This document summarizes Abhishek Kumar Yadav's 4-week summer training at Hindustan Aeronautics Limited's Transport Aircraft Division in Kanpur from June 22nd to July 19th, 2015. It describes the successful completion of his training and wishes him success in his life. It expresses gratitude to HAL TAD Kanpur for providing the opportunity and experience.

1. This is to certify that Abhishek kumar yadav, a student
of B.tech in Mechanical engineering of Kashi institute
of technology, Varanasi has successfully completed his
summer training in Hindustan Aeronautics Limited,
Transport Aircraft Division, Kanpur during the period
of 4 weeks from 22nd June, 2015to 19th July, 2015.
He possesses a good character and I wish him all the
success in his life.
A.K.Pandey
Deputy General Manager
HAL TAD Kanpur

2. Industrial training refer to work experience to that is relevant
professional developmentas an essential component in the
developmentof the practical and professional skill required of a
manager and an aid to prospective employment.
Teaching gives the knowledge of theoreticalaspect of
machine but implementationof theory given practical
knowledge of mechanicalfield.
The aim of this training is to introduce the fundamentaland
the basic principleof mechanicalengineering in real life day
to day applicationof machines.
Practical knowledge of theory is greater importance for
mechanicalstudent. We are thankful to Kashi institute
of technology mirzamurad, Varanasi for arranging
summer training before entering into the specializationfield.
This project report is an onlineof what we have learnt during
out training period at Hindustan aeronautics
limited, transport aircraft Division, Kanpur
one of the prestigious government organizationrunning with
strategy value and time management. We are thankful to
ordnance equipmentfactory for giving me such a valuable
opportunityto work with them.

3. It has been rightly said “whenever people are willing but unable
to perform particular task” they need cooperation of experienced
people which is quite imperative in achieving the desired goals.
I take this opportunity to express my immense gratitude to
Mr.RamAvatar (Chief Manager, Training), HAL TAD Kanpur, who
always motivated me to learn and to do something extraordinary.
He provided me with a very friendly environment in the industry. He
provided me with all necessary resources which greatly helped me in
completing my training in time.
I am also immensely thankful to all staff of HAL TAD, Kanpur for
guiding me throughout the training and planning. My training visits
and providing me with required me with required study material
which helped me in the training report and enhanced my practical
knowledge.
I would like to express my gratitude to my college Kashi Institute of
Technology, Varanasi and my department faculty for giving me the
golden opportunity of pursing my summer training at Hindustan
Aeronautics Limited, Transport Aircraft Division , Kanpur in
MECHANICAL DEPARTMENT.
Abhishek kumar yadav
Mechanical Engineering
3rd
Year

4.  Introduction
 Division of HAL
 Design and development
 Customer profile of HAL
 HAL transport air craft Division
 Division of DPM
 Electroplating
 Detail assemblyshop
 Chemical milling shop
 Welding shop
 Heat treatment process
 Anodizingprocess
 Hydraulic press shop
 RAR shop
 Paint shop
 Fly press shop
 Break press shop
 Conclusion

5. PROFILE OF HAL
Hindustanaeronauticslimited was begun in the year 1940 on
3rd
December, when a far-sighted industrialist,the Seth
WalchandHirachand set up a company called Hindustan
Aircraft Limited at Bangalore, with the object of establishing
an Aircraft industry that can manufacture, assemble and
overhaulaircraft under license. Initiallyaircraft like Curtiss
Hawk, Vutee Bomber and Harlow Trainer were taken up for
the manufacture and overhaul in collaborationwith Inter
ContinentalAircraft Company of the USA.
In six decades, HAL has spread its wings to cover various
activities in the areas of design, development,manufacture
and maintenance.Today HAL has 20 productiondivisions
spread over at Bangalore, Nasik, Koraput, Kanpur, Lucknow,
Korwa and Hyderabad.These divisionsare fully backed by 9
divisioncentres, which are co-located with the production
divisions. These centres are engaged in design and
developmentof Combat aircraft, Helicopter, Aero Engine,
Engine Test Beds, Aircraft Communicationand navigation
system and accessories of mechanicaland fuel system and
instruments.

