ACKNOWLEDGEMENT

It is always a pleasure to remind the fine people in the Engineering Workshops for their sincere guidance I received to uphold my practical as well as theoretical skills in engineering.

Firstly, I would like to thank Wing Commander Seth, Deputy General Manager (production) for guiding me throughout the period of the training and for the positive attitude he showed for my work, always allowing me to question him and giving prompt replies for my uncertainties in all the fields.

Secondly, I would like to thank Mr. Kumar (Manager), Mr. Saha (Deputy Manager), Mr.Bhattacharya (Deputy Manager), Mr. Chakroborty (Deputy Manager), Mr. Topo (Deputy Manager), who helped me to learn more about the helicopters in the every area related for example airframe, structure, power plant, transmission and field service giving me overall idea about them and always removing any doubts i might have had related to the workings of the helicopter.

Finally, I would like to thank my Prof. Shailendra Singh, Head of The Department, Mechanical Engineering, ANAND ENGINEERING COLLEGE, AGRA for providing us with the opportunity to undergo this industrial training which helps us get acquainted with working in a more professional environment.

INDEX

SERIAL NUMBER CONTENTS PAGE NUMBER

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11..

Introduction Hindustan

Aeronautics Ltd Barrackpore

Division

Chetak

Cheetah

Lancer

Anatomy of a Helicopter

Transmission and Control System

Airframe and Structure

Engine and Power plant

Vibration Analysis

Conclusion

Bibliography

4

8

12

13

14

16

19

24

29

34

36

37

Page | 2

INTRODUCTION

HINDUSTAN AERONAUTICS LIMITED

Hindustan Aeronautics Limited (HAL) came into existence on 1st October 1964.  The Company was formed by the merger of Hindustan Aircraft Limited with Aeronautics India Limited and Aircraft Manufacturing Depot, Kanpur.

The Company traces its roots to the pioneering efforts of an industrialist with extraordinary vision, the late Seth Walchand Hirachand, who set up Hindustan Aircraft Limited at Bangalore in association with the erstwhile princely State of Mysore in December 1940. The Government of India became a shareholder in March 1941 and took over the Management in 1942.

Today, HAL has 19 Production Units and 10 Research & Design Centres in 8 locations in India. 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. HAL has manufacture dover 3658 Aircraft/Helicopters, 4178 Engines, Upgraded 272 Aircraft and overhauled over 9643Aircraft and 29775 Engines.

HAL has been successful in numerous R & D programs developed for both Defence and Civil Aviation sectors. HAL has made substantial progress in its current projects :

Advanced Light Helicopter  – Weapon System Integration (ALH-WSI)

Tejas - Light Combat Aircraft (LCA)

Intermediate Jet Trainer (IJT)

Light Combat Helicopter (LCH)

Various military and civil upgrades.

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HAL has played a significant role for India's space programs by participating in the manufacture of structures for Satellite Launch Vehicles like

PSLV (Polar Satellite Launch Vehicle)

GSLV (Geo-synchronous Satellite Launch Vehicle)

IRS (Indian Remote Satellite)

INSAT (Indian National Satellite)

Apart from these, other major diversification projects are manufacture & overhaul of Industrial Marine Gas Turbine and manufacture of Composites.

HAL has formed the following Joint Ventures (JVs) :

BAeHAL Software Limited

Indo-Russian Aviation Limited (IRAL)

Snecma-HAL Aerospace Pvt Ltd

SAMTEL-HAL Display System Limited

HALBIT Avionics Pvt Ltd

HAL-Edgewood Technologies Pvt Ltd

INFOTECH-HAL Ltd

TATA-HAL Technologies Ltd

HATSOFF Helicopter Training Pvt Ltd

International Aerospace Manufacturing Pvt Ltd

Multi Role Transport Aircraft Ltd

Several Co-production and Joint Ventures with international participation are under consideration.

HAL's supplies / services are mainly to Indian Defence Services, Coast Guard and Border Security Force. Transport Aircraft and Helicopters have also been supplied to Airlines as well as State Governments of India. The Company has also achieved a foothold in export in more than 30 countries, having demonstrated its quality and price competitiveness.

HAL was conferred NAVRATNA status by the Government of India on 22nd June 2007.

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The Company scaled new heights in the Financial Year 2010-11 with Turnover of Rs.13, 116 Crores and PBT of Rs 2,841 Crores.

HAL has won several International & National Awards for achievements in R&D, Technology, Managerial Performance, Exports, Energy Conservation, Quality and fulfillment of Social Responsibilities.

Some of the prestigious Awards received during 2009-10 & 2010-11 are:

2009-10

“MoU Excellence Award” for the top performing CPSEs for the year 2006-07(Top Ten Public Sector Enterprises). HAL has been receiving awards consecutively since 2001-02.

