TRAINING REPORT ON HINDUSTAN AERONAUTICS LTD. IJT & DORNIER 228

1. Four Weeks Industrial Training
At
Transport Aircraft Division,
Hindustan Aeronautics Ltd, Kanpur
Submitted in Partial Fulfillment for award of Degree of
Bachelor Of technology in Mechanical Engineering
SUBMITTED BY:-
PARAG PRIYANK
75114037
B.Tech (M.E, 7th Sem)
Batch: 2011-2015
Department Of Mechanical Engineering,
Maharishi Markandeshwar University,
Sadopur,
Session 2014-15

2. DOWN THE YEARS
Hindustan Aeronautics Limited is the outcome of merging of Hindustan Aircrafts
Limited and Aeronautics India limited with Aircraft Manufacturing Depot,
Kanpur and came into existence in Bangalore in 1940. Formerly it was in the hand of
Seth Walchand. The Indian Government bought a one-third stake in the company
and by April 1941 as it believed this to be a strategic imperative. 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). During the 1980s, HAL's
operations saw a rapid increase which resulted in the development of new indigenous
aircraft such as the HAL Tejas and HAL Dhruv. HAL also developed an advanced
version of the MiG-21, known as MiG-21 Bison, which increased its life-span by
more than 20 years. HAL has also obtained several multi-million dollar contracts
from leading international aerospace firms such as Airbus, Boeing and Honeywell to
manufacture aircraft spare parts and engines.

3. MILESTONES
1. Today, HAL has 19 Production Units and 10 Research & Design Centers in 8
locations in India.
2. The Company has an impressive product track record - 15 types of
Aircraft/Helicopters manufactured with in-house R & D and 14 types produced
under license.
3. HAL has manufactured over 3658 Aircraft/Helicopters, 4178 Engines,
upgraded 272 Aircraft and overhauled over 9643 Aircraft and 29775 Engines.
4. Turnover of Rs. 15,180 Crore.
5. Has played an important role in development of SLV for ISRO
6. Bagged many awards by international giants of this sector.
7. Has started 11 joint-ventures to cope with the technical advancement in world.
8. Successfully established own composite and plastic manufacturing divisions.
9. Started designing and development of multirole aircraft.
10. Primary exporter of Pax doors to AIRBUS.
11. Successfully manufactured Light Combat Helicopters and Aircrafts

4. DIVISIONS
1. Aircraft Division, Bengaluru
2. Aerospace Division, Bengaluru
3. Aircraft Division, Nasik
4. Aircraft Overhaul Division, Nasik
5. Engine Division, Bengaluru
6. FMD, Bengaluru
7. F&F Division, Bengaluru
8. Engine Division, Koraput
9. Sukhoi Engine Division, Koraput
10. TAD, Kanpur
11. Avionics Division, Korwa (Amethi)
12. Avionics Division, Hyderabad
13. Accessories Division, Lucknow
14. Helicopter Division, Bengaluru
15. Helicopter Division, Barrackpore
16. CMD, Bengaluru
17. H-MRO Division, Bengaluru

5. PRODUCTS AT A GLANCE
HAL-CHEETAL HAL- DHRUV HAL- CHEETAH
HAL - LCH HAL- CHETAK HAL- LANCER

6. HAL – SUKHOI 30 MKI HAL – MIG 27 HAL – MIG 21
HAL - DORNIER HAL - IJT HAL – ADOUR mk 811
HAL – Artouste III B HAL - DART HAL – GARRETTE 331

7. HAL – GNOME 1400 PT HAL - AVON HAL – OREPHUS 7075
HAL – ADOUR MK 804 HAL - MIRAGE HAL – JAGUAR
HAL – GSLV HAL – R 29 B
HAL – R 25