6. To meet the challenges of open market economy of present
times the mission of the organizationhas been defined as….
“To become a globallycompetitive aerospace industry while
working as an instrument for achieving self-reliance in design
, manufacture and aerospace defence equipment and
diversifying to related areas, managing the business on
commercial lines in a climate of growing professional
competence.”
HAL, Kanpur is Transport Aircraft Division.Kanpur division
was commenced in 1960 in the name of Aircraft
ManufacturingDepot (AMD) under the functionalcontrol of
IndianAir Force for the licensed manufacture of HS-748
(Transport Aircraft). The Aircraft ManufacturingDepot was
merged with AeronauticsIndiaLtd. (A Government of Indian
undertakingthat was constituted for manufacturing of MIG
Aircraft) in June 1964.
Subsequentlyin October 1964, the entire aircraft industry
includingHindustanAircraft Limited with its head office at
Bangalore. The erstwhile Aircraft ManufacturingDepot
becomes the Kanpur Divisionof HindustanAeronautics
Limited. This was originallyset up for manufacture of AVRO-
748 Transport Aircraft; the divisiontoday manufacture
DRONIER-228 aircraft. The divisionalso undertake repair and
overhaul of HS-748, HPT-32, AN-32, Canberra and Gliders.
Kanpur divisionis gearing up for the manufacturingof civil
aircrafts.

7. HAL has produces division these are spread over location in the country.
These are 4 complex and 10 R&D centre.
A. Bangalore Complex:-
 Aircraftdivision
 Engine division
 India marine gas turbine
 Overhauldivision
 Aerospacedivision
 Foundry& forge
 Airportservicecentre
 Facility management
B. Mig Complex:-
 Aircraftoverhauldivision Nasik
 Aircraftdivision Nasik
 Engine division Koraput
 Sukhoiengine division Koraput
C. Helicopter Complex:-
 Helicopter division
 Helicopter MRO
 Barrakporedivision
Composite MFG division
D. Accessories Complex:-
 TAD Kanpur
 Accessories division Lucknow
 Avionics division Hyderabad
 Avionics division Korwa

8.  Aircraft R&D center (ARDC), Bangalore
 Rotary wings R&D Center (RWRDC), Bangalore
 Aircraft upgrade research and design center, Nasik
 Transport Aircraft research and design center,
Kanpur
 Mission and combat system R&D center,
Bangalore
 Engine and test bed R&D center, Bangalore
 Strategc electronic R&D center, Hyderabad
 Aerospace system &Equipment R&D center,
lucknow
 Composite materials & processes laboratory
&Non-destructive testing Center, Bangalore
 Gas turbine R&D Center, koraput

9. DOMESTIC CUSTOMERS:
*Indian Air Forces
*Indian Army
*Indian Navy
*Indian Coast Guard
*Indian Space Research Organisation
*Defence Research & Development Organisation
*Ordnance Factory Board
*Board Security Force
INTERNATIONAL CUSTOMERS:
*Ruag, Germany
*Royal Thai Air Force, Thailand
*Nepal Army, Nepal
*Mauritius Police Force, Mauritius
*Coastal Guard, Mauritius
*Airbus Industries, France

10. HISTORICAL PERSPECTIVE AND GROWTH OF KANPUR DIVISION:-
Activities of HAL Kanpur commenced in 1960 in the name of Aircraft
Manufacturing Depot (AMD) under the functional control of
maintenance command of I.A.F. of the manufacture of HS-748
aircrafts.
AMD was merged with AIL in June 1964 subsequently in Oct 1964;
the entire aircraft industry was reconstituted as HAL (Hindustan
Aeronautics Limited) with its head office at Bangalore. The erstwhile
AMD become the Kanpur division of HAL.
Over the years it has developed its capabilities and is today
considered a pioneer in the field of manufacture and overhaul of
transport category aircraft in the country. The plant accommodates
73500 sq. meters and the total strength of Kanpur division
employees are 1597 (as on 28th
feb,2004) in which the total number
of officers are 320. The workers are divided into two parts:
1. Direct
2. Indirect
The total numbers of indirect workers are 590 and indirect workers
are 687.

