-300 Cargo Conversion Door & Kit
 G-150 Rear Fuselage
HAL is manufacture aircraft parts and export following counters
 1.USA
 2.FRANCE
 3.Russia
 4.Switzerland
 5.Israel
BOEING 777 UPLOCK BOX COMPONENTS
B777 Main landing gear uplock box. Uplock box assembly is attached to main landing
gear wheel well and is used to secure the main landing gear of Boeing 777 aircraft in
closed position.
BOEING 737-300 CARGO CONVERSION DOOR & KIT
Boeing 737-300 cargo conversion door and kit include panel bottom, panel side, support
panel assembly, panel top, support fitting assembly, stiffeners, fittings and bracket made
out of aluminum sheets.

26
A320 FORWARD PASSENGER DOORS
FIG 16
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.

27
TOOL ROOM & TOOL ENGINEERING
In this department they design the cutting tools for manufacturing because the tools
required for doing operation in machine.
They provide the design of product and sequence of operation and they give the route
book to the machine shop.
Route book is a book in which all the thing are mention such as product name, product
number, material name, batch number, sequence of operation etc.This department makes
various types of jigs and fixtures for various operations.
A typical aircraft tool room generally consist of following types of machine tools and
associated production and inspection equipment.
FIG 17
The following tools are manufacture in HAL-
 Assembly & Drill jigs
 Milling & Copy mill fixtures
 Copy mill model
 Drilling and route templates
 Form hocks
 Stretch & Copy forming tools
 Annealing jigs
 Multi point and single point.

28
PROCESS SHOP & WORK TEST LAB
In process shop they give the chemical bath to the parts of the products such as cleaning,
painting, removing oil, soap treatment, pickling, de-oxidization, alkaline clean, water
washing, sealing, and drying.
Chemical Conversion Coatings Many times called chem-film or Anodyne, this treatment
involves a pre-treatment 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, Al2O3.
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.
FIG 18

29
EXTERNAL SOURCES
The work of this department to search about the vendors and suppliers and collect all the
information about them. They outsource the raw materials and semi finished pats or
finished pats from the suppliers or vendors. After outsourcing the material they make
record in which they mention the suppliers name, address, name of parts, name of
material, product number, batch number, serial number and they give the data to stores
and inventory department.
NC PIPE BENDING SHOP
This shop deals with the fuel pipes, air-conditioning pipes, hydraulic pipes. The diameter
of these pipes are 25mm to 65mm. These pipes are made of steel or aluminum. The
bending of pipes is done by numerical control machine.
FIG 19

30
HUMAN RESOURCE DEPARTMENT
HR Department is a function in organizations designed to maximize employee
performance of an employer's strategic objectives. HR is primarily concerned with the
management of people within organizations, focusing on policies and systems. HR
departments and units in organizations typically undertake a number of activities,
including employee recruitment, training and development, performance appraisal, and
rewarding. HR is also concerned with industrial relations, that is, the balancing of
organizational practices with requirements arising from collective bargaining and from
governmental laws.
HR Department maintain the record of the employees who working in their organization
and give the salary to the employee and they know in which department there is a lack of
employee, according to that they announce vacancy in that department of the company
and recruit the employee to maintain the production of the company.
FIG 20

31
CONCLUSION
During the internship in Aircraft Division at HAL, Bangalore i learn that how aircraft
works and how HAL manufacture the parts of the aircraft. Basically the flight
management system is one of the most important that can not be compromised at any cost
as it plays an important role in guiding routes to the pilots as well as keeps an check on
various system through flight management computer.
Day by day HAL. is trying to improve its quality by incorporating more feature into it.
HAL being the premier aircraft manufacturers are not that productive.

32
BIBLOGRAPHY
 www.hal-india.com
 BAE System, UK
 Introduction to Aircraft by Francis J.Hale
 Helicopter Flight Dynamics
 IAF
 Eden, Paul, ed. (2006) [2004], The Encyclopedia of Modern Military Aircraft,
London, UK: Amber Books,ISBN1-904687-84-9
 HAL Dhruv (India), Aircraft – Rotary-wing – Civil/military, 13 July 2011
 Army to soon get indigenous weaponised chopper Advanced Light Helicopter Rudra.
The Times of India. 5 September 2011.
 Indian Army to Induct Weaponized Advanced Light Helicopter “Rudra”Soon.
Defence News. Retrieved 31 July 2012.
 Tejas - The Indian Light Combat Aircraft IOC Brochure. HAL Retrieved 5 February
2015.
 Tejas - Leading Particulars and Performance. Tejas Ofﬁcial Site - Aeronautical
Development Agency, DRDO. Retrieved 28 July 2015.
 HAL rolls out ﬁrst in digenously built Sukhoi-30. Access my library.com, 28
November 2004. Retrieved: 15 July 2011
 IAF to upgrade Su-30MKI to'Super Sukhoi' standard”. Economic Times. 28
November 2012. Retrieved 29 November2012.

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