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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
1.

CONTENTS
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

PAGE NUMBER
4 8

2. 3. 4. 5. 6.

12 13 14 16 19

7. 8. 9. 10. 11. .

24 29 34 36 37

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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)
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Various military and civil upgrades.

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 200607(Top Ten Public Sector Enterprises). HAL has been receiving awards consecutively since 2001-02. Raksha Mantris 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 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 o o o Outstanding contribution to the Defence Industry. Most Influential Company of the year Excellence in Indigenous Technology Excellence in Exports MoU Excellence Award for the top performing CPSEs for the year 2008-

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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 Ministers 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 Ministers 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 countrys 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:

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The main work area in the Division comprises of Two Assembly Hangars having an area of approx. 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 Logistics support Rescue operations High Altitude operations

Observation Surveillance Earth resource survey

Description Empty weight Passenger (Incl. Pilot) Payload (Kg) at 6000mt Fuel consumption (Kg/Kw hr) Fuel Capacity Cruise speed, km/hr

Cheetah 1130 3+2 50 0.47 575 192

Cheetal 1110 3+2 90 0.38 575 192

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CHETAK
A versatile helicopter ideally suited for. Passenger / VIP transport Troop transport Air observation Causality evacuation Anti-tank warfare Anti-submarine warfare

Destruction of enemy machine gun positions Armaments Two 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 Parameters All Up Weight (kg) - 1950 Range (km) - 290 Maximum Speed (kmph) - 210 Endurance (Hrs) - 2.5

SERVICES Barrackpore 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

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Basic Data Empty Weight Total AUW Rate of Firing Max. Range (Gun) Max. Range (Rockets)

1230 kg 970 kg 11.020 meters 12.897 meters 2.602 meters

Performance Max. Speed Service Ceiling Range Endurance Rate of Climb (SL)

210 kmph 5400 m 290 km 2 hrs 30 min 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

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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. 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 Performance Max speed (Vne) Cruising Speed Service Ceiling Range Endurance

Basic Data Empty Weight Max. All Up Wt. Main Rotor Diameter Overall Length (Rotor Rotating) Overall Width (Blade folded) Overall Height Fuel Capacity

1100 kg 1950 kg 11.020 meters 12.910 meters 2.380 meters 3.090 meters 575 litres

210 kmph 192 kmph 5400 m 560 km 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.

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Major Features

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. Performance Max Speed (Vne) Service Ceiling Range Endurance Rate of Climb (SL)

Basic Data Empty Weight Total AUW Rate of firing

1350 kg 1950 kg 1100 rounds per minute Max. Range (Gun) 6 km Max. Range (Rockets) 3 km

210 kmph 5400 m 290 km 2 hrs 30 min 5.5 m/sec

Comparison:

Chetak
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 operation Search and rescue Casualty evacuation Anti-tank guide missile

Cheetah
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 operation Search and rescue Casualty evacuation Forward 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
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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 wheel 5. Inclined drive shaft (IDS) 6. Coupling shaft 7. Tail drive shaft (TDS) 8. Tail gear box (TGB) 9. Tail rotor head (TRH) 10. Tail rotor blade (TRB) 11. Tail rotor guard 12. Main rotor brake 13. Stabilizer 14. Mixing unit 15. A frame (LH and RH) 16. Control items 17. Mandatory spares 18. Spar tube 19. Cyclic stick (pilot and co-pilot) 20. Tail rotor cable 21. Turn buckle 22. Hoses 23. Teleflex cable 24. Bourdon cable 25. Rotor brake conduct 26. Rudder locking pin 27. Tail boom

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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.

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Clutch Unit: Engagement RPM: 19500 to 24000 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: Its 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

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Ball ring bearing lubricating oil: OM 11 Upper and lower taper roller bearing lubricating oil: OEP 70 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

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Inclined drive shaft: Also known as tube and universal joint. 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.

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AIRFRAME AND STRUCTURE


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 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 Cheetah 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
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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

353.2 1938 2 hrs 45 min 21300 feet

353.2 1938 3 hrs 2300 feet

Fuselage: There are three assemblies of fuselage: 1. Cabin assembly 2. Centre section 3. 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 pilots 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

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Hydraulic pump: Type 700 square drive shaft: gear tye. Type 720 splines. 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 Left forward Neutal Right forward Main landing gear:

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

TRB angle 6o10 +/- 30 8o15 +/- 30 22o40 +/- 30

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

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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. 2. 3. 4. 5. 6. 7. 8. Reduction gear assembly Air intake assembly Compressor assembly Turbine casing assembly Combustion chamber assembly Turbine assembly Exhaust diffuser assembly Tail pipe assembly

Accessories of engine: 1. Automatic control box 2. Starter generator 3. Fuel pressure cut out switch 4. Dual ignition coil 5. Micro pump 6. Electric fuel cock 7. Starter valve 8. Idling device 9. EDP or fuel pump 10. 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 drag 1. 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 causes 1. 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 causes 1. Happing inertia The inertia phenomenon at the limits of flapping gives rise to the same vertical or longitudinal phenomena. 2. Dynamic balancing of blades If 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 blades

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Faulty static balancing brings about another form of rotor imbalance conductive to horizontal vibration. 4. Transmission The 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. Its 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. 2. 3. 4. 5. Chetak manual and training book Cheetah manual and training book Study material Employee handwork Official HAL site

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