11. PRODUCTS OF THE DIVISION:
The products of TAD KANPUR DIVISION can be classified in the
following two categories:
A.CLOSED PROJECTS:
1. HS-748 AIRCRAFT PRODUCTION
2. ROHINI GLIDER AND ITG-3 GLIDER
3. BASANT AIRCRAFT
4. ARDHRA GLIDER
5. MOTOR GLIDER
6. A.T.P. TAIL PLANE
B. RUNNING PROJECTS
1. DRONIER-228 AIRCRAFT
2. HS-748 A/C SERVICING
PRODUCTIIONOF HAL KANPUR DIVISION AT A GLANCE
Over the year, HAL Kanpur division has manufacturing following
aircraft in which only the production of Dronier-228 is continuing and
other aircraft servicing and overhauling is carried out.
Production Period Qty
HS-748 Aircraft 1960-83 89
Gliders 1963-86 164
Besant Aircraft(HA31) 1975-78 19
HPT-32 Aircraft 1983-98 142
Dronier-228 Aircraft 1985onwards 105
ATP Tailplane 1987-95 24

12. DETAIL PART MANUFACTURING
Division of detail part manufacturing
(D.P.M.):-
 Welding shop
 Detail fitting
 Pipe Bay
 Fly press
 Break Press
 Routing Bay
 Hydraulic press Anodizing process
 Process shop
Heat treatment process
 Paint shop composite paint shop
Metal paint shop
 Electroplating shop
 Detail assembly
 Chemical milling

13. Welding is process of joining of two metals or non metal by the
application of heat and pressure or without pressure by using filler
material or without filler material.
Welding is a fabrication or sculptural process that joins materials,
usually metals or thermoplastics, by causing fusion which is different
from lower temperature metal joining technique such as brazing and
soldering which do not melt the base metal.
In HAL we are two types are welding machines used:
I. Tungsten inert gas welding (TIG)
II. Spot welding
 Tungsten inert gas welding
(TIG):-
Gas tungsten arc welding (GTAW) is a method of electric arc welding
that fills most of the needs in aircraft maintenance and repair when
proper procedures and materials are used. It is the preferred method
to use on stainless steel, magnesium, and most forms of thick
aluminium. It is more commonly known as Tungsten Inert Gas (TIG)
welding and by the trade names of Heliarc or Heliweld. These names
were derived from the inert helium gas that was originally used.
In TIG welding, the
electrode is tungsten rod that forms the path for the high amperage

14. arc between it and the work to melt the metal at over 5,400 °F. The
electrodes not consumed and used as filler so a filler rod is manually
Fed into the molten puddle in almost the same manner as
When using an oxy-acetylene torch. A stream of inert gas,
Such as argon or helium, flows out around the electrode and
Envelopes the arc thereby preventing the formation of oxides
in the molten puddle.
 Spot welding: -
Two copper electrodes are held in the jaws of the spot welding
Machine, and the material to be welded is clamped between them.
Pressure is applied to hold the electrodes tightly together and
electrical current flows through the electrodes and the material.
The resistance
of the material being welded is so much higher than that of the
copper electrodes that enough heat is generated to melt the metal.
The pressure on the electrodes forces the molten spots in the two
pieces of metal to unite, and this pressure is held after the current
stops flowing long enough for the metal to solidify.

15. In HAL the spot welding machine is use that has following
specification:-
 Capacity: - 75 KVA
 Weld thickness up to 0.4 mm to 1.6 mm sheet can weld by
spot welding machine that used in HAL.
 It can use for join the similar metals.

16.  Detail fitting shop:-
It is important to have basic skills of manufacturing
technology to survive in the industry. Therefore, it is
essential to empower undergraduates with basic
manufacturing skill. The fitting shop offers series of practical
for students where student have to manufacture machine
element while using elementary tools.
In fitting shop drilling, bending, marking,
cutting operations can be done by following machines:
 Hand fly press machine
 Hand forming machine
 Bench drilling machine
 All cut machine counter
 Shearing machine
 Hand fly press machine:-
Hand fly press
machine is used to done the following operations such bending,
piercing, joggling.
A machine fly, alternatively called a seated lever fly is strength
training exercise based on the free weight chest fly. Hand fly press
machine is done manually operations.
 Hand forming machine:- In hand forming machine the sheet
metal form according to the tool. In this machine to get the