8. Well the list of the products is very long, but some more important product for
which HAL is known worldwide are following:-
 PAX DOORS (For Airbus A 320)
 LANDING GEARS
 CANOPY
 MISSILES
 DRONES (Un-maned Air Vehicle)
 ENGINE FUEL CONTROL SYSTEM
 TEMPERATURE SENSORS
 RUBBER ITEMS
 BRAKES
 HYDRAULIC PUMP
 STARTER GENERATOR
 ACCESSORIES
 FLIGHT DATA RECORDER
 AIR DATA COMPUTER

9. KANPUR DIVISION
In this division there is total emphasis being made on the Transport Aircrafts which
means the aircraft that are used for transport purpose. This division was set-up in
1960 to manufacture HS-748, but with the passage of the time the division has
vastly developed infrastructure and built its technological force to manufacture
varieties of aircrafts, structural assemblies, paint shop and detailed part
manufacturing of various components.
Following are ongoing work in this division:-
HS-748 Aircraft Overhaul
Dornier-228 Aircraft (1985 onwards)
IJT Structural Assembly
Following were the plane which were developed in this division but are obsolete
now:-
HS-748 Aircraft 1960-83
Gliders 1963-86
Basant Aircraft (HA-31) 1975-78
HPT-32 Aircraft 1983-98
ATP Tailplane (for Export) 1987-95

10. Apart from the above, this division is doing servicing of engines and landing
gears of Unmanned Air Vehicles (Searcher-I and Searcher-II) and Heron
since Jan’2004. Even this division has the R&D center located in the campus
which carries out production updates, role modification and other related
activities.
Recently the division has undergone for the LSP (limited series production) for
Intermediate Jet Trainer (IJT) aircraft which is used for training, night flying
and patrolling purposes. The structural assembly is done here and all other
fitments of engine, rudder and other avionics items are made in the Bengaluru
Division. This plane is totally scrutiny over this division all deflections are
checked and maintained by R&D department (wing of DRDO). Over the decades
this division has equipped itself with ample of workforce to meet the demand and
the goals.
There are some of the future plans like:-
Production of 14 seater Saras Aircraft
Series production of 100 seater Multirole-Transport Aircraft
Series production of Intermediate Jet Trainer (HJT-36)
Production of Turbo-Prop Trainer aircraft (HTT-40)

11. There are various departments inside HAL, Kanpur which are integrated and have
cohesion so that there is smooth flow in manufacturing and less deflection according
to the demand. Following are the various departments:-
Dornier-228 Manufacturing
Dornier-228 Maintenance and Servicing
Intermediate Jet Trainer Structure Assembly
HS-748 Overhaul
HPT-32
UAV Engine Maintenance
Avionics
Electronics
Information Center
Data Center
Workshop(CNC, NC, Unconventional and Conventional Processes)
Paint Shop
Human Resource
Detailed Part Manufacturing
R&D Department

12. Central Library
Powerhouse
Rotables
Technical Training Institute
Tool Room
Spare Parts
HAL – Intermediate Jet Trainer
IJT (Intermediate Jet Trainer) is also known as HJT-36 or Sitara. This aircraft is
basically a two-seater aircraft where the trainee pilot seats in front and the instructor
in rear. It has a jet engine.
This aircraft is basically used for training, night flying and surveillance purpose.
Its speed is .75 MK almost 750 km/hr. The student pilot who completes training
successfully can fly in the fighter jet aircraft of Indian Air Force without any doubt.
This plane is sub-sonic. This aircraft is half produced in the Kanpur division and half
in the Bengaluru division.

