This presentation provides an overview of Hindustan Aeronautics Limited (HAL) and its Korwa division. HAL was formed in 1940 and is involved in aerospace and defense manufacturing. The Korwa division produces parts for fighter planes like the Sukhoi 30 MKI and some parts for missiles. It specifically manufactures the internal and external flexible joints for the Sukhoi 30 MKI using electric discharge machining. The presentation describes the EDM process and its advantages and disadvantages for precision machining of parts like the flexible joints.

1. PRESENTED BY-
PRASHUN JAISWAL
ROLL NO. 213449
B.TECH 4TH YEAR ME
KORWA
An
Industrial
training
PRESENTATION

2. INTRODUCTION TO HINDUSTAN
AERONAUTICS LIMITED
• THE LATE “SETH WALCHAND HIRACHAND” ,WHO SETUP
HINDUSTAN AIRCRAFT LIMITED AT BANGALORE IN
ASSOCIATION WITH “ERSTWHILE PRINCLY STATE” OF MYSORE
IN 1940.
• THE COMPANY WAS FORMED BY THE MERGER OF “HINDUSTAN
AIRCRAFT LIMITED” WITH “AERONAUTICS INDIA LIMITED”
AND “AIRCRAFT MANUFACTURING DEPOT,KANPUR”.
• HINDUSTAN AERONAUTICS LIMITED CAME INTO EXISTENCE
ON 1ST OCTOBER 1964

3. Type State-owned enterprise
Industry Aerospace and defence
Founded
1940 (in 1964, company
took on current name)
Headquarters
Bangalore, Karnataka,
India
Products
Aerospace equipment
Military aircraft
Communication &
Navigation equipment
Space systems
Revenue US$2.35 billion (FY 2010)
Employees 30,000

4. DIVISIONS OF HAL

5. Fighter Aircraft
1.Su-30 MKI
2. Mig Series
3.Tejas
4.Jaguar
5.MIRAGE -2000
Helicopters
1.Dhruv
2.Cheetah
3.Chetak
4.Advanced Light Helicopters
Unmanned Aerial Vehicles
Engines
1.Lakshya PTA
Passenger Aircraft
1.Dornier
2.Indian Regional Jet
Transport Aircraft
1.Saras
Light Trainer Aircraft
1.Kiran
2.Basant
3.Sitara
Glider
1.HAL G-1
2.Ardhra
Satellite Launch Vehicles
1.PSLV
2.GSLV
3.IRS
4.INSAT
PRODUCTS OF HAL

6. CUSTOMER PROFILE
• Air force
• Army
• Navy
• Coast Guard
• Flying Academics & Educational
Institutions
• Airlines / Air taxi / Air cargo
• Defence R&D Laboratories / Department
of Space

7. HAL KORWA
Avionics Division, Korwa of Hindustan Aeronautics Limited. Avionics
Division Korwa was established in the year 1982.
The Division of HAL, has been built in a pollution free environment
sprawling over approximately 1 million sq.mts. of lush green area .
The total covered area for manufacturing is around 38000 sq. mts
Division has got a highly skilled work force of approximately 1100
including 200 highly qualified engineers.

8. Production of various part of fighter
plane
• JAGUAR
• MIG
• SU-30MKI
• SOME PART OF BARMHOS MISSILE

9. SUKHOI-30 MKI

10. SUKHOI Su-30 MKI
The Sukhoi Su-30MKI has been jointly-developed by Russia's
Sukhoi Corporation and India's Hindustan Aeronautics Limited
(HAL) for the Indian Air Force (IAF).
 It is a heavy class, long-range air superiority fighter aircraft.
 The Su-30 MKI is more advanced than the basic Su-30MK, the
Chinese Su-30 MKK, and the Malaysian Su-30 MKM.
 The aircraft features state of the art avionics developed by
Russia, India , Israel , France and South Africa which includes
display, navigation, targeting and electronic warfare systems.
MKI stands for "Modernizirovannyi Kommercheskiy Indiski"
meaning "Modernized Commercial India".

11. GENERAL FEATURES OF Sukhoi 30 MKI
 Sukhoi 30 MKI is a 4.5 generation fighter aircraft . Fifth
generation planes are yet to come.
 Cost of single Su-30 MKI is $ 35 million or Rs 1.61 billion
 As per deal between Russia’s Sukhoi Corporation and
India’s HAL , in the first phase, components will be
imported from Russia and only assembling will be done
in India.
 In the second phase , there will be transfer of technology
from Russia to India , and then both manufacturing &
assembling will be done in India.
 Various independent sources have claimed Su-30 MKI
to be the most superior fighter plane in present World.

12. IFJ & EFJ
• It is the part of SU30-MKI
• IFJ means internal flexible joint
• EFJ means external flexible joint
• Cost 1 lakh after manufacturing

13. MANUFACTURING SHOP
• This shop manufacture various part of fighter
plane and some part of Barmhos missile
• Present time ,manufacturing parts of Su30-
MKI
• IFJ and EFJ are the part of SU30-MKI fighter
plane
• EDM (electric discharge machine) is use for
the IFJ and EFJ part

15. • Localised extreme rise in temperature of
10,000oC
• heat affected zone is limited to only 2 – 4 μm
of the spark crater

16. Functions of the Dielectric are as follows:
• Insulation
dielectric is to insulate the work piece from the
electrode
• Ionization
spark path must be de-ionized quickly
• Cooling
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

17. ADVANTAGE
• 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.
• No complicated fixtures are needed for holding the job.
• Material of any hardness can be cut.
• High accuracy and good surface finish are possible.
• Intricate-shaped cavities can be cut with modest tooling costs.
• Holes completed in one “pass”
• The EDM process is burr-free.
• Thin fragile sections such as webs or fins can be easily machined
without deforming the part.

18. DISADVANTAGE
• Electrode wear takes place during the EDM
operation when the electrode (i.e. the tool) gets
eroded due to the sparking action.
• Limited to electrically conductive materials.
• Slow process, particularly if good surface finish
and high accuracy are required
• Dielectric vapour can be dangerous.
• Tool life is limited.
• There is a possibility of taper and overcut in
EDM.

19. 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 )

20. EDM WIRE CUT
• Thin metallic wire is fed on-to the work piece
• process can also cut plates as thick as 300mm
• used for making punches, tools and dies from
hard metals
• guides are usually CNC-controlled
• deionized water is commonly used as the
dielectric fluid
• diameter between 0.02 and 0.30 mm.

22. Subsystems of wire EDM
• Power supply.
• Dielectric system.
• Wire feeding system.
• Positioning system

23. Thank You
Any Queries??