17. desired shape can be obtain by shape of tool. It is totally manually
based operation.
 Bench drilling machine:- Bench drilling machine is type of
drilling machine. In drilling machine, it is a cutting process that
uses a drill bit to cut or enlarge a hole of circular cross section in
solid material. The drill bit is a rotary cutting tool, often multipoint.
The bit is pressed against the work piece and rotated at rates from
hundreds to thousands of revolution per minute.
Operation:- drilled holes are characterized by their sharp edge on
the entrance side and the presence of burrs on the exit side(unless
they have been removed).also, the inside of the usually has helical
feed marks.
Drill chuck capacity: 1 mm to 12 mm

18.  All cut machine countour: - Allcut countour machine is a
multi operation machine. In all cut machines following
operations can be performed:
 Radial cutting
 Buttress
 Precision
 Claw tooth
 Friction
This machine is used for cutting the aluminium sheet or
parts up to 4 mm.
Throat depth: - 400 mm
Pipe bay is play very important role in the aircraft industry. In pipe
bay shop bend the pipe according to the requirement/design.
In this shop two type of machine is used to bend the pipes.
 Stretch forming machine:-
Capacity: - 10 tons
It is used for stretch or wraps forming of sheet metal part and
extruded sections.
 Stretch forming machine:-
Capacity: - 5 tons
Used for stretch or wrap forming of sheet metal parts and
extruded sections.

19. Electroplating is a process that uses electric current to reduce
dissolved metal cations so that they form a coherent metal coating
on an electrode. These terms is also used for electrical oxidation of
anions onto a solid substrate, as in the formation silver chloride on a
silver wire to make silver chloride electrodes.
Electroplating is primarily used
to change the surface properties of an object but may also be used
to build up thickness on undesired parts or to form objects by
electroforming. The process used in electroplating is called electro
deposition.
Process: - electroplating of a metal with copper in a copper
sulfatate bath. The cations associate with the anions in the solution.
These cations are reduced at the cathode to deposit in the metallic,
zero valance state.

20. Flow chart of electroplating process:-

21. All routing machines are that the tool is located above the work
piece support, which is normally a table. The tool-spindle axis is the
nearly always vertical, but on some machines the router head, and
thus also the tool spindle axis, may be titled. The machining head is
lowered for machining and returns automatically initial rest position.
On older machines the machining head is lowered manually by
operating a mechanical pedal or hand lever. On modern machines
the head is generally lowered by a pneumatic or hydraulic system.
The tool-spindle is driven either by a belt drive or directly by a high
frequency motor, which is often of the two-speed type.
1. RAR (Radial arm routing) machine
2. FHR(fixed head routing) machine
3. Gang drilling machine
4. Dressing machine
1. RAR(Radial arm routing) machine:
It performs two processes in a single machine i.e. drilling and
Routing. It can move at 360° at any radius.
In this machine tool
and work piece are clamped to the plywood and machine head
can be move for routing and drilling operation according to
design.
 Speed: - 18000-24000 RPM

22.  Cutter used:- High sped steel cutter.
 It is used for the long job manufacturing process.
2. FHR(Fixed head routing) machine:
It performs only drilling operation.
It cannot be move in any direction.
The machine is fixed in one direction and the work piece and the
tool can be move to any direction to get the desired shape.
In FHR machine the arrangement of tool and wood is such that
firstly tool than wood than metal.
 Speed:-18000-24000 RPM.
 Cutter used:-High speed steel cutter.
 It is used for the small job manufacturing process.
3. Gang drilling machine:
In this machine two operation can be performs in a single
machine at a time i.e. Drilling and Finishing.
One side of machine drilling operation and other side finishing
the surface roughness.
The machine is fixed and work piece is moved according to
design.
4. Dressing machine:
It is a type of belt machine which is used for the smooth the
outer surface of work piece by high speed of belt moving. In
Dressing machine the belt are moving at high speed and the
workpiece is take to the worker which touch the workpiece on
rotating belt and get the good outer surface finish.
It is totally
based on manually operated.