13. HAL started design work on IJT in 1997. The concept was developed as a successor to
earlier trainer, the HJT-16 Kiran. The first and second prototypes labeled PT-1 and PT-2
flew on 7 March, 2003 and March 2004 respectively.
After further development on engines and extensive testing the Indian Air Force
placed an order for 73 aircraft. After 280 test flights, the aircraft entered in Limited
Series Production in 2009.
In the Kanpur division the structural assembly is done, meaning that development of
front fuselage, rear fuselage and wings and then they are assembled and moved to
Bengaluru division for the installation of engine and other equipment after which the
aircraft will roll out of the production process.
FRONT FUSELAGE
There are four front fuselage jig. In the front fuselage the structure starting from nose
to the rear seating area is assembled. In this section there are stations mentioned on
jig. The station denoted as STA N X starts from 0 to 23 in the front fuselage area. The
X denotes the flight direction towards the nose of the aircraft and N denotes the
number of station. There are longerons/stringers and bulk-heads used to make the
skeleton of the aircraft.

14. In the front section of the aircraft there are 23 bulkheads which are vertical in direction
positioned at different X values. The skeleton structure is also known as spine
structure. The spine structure is totally riveted with the help of snap head rivet, counter
sunk rivet. The diameter of the rivet may vary from 2.7mm to 4.8mm. The riveting is
done with the help of pneumatic riveting device. In the front fuselage the part from STA
0 to STA 1 X=1250 (mm) is known as Nose cone and consists of 10 longerons. From
STA 10 to STA23 there is seating area. The front fuselage extends from STA 1
X=1250(mm) to STA 23 X = 5390(mm).
After the spine structure is ready the skin is fixed on this structure with the help of rivet
and the sealant. The sealant may be 1422B2, 1770 or 8012.
Pic of Front Fuselage

15. REAR FUSELAGE
Rear fuselage of this aircraft starts from STA 24 X= 5690 to STA 42 X= 10770. The rear
fuselage is very long. There are 18 bulkheads in the rear fuselage and 12 longerons.
There are 4 shear-walls between STA 26 to STA 29 and STA 29 to STA 34 which
provides strength to the structure. Between STA 24 to STA 29 there is fuel tank of
capacity 550 ltr. Between STA 29 to STA 32 is the brake assembly. STA 32 to STA 35
provision of fitment. STA 24, STA 26 and STA 29 are wing built up-point during
coupling for fixing the wings on both the sides of this rear fuselage. And the rest of the
structure consists of exhaust manifold. The rear fuselage starts from air intake manifold
and ends at the last tail point of the aircraft.
REAR FUSELAGE

16. WINGS
The wing is conventional and low setting. The total wing span of this aircraft is 9.8
meters. A wing also consists of the skeleton structure but is different. It consists of Spar
and ribs. Ribs are the small and are like the bulk heads and spar are like longerons
running from starting to the tip of the wings. There are 5 spar and 18 ribs. The various
spars are front spar, rear spar and others. The wings are also completed with the help of
Jig known as Wing Assembly Jig. The wing starts from station 1 to station 18. The
measurement of the wing is STA 1 X= 350 to STA 18 X= 4547.7.
After the successful assembly of the structure of the wing the leading edge and trailing
edge of the wing is fixed on the structures with the help of rivets and sealant. Also the
wings of this aircraft contains internal fuel tank of 175 ltrs each, means a total of 350
ltrs.
Also it can carry an external fuel tank of 235 ltrs on each side meaning total external
fuel 470 ltrs.

17. COUPLING
After completion of the above works each aircraft is assembled at COUPLING JIG and
all the respective parts meets the aircraft here. At this floor all the four components Rear
fuselage, Front fuselage and both the wings arrive here are fixed. This is also called as
MEETING POD. Here all the four basic components of aircraft are bolted together with
bolts of high strength. After the completion of this coupling the body is transported to the
BANGLORE DIVISION with the help of freightliner aircrafts where it meets it all
other equipment and auxiliary like engine, landing gears, avionics and others. The
structure developed after this assembling process is known as SKELETON
STRUCTURE.
ENGINE
Engine used is “SATURN- AL- 551”. Developed by: JSC "NPO" Saturn "
Production: JSC "NPO" Saturn "in cooperation with JSC" UMPO "AL-551 - turbofan
engine for training and light combat aircraft. Engine design allows you to create on
its base engine family for various purposes traction from 1500 to 5000 kgf. You can
also create modifications base engine nozzle equipped with thrust vector control, as
well as an afterburner. .