Raksha Mantri’s Award for Excellence for the year 2007-08 under the “Institutional” category.

“Regional Export Award” from EEPC, India for the year 2007-08.This award was presented on 21st Feb 2010 in Maldives.

“The Supplier of the year 2009” by Boeing, USA.

Foundry & Forge Division, Bangalore conferred with International Diamond Star Award for Quality in the realm of customer satisfaction, leadership, innovation and technology as established in QC100 TQM Model.

Foundry & Forge Division, Bangalore conferred with “Gargi Huttenes-Albertus Green Foundry Award” of the year 2008-09 by Institute of Indian Foundrymen.

2010-2011

          “MoU Excellence Award” for the top performing CPSEs for the year 2008-09.

         Raksha Mantri's Award for Excellence for the years 2008-09, for Export under the “Institutional” category.

         International Aerospace Awards (instituted by SAP Media Worldwide Ltd) as mark of recognition to the Indian Industry for excellence in innovation, indigenous technology and entrepreneurship under the following categories:-

o          Outstanding contribution to the Defence Industry.

o           Most Influential Company of the year

o           Excellence in Indigenous Technology

o          Excellence in Exports

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         Golden Award for Quality and Business Prestige from Otherways Management Association Club, France

         Performance Excellence Award -2009 (Organisation) for the year   2008-09 by Institution of Industrial Engineering.

         Foundry & Forge Division, Bangalore conferred with “Casting of the Year 2010” award to Main Gear Box (MGB) casting of ALH from the Institute of Indian Foundrymen.

         Aerospace Division, Bangalore: Runner-Up in “Viswakarma Rashtriya Puraskar and National Safety Award – 2008 “instituted by Ministry of Labour, Government of India.

         Aerospace Division, Bangalore was awarded Gold Medal by the Society of Aerospace Manufacturing Engineers (SAME) for the year 2010 for outstanding contribution in the field of Aerospace Manufacturing.

         Engine Division, Bangalore won Rajiv Gandhi National Quality Awards 2009, instituted by Bureau of Indian Standards, New Delhi for Commendation for Large Scale Manufacturing Industry-Engineering & Others.

         Avionics Division, Korwa conferred with “IMTMA-SIEMENS Productivity Championship Award” for excellence and outstanding work in the area of productivity.

         Shri G.C Bhagwanani, Chief Supervisor, HAL- TAD, Kanpur, was awarded the Prime Minister’s “Shram Shree” Award for 2006 on 15th Sept 2010.

         Shri A.Selvaraj, AGM (Mfg), Foundry & Forge Division, Bangalore was awarded the “Foundryman of the year 2010” by the Institute of Indian Foundrymen.

         Shri Mohan Lal, Chief Supervisor of Accessories Divison, Lucknow was selected for Prime Minister’s “Shram Vir” for the year 2009.

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BARRACKPORE DIVISION

ABOUT US

 Barrackpore Division is located at Barrackpore, Dist. 24 Pgs. (N),Kolkata. It is a part of Helicopter Complex, Bangalore.

 Barrackpore Division is involved in Maintenance, Repair and Overhaul of Cheetah and Chetak Helicopters. It also has capability for assembly of new Cheetal and Chetak Helicopters, catering to the need of the country’s Defence establishment.

 BRIEF HISTORY

Barrackpore Division was established as a Repair Base in 1940 during Second World War under the name of Tata Aviation. In 1951, Barrackpore Factory became a part of Hindustan Aircraft Pvt Ltd, Bangalore. Subsequently in 1957, it started functioning as an Outstation Base of HAL, Overhaul Division. In 1957, Repair and Overhaul of Dakota Aircraft was undertaken and 1020 aircraft were overhauled till 1984. In 1973, Major Servicing of Caribou aircraft was established and 108 aircraft were serviced till 1984. In 1980, Major Servicing line of single engine Otter aircraft was setup and 81 aircraft were serviced till 1985.

During 1982-83, Major Servicing of Chetak / Cheetah helicopters of IAF was started and subsequently Army, Navy and Coast Guard helicopters were also added. Servicing of AN-32 aircraft was also started from 1988-89 and continued upto 99-2000.

In 2004, HAL, Barrackpore became a Branch unit of Helicopter Division, Bangalore. Till 2010-11, 607 helicopters (MI: 304 Cheetah / Lancer and 224 Chetak and T1SI/T2SI: 79 Chetaks) have been overhauled at Barrackpore Division. Assembly of 10 nos. of Cheetal Helicopters for Indian Air Force and assembly of 3 nos. of Chetak Helicopters for Indian Coast Guard has been done at Barrackpore.Barrackpore Factory was designated as a Division in October 2006 and it became a part of Helicopter Complex in June, 2009.