23. A chemical milling is the subtractive manufacturing process
of using baths of temperature-regulated etching chemicals to
remove materials to create an object with the desired shape.
It is mostly used on metals, through other materials are
increasingly important. It was developedfrom armour-
decorating and printing etching processes developedduring
the renaissance as alternativesto engraving on metal. The
process essentially involvesbathing the cutting areas in a
corrosive chemical known as an etchant, which reacts with
the material in the area to be cut and cause the solid material
to be dissolved inert substances known as mask ants.
Chemical millingis normally performed in a series of five
steps:
(1) CLEANING
(2) MASKING
(3) SCRIBING
(4) ETCHING
(5) DEMASKING

24.  CLEANING:- Cleaningis the preparatory process of
ensuring that the surface to be etched is free of
contaminantswhich could negativelyimpact the quality
of the finished parts.
 MASKING: - Masking is the process of applyingthe mask
ant material to the surface to ensure that only desire
areas are etched.
 mask ants types:- The mask ants to be used is
determined primarily by the chemical used to etch the
material, and the material itself.
 SCRIBING: - Scribing is the removal of mask ants on the
areas to be etched. For decorative applicationsthis is
often done by hand through the use of a scribing knife,
etching needle.
 ETCHING: - Etching is the manual immersion of the part
into the chemical bath and the action of the chemical
bath and the action of the chemical on the part to be
milled.

25. Paint, or more specifically its overall color and application, is usually
the first impression that is transmitted to someone when they look
at an aircraft for the first time. Paint makesa statement about the
aircraft and the person who owns or operates it. The paint scheme
may reflect the owner’s idea sand color preferences for an amateur-
built aircraft project, or it may be colors and identification for the
recognition of a corporate or air carrier aircraft.
Paint shop is basically divided into two sections:
 Composite paint shop
 Metallic paint shop
1. COMPOSITE PAINT SHOP:- In composite paint shop, we can
paint over the fiber glass. In this shop fiber glass is coated by
conductive paint to convert the fiber glass into metallic.
In this shop conductive primer and conductive paint are used for
coating operation. The ratio of hardener, base and thinner is
very important in the coating.
In composite paint shop this ratio is,
Base: hardener: thinner: - 5:1:2
The hardener and thinner which used in DON-228 is following,
Hardener: - N39/1327
Thinner: - N39/3460
PROCESS:- In composite paint shop, firstly coated the fiber by
primer then after certain time latter the conductive paint is
coated over the primer and then again coated by primer escape
the outer edge of the fiber glass to check the conductivity of the
material. After this the fiber is heated in furnace for 3 hours at
60°C because the paint and primer is totally attached to the fiber
glass.

26. If the total conductivity of fiber glass is 50KOhms then
material is rejected and the conductivity range of one part of
fiber is 1.5 to 25 KOhms’.
2. METALLIC PAINT SHOP:-
In metal shop we paint the metals by paint and primer.In paint
metal shop two types of the primer are used for coating such as
epoxy primer and wash primer.
EPOXY PRIMER:-
Epoxy is a synthetic, thermosetting resin that produces tough, hard,
chemical-resistant coatings and adhesives. It uses a catalyst to
chemically activate the product, but it is not classified as hazardous
because it contains no isocyanates.
Epoxy can be used as a no sanding
primer/sealer over bare metal and it is softer than urethane, so it has
good chip resistance. It is recommended for use on steel tube frame
Aircraft prior to installing fabric covering.
It coated 25 micron layer
thickness on metals.
Wash primer:- Wash primers are water-thin coatings of phosphoric
acid in solutions of vinyl butyral resin, alcohol, and other ingredients.
They are very low in solids with almost no filling qualities.
Their functions are to passivation the surface, temporarily
Provide corrosion resistance, and provide an adhesive base
for the next coating, such as a urethane or epoxy primer.
Wash primers do not require sanding and have high corrosion
Protection qualities.
Temperature apply 15 to 30
Humidity:- 30 to 70
Base:- hardener or thinner 2:1:1

27. In pint metal shop spray gun are used to coating the metal at a
distance 8 to 10 inch.
Spray Gun Operation
Adjusting the Spray Pattern
To obtain the correct spray pattern, set the recommended air
pressure on the gun, usually 40 to 50 psi for a conventional
Gun. Test the pattern of the gun by spraying a piece of
Masking paper taped to the wall. Hold the gun square to the
Wall approximately 8 to 10 inches from the surface. (With
hand spread, it is the distance from the tip of the thumb to
the tip of the little finger.)
All spray guns (regardless of brand name) have the same type
of adjustments. The upper control knob proportions the air
flow, adjusting the spray pattern of the gun.