18. Features are 3-stage low-pressure compressor, 5-stage high-pressure compressor,
annular combustion chamber, 1 speed high-pressure turbine, 1 speed low-pressure
turbine. Application On database engine AL-55 engine created Saturn AL-55I for
training aircraft HJT-36 development corporation HAL (India). The first flight of
HJT-36 took place on 9 May, 2009. Implement made by company for license
production of AL-55I in India. Engine family on the basis of the gas generator of the
AL-55 can be mounted on various types of modern aircraft like trainer aircraft for
basic training, advanced drones, trainer and light combat aircraft, Lightweight front-
line fighters. Benefits are latest designs and materials, including tested on a family of
engines AL-31F / FS and 117C, modular engine design provides high maintainability,
reducing operating costs, modern automatic control system ensures the safety of the
engine flying and easy maintenance.
SATURN AL - 551

19. PROCESS CHART
FRONT
FUSELAGE
WINGS
REAR
FUSELAGE
ASSEMBLING
QCD From
DRDO

20. THREE VIEWS OF INTERMEDIATE JET TRAINER
PICTURE of IJT

21. Labeled diagram of IJT

22. TECHNICAL SPECIFICATIONS
 Overall Length – 11 m
 Height (rudder) - 4.4 m
 Wing Span – 10 m
 Vision of front pilot over nose- 18 degree
 Fuselage Length – 11 m
 Max. Width ( without intake) – 1 m
 Vision of rear pilot – 8 degree
 Fuselage fuel Capacity – 550 kg
 Wing fuel Capacity – 175 kg/wing
 External fuel Capacity – 470 kg
 Total fuel Capacity – 1370 kg
 Maximum range with external fuel – 1510 km
 Maximum range with internal fuel - 1055 km
 Maximum altitude – 6 km
 Clean Aircraft Weight – 4250 kg
 Max. all up weight – 5400 kg

23.  PERFORMANCES:-
 Max. Speed/ Mach No. - 750 km/hr/ .75
 Max. rate of climb > 1500m/min
 STAL speed (clean configuration) < 185km/hr
 Take off run < 500m
 Landing Roll < 500m
 SALIENT FEATURES:-
 State of art, DC-Novo Design
 Tandem Seating arrangement
 Conventional configuration with good flying qualities
 Simple mechanical systems
 Manual control
 New modern turbo fan engine
 Active Matrix LCD
 Simple HUD with HUD repeater for rear cockpit
 Failure simulation from rear cockpit
 Command mode ejection

24.  Zero-Zero ejection seat
 Effective training
 Ergonomically spacious designed cockpit
 Adequate internal fuel for normal training
 Data recording
 High thrust to weight ratio engine
 Low specific fuel consumption
 Digital FADEC and hydro-mechanical backup system
 Easy removal
 On condition maintenance, high reliability and maintainability
 ROLES:-
 Pilot Training
 General flying
 Navigation formation flying
 Instrument & cloud flying
 Basic air to ground & air to air aiming
 Tactical flying
 Night flying

25. DORNIER
The Dornier Do 228 is a twin-turboprop STOL utility aircraft, manufactured by
Dornier GmbH (later DASA Dornier, Fairchild-Dornier) from 1981 until 1998. In
1983, Hindustan Aeronautics (HAL) bought a production licence and manufactured
117 aircraft for the Asian market sphere. Approximately 270 Do- 228 were built at
Oberpfaffenhofen, Germany and Kanpur, India. In August 2006, 127 Dornier Do
228 aircraft (all variants) remain in airline service. This is an Un-pressurised aircraft
with Service Ceiling of 25000ft – 28000 ft easily, but after 16000ft there is need of
oxygen from external sources for individual travelling in this aircraft.