FACILITIES

Man Power:

Barrackpore Division employs about 400 highly skilled personnel for disassembly, repair and overhaul, assembly, flight preparation and flight testing of Cheetah and Chetak Helicopters and Rotables.

Infrastructure:

The main work area in the Division comprises of Two Assembly Hangars having an area of approx.

Page | 7

6000 sq. mtr. each for Dismantling, Re-assembly, Equipping and Flight Preparation activities and Accessories Overhaul Centre for repair and overhaul of Rotables.

Manufacturing Facilities comprise of

A. Machine Shop B. Welding Shop C. Electroplating and Painting facility        D. Body structure Welding / Assembly facility

Servicing of Accessories

A. Hydraulic and Mechanical Units

 Landing gears and Shock struts  Fuel Booster pumps, filters and fuel system items  Hydraulic pumps, valves, filters and servo units  Oil coolers, Wheels & Brakes  Flight Control items

B. Radio/ Instrument Items

V/UHF transmitters/receivers ADF, Intercom Magnetic compass, Altimeter & Collective Pitch Indicator

C. Electrical Items

Electrical looms Anti Collision lights Voltage regulator & Relays

D. Propeller Shop

Hartzell Propellers Constant Speed Governor

E. NDT Laboratory

Magnetic Particle Inspection X-Ray Inspection Die Penetrant Test

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Certification:

The Division has been accredited to

·     ISO 9000 QUALITY MANAGEMENT SYSTEM STANDARD (ISO 9001:2008 Certified).

·     ISO 14000 ENVIRONMENT MANAGEMENT SYSTEM STANDARD  (ISO 14001:2004 Certified).

The Division has the firm approval from DGAQA.

Products:

CHEETAH / CHEETAL

•          Agile and highly maneuverable light aerial platform.•          Ideally suited for

Observation Logistics support

Surveillance Rescue operations

Earth resource survey High Altitude operations

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DescriptionCheeta

h

Cheetal

Empty weight 1130 1110

Passenger (Incl. Pilot)

3+2 3+2

Payload (Kg) at 6000mt

50 90

Fuel consumption (Kg/Kw hr)

0.47 0.38

Fuel Capacity 575 575

Cruise speed, km/hr

192 192

CHETAK

A versatile helicopter ideally suited for.

Passenger / VIP transport Causality evacuation

Troop transport Anti-tank warfare

Air observation Anti-submarine warfare

Destruction of enemy machine gun positions

ArmamentsTwo Jettisonable Gun-cum-Rocket Pod.Gun sight for accurate aiming & firing. Each pod carries one 12.7 mm. gun and three 70 mm. Rockets. Gun fire rate per min 1100 rounds.Effective range (km) -1 : Against Light Armour -2.5 : Against Vehicle

Performance ParametersAll Up Weight (kg) - 1950Range (km) - 290Maximum Speed (kmph) - 210Endurance (Hrs) - 2.5

SERVICESBarrackpore Division offers service to customers on

Major Servicing (3200 hrs.) of Cheetah , Chetak and Lancer Helicopter of Indian Air Force, Indian Army, Indian Navy and Indian Coast Guard.

T1SI (400 hrs.) & T2SI (800 hrs.) Servicing of Chetak Helicopters of Indian Navy and Indian Coast Guard.

Repair , Servicing and Overhaul of Rotables - Directly from customers.- Other HAL Divisions.

Assembly of new Cheetal helicopters and new Chetak helicopters. Repair , Servicing and Overhaul of

- Propellers.- Constant speed governor.

In-situ repairs of helicopters. Scheduled and unscheduled servicing of helicopters. Supply of spares against AOG demands. Supply of Ground Handling and Ground Service Equipment.

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CHETAK

The Helicopter Division manufactures the versatile and multi-purpose Chetak Helicopters for Civil and Military applications both for Domestic and International customers.Major Features

Multi-role, seven seater Helicopter   Spacious and simple in design Highly manoeuverable and well suited to flying over sea, tropical and desert

conditions Can be effectively deployed for a variety of civil and military roles that include

communication, rescue, aerial survey, cargo and passenger transport and combat

Armed with missiles and torpedoes, it also caters to the exacting requirements of anti-submarine and anti-tank warfare

The automatic starting system gives the Chetak an uncommon instant start capability cutting down the time from start to take-off to less than a minute

With an all up weight of 2200 kg, it can cruise at 185 kmph covering a range of 500 km and has endurance of 3.40 hours

Basic Data Performance

Page | 11

Empty Weight 1230 kgTotal AUW 970 kgRate of Firing 11.020 metersMax. Range (Gun) 12.897 metersMax. Range (Rockets) 2.602 meters

Max. Speed 210 kmphService Ceiling 5400 mRange 290 kmEndurance 2 hrs 30 minRate of Climb (SL) 5.5 m/sec

CHEETAH

 The Helicopter Division manufactures the versatile and multi-purpose Cheetah Helicopters for Civil and Military applications both for Domestic and International customers. 