28. HEAT TREATMENT
A Heat treatment process is a group of industrial and
metalworking process used to alter the physical, properties of a
material. The most common application is metallurgical. Heat
treatments are also used in manufacture of much other
material, such as glass. Heat treatment involves the use of
chilling or heat normally to extreme temperatures to achieve a
desire result such as hardening or softening of a material.
In heat treatment process different process are to be done:-
(1).Normalizing:-Normalizing is a heat treatment process for
making material softer but does not produce the inform
material properties of annealing in normalizing material can be
heated to a specific temperature and then letting the material
cool to room temperature outside the furnace.In normalizing
process a salt bath is used which is a mixture of sodium
potassium nitrate.
The furnace temperature is 495°C and the
soaking time is 8 to 10 min.
(2).ANNEALING:- Annealing is a heat treatment process which
alters the microstructure of a material to change it mechanical
or electrical properties. The temperature range in annealing
process is 350 to 580°C and soaking time 2 hours.

29. In heat treatment process different type of machine are used
(1).planising machine:-
Capacity- width 4ft up to any length
It is used for planisingof aluminiumsheet
(2).rotary cable swang machine:- it is used for the
permanent fastening joint.
(3).slitting machine:- it is used for cutting exact width of
sheets for standard sections manufacturing with the help of
slitting gauge.
(4).belt sender machine:-it is a horizontal type of machine
and it is used for surface finishing. In this machine the thick
material remove from the workpiece.
(5).wadkin circularsaw machine:- it is basicallyused for
cutting operationit cut the sheets the desired shape and size
as per requirement.
(6).straight stretching machine: - it is used for the
straightening of standard section of length up to 8000mm.
(7).famham rolling machine: - it is used to roll the sheet up
to 200 mm radiusjobs.

30. Anodizing is an electrolytic passivation process used to increase the
thickness of the natural oxide layer on the surface of metal parts.
The process is called anodizing because the part to be treated forms
the anode electrode of an electrical circuit.
Anodizing increase resistance
to corrosion and wear, and provides better adhesion for paint primer
and glue than does bare metal. Anodic film can also be used for a no.
of cosmetic effect, either with thick porous coating that can absorb
dyes or with thin transparent coating that add interference effect to
reflected light.
Anodic films are most commonly applied to protect
aluminium alloys, although process also exist for titanium, zinc,
magnesium, niobium, zirconium, hafnium, and tantalum.
Anodization changes the microscopic texture of the surface and
changes the crystal structure of the metal near the surface. Thick
coatings are normally porous, so a sealing process is often needed to
achieve corrosion resistance.
Aluminium alloys are anodized to increase corrosion
resistance and to allow dyeing (coloring), improved lubrication, or
improved adhesion. However anodizing does not increase the
strength of the Aluminium object. The anodic layer is non-
conductive.

31. PROCESS CHART OF ANODIZING :-

32. VOLTAGE VS TIME GRAPH IN ANODIZING PROCESS:-

33. ANODISING PROCESS FORT T₇ MATERIAL:-

34. Hindustan aeronautics limited (HAL) is in the business
of building a whole range of aircraft helicopters and jet
trainer. Besides, the company a manufacture the
aircraft component overhauls fighter plane and trains
future pilots its success in the design and the
development of light combat aircraft tejas and advance
light helicopter Dhruv has one admiration.HALis the
backbone of India’s air defence and continues to
occupy the importance reflecting a new a pace of
growth.
The project is based
on the instrument that is used in manufacture of the
various aircraft. A deep knowledge of these
instruments is crucial in the perfect design and
manufacture of the aircraft. The project will benefit
those who have interest in the instrument and will
provide the redar with dipper knowledge of the topic.