26. FRONT FUSELAGE
The fuselage of the DORNIER is made of 7075 aluminium which is an aluminium
alloy, with zinc as the primary alloying element. It is strong, with a strength comparable
to many steels, and has good fatigue strength and average machinability, but has less
resistance to corrosion than many other Al alloys. Its relatively high cost limits its use
to applications where cheaper alloys are not suitable. 7075 aluminum alloy's
composition roughly includes 5.6–6.1% zinc, 2.1–2.5% magnesium, 1.2–1.6%
copper, and less than half a percent of silicon, iron, manganese, titanium, chromium,
scandium and other metals.
The front fuselage extends after nose cone that is STA 1 X= 1200mm to STA 12 X =
5420m where X denotes the flight direction. In this fuselage there is upper section
and lower section which are joined together. The front fuselage basically consists of
cockpit.

27. CENTER FUSELAGE
The center fuselage extends from STA 13 X = 5480mm to STA 24 X= 10680mm. There
are two parts of the center fuselage namely center fuselage front section and center
fuselage rear section. This section of aircraft is basically used for passenger/crew
seating arrangement or material store which is to be transported.
REAR FUSELAGE
Rear fuselage extends from STA 25 X= 11000mm to STA 34 X = 16560mm. This
section is also known as tail section of the aircraft and is converging. It consists of dorsal
fin, tail plane, vertical stabilizer, horizontal stabilizer, elevator.
WING
This aircraft is high-wing aircraft which means that the wings are attached to the upper
section of center fuselage. The total wing span is 16.97 m. The wing consists of one
turbo-prop engine on each side. . There are front, top, bottom and rear spar and 19 ribs.
The wing stretches from STA 1 X = 000mm to STA 19 X = 8485mm

28. Both the wings are equipped with flaps and ailerons which are used during climb and
decent. The flaps and aileron provides the aircraft to take-off and to glide in air and to
land.

29. HORIZONTAL STABILIZER
The working of horizontal stabilizer is to give aircraft desired pitch for take-off and
climb due to varying conditions. This is located at tail of the aircraft. It is controlled
with the help of hydraulic system using trimmer. The pitch that is the angle of
horizontal stabilizer is fixed before take-off as per the operating conditions. The
horizontal stabilizer consists of the elevator which moves up and down providing the
desired airflow at the tail. This elevator also comprises of trim tab which is used when
aircraft needs small vertical climb or decent.
VERTICAL STABILIZER
The vertical stabilizer is one standing vertically at tail of the aircraft. It is joined with
the fin of the aircraft. The vertical stabilizer is responsible for functioning of aircraft in
mid-air.
RUDDER TRIM & TAB
The rudder is that component of aircraft which is responsible for the turning of aircraft
in the air. The rudder is operated from the help of rudder pedal provided at the nose
cone of the cockpit. This rudder also comprises of the trim tab which is used when
there is need of small deflection in direction.

30. Diagram Showing all the basic components of aircraft discussed above
ENGINE
The Garrett AiResearch TPE331 is a turboprop engine originally designed and
manufactured by Garrett AiResearch, and produced by Honeywell Aerospace since
1999 after that company acquired Garrett. It is a 2 stage centrifugal compressor and 3
stage axial turbine engine. It produces maximum 715 horsepower which is ample to
throw this aircraft into air.

31. Basic diagram of Turbo-Prop Engine
In the beginning the propellers blade are at 18 degree that is on-lock condition and
when the maximum power is required the angle is increased to 78 degree. In this engine
there are 15 fuel sprayers in which 5 are primary and 10 are secondary. There are two
spark plugs in the combustion chamber. This is a spark ignition engine and use
aviation turbine fuel. It also has 2 boosters and oil dumper unit using a solenoid and
non-return valve. The engine power provides the THRUST to the aircraft which makes
it to move and further the air profile inside wing helps it to the lift.