Major Features HAL version of Aerospatiale Lama SA 315  Lightweight high performance helicopter  Specially designed for operation over a wide range of weights, centers of

gravity and altitude conditions  Simple in concept and rugged in construction  Powered by the tried and trusted. Artouste-IIIB engine, also manufactured at

HAL under licence from Turbomeca of France  The turbo-shaft engine produces 550 S.H.P. at 33500 rpm. 

Page | 12

Incorporates the latest technologies viz., hydraulic servo controls, ultra sensitive constant speed governor and an automatic starting system facilitating starting and take-off in less than a minute 

With minimal adaptation it can be transformed into an excellent sprayer  Agile and highly manoeuverable, the Cheetah can carry external cargo up to 1

MT  Excels in observation, surveillance, logistics support, earth resource survey

and rescue operations  Comfortably seats five   Can operate in unfavorable environmental conditions

Basic DataEmpty Weight 1100 kgMax. All Up Wt. 1950 kgMain Rotor Diameter 11.020 metersOverall Length(Rotor Rotating)

12.910 meters

Overall Width(Blade folded)

2.380 meters

Overall Height 3.090 metersFuel Capacity 575 litres

PerformanceMax speed (Vne) 210 kmphCruising Speed 192 kmphService Ceiling 5400 mRange 560 kmEndurance 4.1 hrs

LANCER

The Lancer Helicopter is a light attack

helicopter developed by Hindustan Aeronautics Limited as a cost-effective airmobile area weapon system. The basic structure of the Lancer is derived from the reliable

and proven Cheetah Helicopter.

Major Features

Page | 13

Optimized for anti-insurgency operations, close air support, suppression of enemy fire, attack on vehicular convoys, destruction of enemy machine gun positions and anti-armour applications.

Carries two jettisonable combination gun-cum-rocket pods, one each on right and left side on suspension points located on the armament pylon.

A gun sight is provided for accurate aiming and firing by the pilot. Each pad carries one 12.7 mm gun and three 70 mm rockets.

Basic DataEmpty Weight 1350 kgTotal AUW 1950 kgRate of firing 1100 rounds

per minuteMax. Range (Gun) 6 kmMax. Range (Rockets) 3 km

PerformanceMax Speed (Vne) 210 kmphService Ceiling 5400 mRange 290 kmEndurance 2 hrs 30 minRate of Climb (SL) 5.5 m/sec

Comparison:

Chetak Cheetah Empty Weight Maximum AUW Fuel Capacity Endurance Maximum Speed Ceiling Height Seating capacity Cargo Load Under Carriage Use

1105 kg 2100 kg 575 litres 2.45 hrs 113 knots 17400 feet 7 750 kg Tri-cycle wheel type Flood relief operation

High altitude glacier operationSearch and rescueCasualty evacuationAnti-tank guide missile

1043 kg 2200 kg 575 litres 3.20 hrs 113 knots 21000 feet 5 1000 kg High skid type Flood relief operation

High altitude glacier operationSearch and rescueCasualty evacuationForward area control

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ANATOMY OF A HELICOPTER

Sikorsky and a few of his contemporaries brought a technical rigor to the field that

finally made vertical flight safe, practical and reliable. As the flight-crazy Russian

continued to refine his helicopter designs, he worked out the fundamental

requirements that any such machine needed to have to be successful, including:

a suitable engine with a high power-to-weight ratio

a mechanism to counteract rotor torque action

proper controls so the aircraft could be steered confidently and without catastrophic

failures

a lightweight structural frame

Page | 15

a means to reduce vibrations

Many of the basic parts seen on a modern helicopter grew out of the need to

address one or more of these basic requirements. Let's look at these components in

greater detail:

Main rotor blade -- The main rotor blade performs the same function as an airplane's

wings, providing lift the blades rotate -- lift being one of the critical aerodynamic

forces that keeps aircraft aloft. A pilot can affect lift by changing the rotor's revolutions per minute (rpm) or its angle of attack, which refers to the angle of the

rotary wing in relation to the oncoming wind.

Stabilizer -- The stabilizer bar sits above and across the main rotor blade. Its weight

and rotation dampen unwanted vibrations in the main rotor, helping to stabilize the

craft in all flight conditions. Arthur Young, the gent who designed the Bell 47

helicopter, is credited with inventing the stabilizer bar.

Rotor mast -- Also known as the rotor shaft, the mast connects the transmission to

the rotor assembly. The mast rotates the upper swash plate and the blades.

Transmission -- Just as it does in a motor vehicle, a helicopter's transmission

transmits power from the engine to the main and tail rotors. The transmission's main

gearbox steps down the speed of the main rotor so it doesn't rotate as rapidly as the

engine shaft. A second gearbox does the same for the tail rotor, although the tail

rotor, being much smaller, can rotate faster than the main rotor.

Engine -- The engine generates power for the aircraft. Early helicopters relied on

reciprocating gasoline engines, but modern helicopters use gas turbine engines like

those found in commercial airliners.

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Helicopter terminology:

1. Main gear box (MGB)2. Main rotor shaft (MRS)3. Main rotor head (MRH)4. Free wheel5. Inclined drive shaft (IDS)6. Coupling shaft7. Tail drive shaft (TDS)8. Tail gear box (TGB)9. Tail rotor head (TRH)10.Tail rotor blade (TRB)11.Tail rotor guard12.Main rotor brake13.Stabilizer14.Mixing unit15. ‘A’ frame (LH and RH)16.Control items17.Mandatory spares18.Spar tube19.Cyclic stick (pilot and co-pilot)20.Tail rotor cable21.Turn buckle22.Hoses23.Teleflex cable24.Bourdon cable25.Rotor brake conduct26.Rudder locking pin27.Tail boom

Page | 17

TRANSMISSION AND CONTROL SYSTEM

There are two types of transmission runs:

Transmission to main rotor system Transmission to tail rotor

Rotary Wing Terminology

Lets talk a moment about terminology. There are many terms associated with rotary wing flight. One must become familiar with the terminology of rotorcraft before they can expect to understand the mechanics of rotary wing flight. Let's look at a few definitions.

Main Rotor System

Root: The inner end of the blade where the rotors connect to the blade grips.

Blade Grips: Large attaching points where the rotor blade connects to the hub.

Hub: Sits atop the mast, and connects the rotor blades to the control tubes.

Mast: Rotating shaft from the transmission, which connects the rotor blades to the helicopter.

Control Tubes: Push \ Pull tubes that change the pitch of the rotor blades.

Pitch Change Horn: The armature that converts control tube movement to blade pitch.

Pitch: Increased or decreased angle of the rotor blades to raise, lower, or change the direction of the rotors thrust force.

Jesus Nut: Is the singular nut that holds the hub onto the mast. (If it fails, the next person you see will be Jesus).

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Main Rotor Blade

Leading Edge: The forward facing edge of the rotor blade. Trailing Edge: The back facing edge of the rotor blade. Chord: The distance from the Leading Edge to the Trailing Edge of the rotor

blade. 

Controls

Swash Plate: Turns non-rotating control movements into rotating control movements.

Collective: The up and down control. It puts a collective control input into the rotor system, meaning that it puts either "all up", or "all down" control inputs in at one time through the swash plate. It is operated by the stick on the left side of the seat, called the collective pitch control. It is operated by the pilots left hand.

Cyclic: The left and right, forward and aft control. It puts in one control input into the rotor system at a time through the swash plate. It is also known as the "Stick". It comes out of the center of the floor of the cockpit, and sits between the pilots legs. It is operated by the pilots right hand.

Pedals: These are not rudder pedals, although they are in the same place as rudder pedals on an airplane. A single rotor helicopter has no real rudder. It has instead, an anti-torque rotor (Also known as a tail rotor), which is responsible for directional control at a hover, and aircraft trim in forward flight. The pedals are operated by the pilots feet, just like airplane rudder pedals are. Tandem rotor helicopters also have these pedals, but they operate both main rotor systems for directional control at a hover.

Clutch Unit:

Engagement RPM: 19500 to 24000

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Synchronization time: 35 to 45 sec

Clearance between she and copper drum: 0.4 to 0.6 mm

Number of friction lining shoes: 10

Life: on condition

MDS and Free wheel Unit:

Transmission of torque in one direction only and prevent any feed back to engine in case of auto rotation/ engine failure.

Axial play: 1 mm

Life: 1800 hrs/ 10 yrs

Main Rotor Break:

It’s utility on ground to stop the rotor quickly.

Appiction: less than or equal to 170 RPM

Time to stop: 12 to 15 sec

MGB:

Function: To step down the rotational speed of main rotor and tail rotor.