32. COCKPIT
The cockpit of the aircraft contains all the control systems and indicators. Some of
them are:-
 PUSH PULL ROD
 RUDDER PEDAL/BRAKE
 RUDDER TRIM
 AIR SPEED INDICATOR
 VERTICAL SPEED INDICATOR
 TURNING & ROTATING SPEED INDICATOR
 MICROPHONE BUTTON
 RUDDER TRIM
 AUTO PILOT
 NAVIGATION MODE
 CENTRAL WARNING SYSTEM
 GPS
 ENGINE CONTROL
 LANDING GEAR CONTROL
 LAT- LONG SYSTEM
 FLIGHT DATA RECORDING

33. COCKPIT OF DORNIER

34. LANDING GAER
The total number of wheels in the landing gear is 4. The nose landing gear consists of 2
wheels and the rear landing gears contain one wheel on either side. The landing gear is
hydraulic and operated with the help of motor. The hydraulic fluid used in the landing
gear comprises of hydraulic oil & nitrogen. The tire pressure for rear landing gear
should be maintained to 72 psi and in front tires the pressure must not exceed maximum
value of 62 psi. The brakes are controlled with the rudder pedal. In the brakes there are
6 pistons which are operated with the help of hydraulics. If in the case the landing gear
is not working then a backup system already stored in the aircraft is used. This backup
system consists of compressed nitrogen stored in the cylinder with a pressure of 2400
Psi.
PAINTING
For this aircraft the painting time taken is one week often. In the painting process first
the structure is cleaned and then a H-primer one time is coated. After 24 hours the coat
of an epoxy primer is applied and then the two coats of Poly-Urethane paint are applied
within quick succession of 72 hours. Different agencies have their own painting styles.
Thus it is not very easy to paint two aircraft for different customers at a single time. The
painting is done with the help of manual spray.

35. PROCESS CHART
NOSE
SECTION
Front Fuselage
Upper Section
Front
Fuselage
Lower Section
Center
Fuselage
Rear
Fuselage
ASSEMBLING
Vertical
Stabilizer
Horizontal
Stabilizer
Wings, Flaps,
Ailerons &
Elevator
ENGINE
Landing
Gears
Chairs, Doors,
Wind Screens
QCD OF DRDO PAINTING

36. MEASUREMENT OF DORNIER

37. TECHNICAL SPECIFICATIONS
 Wing Span – 16.97 m
 Overall Length – 16.56 m
 Overall Height – 4.86 m
 Engine Model – Garrett TPE 331-5-252 D
 Take-off power – 2 x 715 SHP flat rated to ISA
 Propeller type – Hartzell four-bladed
 Propeller Diameter – 2.69m
 Fuel Capacity – 2850 ltrs ( 2250 kg)
 Fuel Consumption – 213 kg/hr
 Weights:-
 Max. Take-off Weight
 Maritime Role - 6400 kg
 Commuter Role – 6200 kg
 Max. Landing Weight – 6100 kg
 Max. Zero fuel Weight – 5590 kg

38.  ROLES:-
 Maritime Surveillance
 Pollution Prevention
 Troop Transport
 Aerial Survey
 Search and Rescue
 Commuter Transport
 Calibration of airport NAV-COM aids
 Remote Sensing Applications
 Casuality Evacuation
 Executive Transport
 Cargo & Logistics Support

39. LESSON EARNT
The most important lesson what I have learnt here is that how to keep in cohesion with
each other and work for the best output in the time when your competitors are just not
following but trying to pull you down. The discipline and the keen and magnanimous
“love with the work” and cohesion and team spirit have been a lesson that inspired
me more in my whole training period.
Well apart from this the lesson what has been in-housed in me was from the section in
what I was training. The manufacturing of Intermediate Jet Trainer and DORNIER
is totally captured in me. I saw the pupils having high moral and total enthusiasm
while working. The workforce of Kanpur division not only comprises of better work
force but also a workforce that has cohesion among all the level of workers.
My moral has become all time high and it only means achieve goals in life ahead.