Type of lubrication: pressure type

Type of oil: OEP 70

Lubrication system pressure: 73 +- 15 PSI

Life: 1500 hrs

Main Rotor Shaft:

Inclined forward: 3o

Ball ring bearing lubricating oil: OM 11

Upper and lower taper roller bearing lubricating oil: OEP 70

Page | 20

Upper roller bearing takes the weight of helicopter during flight

Lower roller bering takes the weight of main rotor at rest.

Main Rotor Head:

3 bladed articulated type (flap hinge, drag hinge, feathering hinge)

Weight: 106 kg

Life: 1800 hrs/10 yrs

Droop restrainer engages at 185 RPM

Droop restrainer disengages at 195 RPM

Hydraulic Drag Dampers:

Set of 3.

Type of oil used: OM 15

Life: 1800 hrs

Oil change: 100 hrs

Main Rotor Blade:

Twist: 6o30’

Length: 4655 mm

Weight: 34.8 kg

Design angle: 12o40’

Life (15 series): 3200 hrs

Life (30 series): 4500 hrs

Inclined drive shaft:

Also known as tube and universal joint.

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Life: on condition

Weight: 4 kg

Coupling shaft:

Intermediate bearing.

Housing filled with bearing shell- 14 grease to half of its capacity.

Life: on condition

Tail drive shaft:

Supported on five float bearings. Lubricating oil used: OM 11

Twist should not exceed: 6o

Life: on condition

Weight: 10 kgs

Tail gear box:

Changes the drive 95o towards RHS and reduces the RPM from 2393-1938.

Type of lubrication: splash type

Type of oil: OEP 70

Capacity: 0.5 litres

Life: 2000 hrs

Tail rotor blade:

Twist: none

Length: 838 mm

Weight: 1.360 kg

Tapered from root end to tip end in chord wise and thickness.

AIRFRAME AND STRUCTURE

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Introduction:

The Cheetak SE 3160 Artouste III and Cheetah SA 315 LAMA helicopter are high performance all purpose all weather helicopter. Cheetak was awarded civil air worthiness certificate on 12.12.61 and Cheetah was awarded on 21.1.1972. These helicopters were originally were originally designed and manufactured in France.

Leading Particulars:

Chetak Cheetah Main Rotor Diameter Tail Rotor Diameter Overall width Overall height Overall length All up weight Useul load Seating capacity Cargo capacity Rescue hoist load Maximum speed Main rotor RPM Tail rotor RPM Endurance at sea

level Maximum altitude

11.020 m 1.912 m 2.59 m 2.97 m 10.030 m 2100 kg 995 kg 7 750 kg 175 kg 113 knots 353.2 1938 2 hrs 45 min

21300 feet

11.020 m 1.912 m 2.38 m 3.090 m 10.136 m 2200 kg 1157 kg 5 1000 kg 175 kg 113 knots 353.2 1938 3 hrs

2300 feet

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Fuselage:

There are three assemblies of fuselage:

1. Cabin assembly2. Centre section3. Tail boom assembly

Cabin assembly: consists of canopy, cabin floor, bottom structure. Cabin floor is painted with non-slip paint.

Centre section: consists of hollow tubes welded together in form of cradle shape. Structure is charged with dry nitrogen to a pressure of 23 PSI. 3RH to intricate serviceability of the structure. This indicator wil turn to red if there is any drop of pressure in structure due to cracks/flaw in the structure.

It is a semi-monocoque type of construction. It consists of 3 longerons, 8 frames and covered by light alloy metal sheet. It is tapered towards rear to reduce the weight and drag.

Servo system:

Eliminates the control loads from cyclic stick and collective lever. Its action is irreversible and no feed back on pilot’s control.

System pressure: 400 PSI

System efficiency: 85 PSI

Type of oil: OM 15

Reservoir:

Flat shaped for cooling the oil.

Capacity: 2.3 litres

Hydraulic pump:

Type 700 square drive shaft: gear tye.

Type 720 splines.

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Rotational speed: 2500 RPM

Oil delivery rate: 4.1 ltr/min

Filter and valve unit:

50 micron filter safety valve opens at 400 PSI

20 micron bypass valve opens at 29 PSI

3 hydraulic servo units:

Eliminates the stick forces.

Servo cock:

In the event of hydraulic system failure ac is still flyable but but servo cock is to be opened to alleviate the control stick forces.

Houdaille damper:

It dampens out the vibration caused by tail rotor.

Type of oil: OM 15

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Rudder pedal position Drum dimension TRB angle Left forward Neutal Right forward

73.7 +/- 0.3 mm 86.3 +/- 0.3 mm 98.8+/- 0.3 mm

6o10’ +/- 30’ 8o15’ +/- 30’ 22o40’ +/- 30’

Main landing gear:

Main wheel track: 2410 mm (outer axle to axle).

Wheel base: 3400 mm

Tyre pressure (main and nose): 71 PSI

Main oleo leg N2 pressure: 342 PSI

Nose oleo leg N2 pressure: 787 PSI

Main landing gear cross tube bow: 3 mm

Main and oleo leg extension: 50 mm

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Parking brake:

Type of oil: OM 15

Braking pressure: 90 bar

Accumulated N2 pressure: 1204 PSI

Cabin heating and defrosting system:

It increases the cabin temperature by 20oC relative to the prevailing outside temperature with in 10 min.

Source of hot air: P2 engine

Temperature of P2: 250oC

Pressure at P2: 74.4 PSI

Temperature at cabin duct: 55-60oC

Pressure at cabin duct: 35.5 PSI

Optional equipment:

Cargo swing Rescue hoist Main rotor blade floating kit Litters carriers Floats Ski

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ENGINE AND POWER PLANT

Introduction:

Artouste III B engine is a constant speed, single shaft, gas turbine engine fitted on chetak/cheetah helicopters. This engine is named after a lake in France. It is manufactured by Turbomeca factory-France and presently being manufactured by HAL(BC) engine division under license from Turbomeca factory.

Characteristics:

It is a free turbine turbo shaft engine. The gas generator shaft and the power turbine shaft are co-axial shafts rotate independently at different speeds.

FADEC maintains the free turbine speed constant, irrespective of the power required for the flight, by varying fuel quantity.

Maximum take off rating: 456 kW Free turbine rotational speed: 37562 RPM Engine reduction gear output shaft speed: 6000 RPM

Page | 28

Leading particulars and limitations:

General performance:

Overall length: 1815 mm or 711/2”

Overall width: 520 mm or 20”

Overall height: 627 mm or 24”

Total weight: 182.5 kgs +/- 3%

Total power output: 550 SHP

Take off power: 542 SHP

Normal power: 444 SHP

Sp. Fuel consumption: 0.345 kg/HP/hr or 180ltr/hr

Compression ratio: 5.2:1

Air flow: 10 lbs/sec or 4.5 kg/s

Residual thrust: 44.2 kg

Exhaust gas velocity: 95.2 metres/sec

RPM Limitations:

Maximum speed: 33500 +/- 200 RPM

Maximum speed variation in transient condition: +/- 1000 RPM

Idling speed: 17500 +/- 1500 RPM

Output shaft speed: 5773 RPM

Rotor engagement speed: 19500 to 24000 RPM

Speed at end of ignition phase: 6000 RPM

Ventilation speed: 5000 RPM

Starter cut-off speed: 14000 +/- 1000 RPM

Self-sustaining speed: 13000 +/- 1000 RPM

Time required to stabilize maximum RPM: 4.5 sec

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Temperature limitations:

Maximum continuous T4 temperature (JPT): 500oC

Maximum continuous over JPT: 550oC for 5 min

Maximum JPT during starting: 630oC

Maximum JPT during acceleration at a time: 50oC

Maximum permissible residual temperature (JPT): 150oC

Standard atmospheric temperature T0: 30oC

Temperature after axial flow compressor T1: 60oC

Temperature after axial flow compressor T2: 250oC

Temperature before first stage nozzle guide vanes T3: 700oC

Temperature at exhaust diffuser assy T4: 500oC

Fuel system limitations:

Fuel specifications: ATF K50

In emergency any octane fuel can be used with addition of 3% of mineral oil but the life of the engine will be limited to 25 hrs only.

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Fuel tank standard:

Chetak:

Total capacity: 565 litres

Refuelling capacity: 560 litres

Usable capacity: 550 litres

Cheetah:

Refuelling capacity: 565 litres

Usable capacity: 555 litres

Oil system limitations:

OIL specifications: Mineral AIR 3515 (OM 11)

Synthetic AIR 3513 (OX 9, OX 27, OX 38, CASTROL 98)

Oil tank capacity: 13 litres

Engine over speed limitations:

1. If the speed is between 34500 and 35500 RPM and running time was less than 5 min then speed can be adjusted on the governor.

2. If the engine is between 33700 and 34500 RPM but not stabilizing then speed an be adjusted on the governor.

3. If the engine speed is 35500 RPM and running time was more than 5 min then engine is to be sent for overhaul.

Overhaul life of ARTOUSTE III B:

Overhauling of the engine is based on modifications carried out on it. Accordingly the engines are divided in 3 groups. They are:

1. Group A engines Manufactured by Turbomeca have 2500 hrs Manufactured by HAL(BC) have1750 hrs.

2. Group B engines have 1500 hrs.3. Group C engines have 750 hrs.

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Overhaul life of components:

All the components of engine have same overhaul life as engine (TPO) life other than a few components which are mentioned below. The life of these components is based on their condition.

Oil tank Oil cooler Air intake Tail pipe Fuel filter assembly Fuel filter cartridges Oil filter cartridges Four way union ball valve

Main assemblies of engine:

1. Reduction gear assembly2. Air intake assembly3. Compressor assembly4. Turbine casing assembly5. Combustion chamber assembly6. Turbine assembly7. Exhaust diffuser assembly8. Tail pipe assembly

Accessories of engine:

1. Automatic control box2. Starter generator3. Fuel pressure cut out switch4. Dual ignition coil5. Micro pump6. Electric fuel cock7. Starter valve8. Idling device9. EDP or fuel pump10.Constant speed governor

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VIBRATION ANALYSIS

General:

A no. of cases of dissymmetry due to the periodic variation of lift or drag or to faulty balancing have already been noted as source of vibration phenomena. A closer investigation would call for a mathematical analysis.

Vibration phenomena

(a) Vibration from aerodynamic causes 1. Dissymmetry in lift

The periodic variation of lift may give to vibratory phenomena. Lateral dissymmetry in forward flight. Longitudinal dissymmetry due to the rotor tilt, give rise to vertical vibration.

(b) Vibration due to dissymmetry in drag1. The periodic variation of drag due to periodic vibration of lift, gives rise to

horizontal vibration.2. Blade stalls at limit speeds.

(c) Vibration from geometrical causes1. Virtual axis of a conical surface.2. Hinge off set through drag

Other forms of complex vibration are created through:

1. By the tilt of the rotor disk, its virtual axis of rotation no longer coincides with the hub centre but describes a tilted cone.

2. By the blades being articulated on opposite sides on the drag hinges, the centre on the drag hinges, the centre of gravity is offset in relation to hub centre.

(d) Vibration from mechanical causes1. Happing inertia

The inertia phenomenon at the limits of flapping gives rise to the same vertical or longitudinal phenomena.

2. Dynamic balancing of bladesIf dynamic balancing of the blades is faulty, the resultant rotor imbalance will generate vertical vibration.The alignment of blade tips in the same plane is generally known as “tracking”. This term is further used in a wider sense to designate the operation by which the alignment is adjusted.

3. Static balancing of bladesFaulty static balancing brings about another form of rotor imbalance conductive to horizontal vibration.

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4. TransmissionThe transmission components between the engine and the rotor also foster vibration.

5. Engine:Certain engine components rotating at high speeds have resonance frequencies which affect transmission..

Remedies:

The effects of these phenomena have presented the designer with serious problems:

The remedies applied involve the following:

1. Accuracy of dynamic and static balancing.2. Extra weight built in at the blade tips to increase their inertia.3. Damping of the horizontal and vertical movement by means of hydraulic or

friction dampers.4. The balancing of all rotating masses.5. A geometric location of the blade axes in relation to the hub rotation.6. A determination of the length of the landing gear shock absorbers so as to

give a frequency which will not resonate with the horizontal vibration frequency of the rotor.

Remarks:

(A)General:Vibrations are alternating cyclic phenomena periodically repeated as a function of the rotating speeds of the component from which they originate.They occur, either once per revolution or at different frequencies.In certain vibrations, the points of maximum amplitude can be out of place with each other.

(B)Compositions of vibrations:The composition of vibrations give rise to phenomena ranging from the simple mode in which they cancel out by opposition, to the complex mode in which either combine or interfere.

(C)Practical applications:

By the determination of the frequency of vibration their fundamental causes may be discovered and remedy devised.

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CONCLUSION

In conclusion, there were many things that i have experienced and learned during the stretch of my Industrial Training at Hindustan Aeronautics Ltd (Barrackpore). The whole training period was very interesting, instructive and challenging. Throughout this training i was able to gain new insights and more comprehensive understanding about the real industry working condition and practice.

The Industrial Training also has provided me the opportunities to develop and improve my soft and functional skills. All of this valuable experience and knowledge that I have gained were not only acquired through the direct involvement in task given but also through other aspect of the training such as work observation, interaction with colleagues, superior, and related to the company. From what I have undergone, I agree that the industrial training program have achieve its entire primary objective. It’s also the best ways to prepare student in facing the real working life. As a result of the program now I am more knowledgeable about the subject and confident to enter the employment world to build my future career.

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BIBLIOGRAPHY

1. Chetak manual and training book2. Cheetah manual and training book3. Study material4. Employee handwork5. Official HAL site

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