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 AERDC is a R&D wing of Design Complex, HAL playing a vital role in the design and development of Gas Turbine Engines in India. It has successfully designed, developed, produced and type certified aero engines (PTAE & GTSU) which are in operation with the defence services. Patents have also been issued by Patent Office, Govt. of India for these two engines.

The Centre started functioning in the year 1960 as a hub of engine research and development with the aim of achieving self reliance in design and development of Gas Turbine Engines and Test Beds in a climate of growing professional competence.

The Hindustan Jet Engine or HJE-2500 project was the first jet engine design and development project in the country taken up by the Centre. A prototype engine was successfully developed and proven on the test bed in 1965 and was proposed for the HJT -16 aircraft. The centre also designed and type certified a piston engine and other engine accessories including a pneumatic starter and hydraulic pump in its early days. The centre also has the unique distinction of being the only design house which has developed test beds for both Western as well as Russian origin engines.

Leveraging on this experience end to end services right from preliminary design to the final product manufacturing and testing are offered. AERDC has fledged its wings and is continuously improvising to meet customer requirements. With the advent of new technologies the division has equipped itself with high end design, analysis and manufacturing tools to meet the challenges of the future.
Developed and Certified projects
  • HJE-2500 engine
  • PTAE-7 engine for Lakshya aircraft
  • GTSU-110 starter engine for LCA (Tejas)
  • Shakti engine co-development with Turbomeca, France
  • Test Bed Projects
        o TM 333-2B2 / Shakti Engine Test Bed
        o Adour Engine Test Bed
        o Pegasus Engine Test Bed
        o Garrett Engine Test Bed
        o R29B Engine Test Bed
        o LM 2500 Engine Test Bed
  • Accessories
        o Pneumatic starter (HFES)
        o Hydraulic pump (HHP)
Current Projects
  • GTSU-127 Starter for LCA Mk II main engine
  • Auxiliary Power Unit for FGFA
  • Turbocharger
  • Smoke generator
  • Air producer for Jaguar aircraft
  • Compact Auxiliary Power Unit
  • Indigenisation
        o Air Turbine Wheel (ATW)
        o Air Turbine Starter (ATS)
  •    Test beds
        o Shakti Engine Test Bed at Bangalore.
        o GE F 404 engine Test Bed at Sulur.
        o Al 31 FP engine Mobile Test Bed
        o Al 55I engine test bed at Hakimpet.
Future Programs
  • Small Turbofan Engine for UAVs
  • APU for MTA
  • Starter Engine for Fighter Aircraft Engines
  • Turboprop engine for Trainer Aircraft
  • Gas Turbine Engine for Industrial Application-4 MW Class

Aerodynamic Design

  • Aerodynamic design of components for aerospace application w ith state-of-the-art advanced design softwares.
  • Product range – Compressor (axial, radial, mixed flow), turbines (axial, radial), Combustor (can, straight annular and reverse flow annular), air intakes and exhaust nozzles
  • Product designed for high reliability satiating the desired output over a wide operating range.
  • Design process using state-of-the-art high end analyses and design systems

Structural Design

  • Well established Structural design group equipped with latest FEA softwares (ANSYS, LS Dyna, DyRoBeS), capable of carrying out the following structural analyses to validate mechanical integrity and to optimize the structural designs.
  • Implicit analysis
    o Linear / Non linear static analyses.
    o Dynamic analyses eg. Transient, modal & harmonic analysis.
    o Other analyses eg. Spectral analysis, Random vibrations, Buckling analysis.
    o Fatigue analysis (LCF & HCF), Creep analysis.
  • Explicit Dynamic analysis
    o Analyses are done to simulate impact, blade out, bird hit scenarios.
  • Rotordynamics
    o Prediction of critical speeds of Rotor-Bearing systems.
    o Response to unbalance due to residual unbalance after Balancing.
  • Other areas
    o Defect analysis
    o Weight optimization
    o Life extension studies to support manufacturing operations.

Mechanical & Electrical System Design

The Centre has attained adequate competence in Gas Turbine engine system design through rich experience gained in successful execution of various projects.

Product Design

  • Engine Layout design
  • Conceptual design
  • 3D Solid Modeling
  • Component design
  • Assembly design
  • Tolerance analysis for components and assemblies.
  • Generating production drawings & assembly layout drawings as per standards.

System Design

  • Engine Starting systems
o Air starting system
o Cartridge starting system
o Jet Fuel starter
  • Engine Fuel system
o Hydro mechanical and electronic
  • Engine Lubrication systems
o Total Loss Mist Lubrication
o Closed Loop Oil Lubrication system
  • Engine Electrical and Control systems
o Engine Harness and routing
o Power generator
o Digital Electronic Control unit
o Integration

Accessories Design

 The Centre has designed and developed several accessory systems such as

o HFES Pneumatic starter (to start Orpheus engine)
o Hydraulic Pump (HHP) Hydro-mechanical Fuel Systems

Test Facilities

The Centre has established diverse capabilities to test various engine components including :
 
  • Dynamic balancing machine
  • Overspeed test rig
  • Vibration testing of blades & engine systems
  • AMAGB test facility
  • Cyclic spin test rig

Manufacturing Facilities

A prototype shop with additional support from Engine Division, HAL equipped with modern manufacturing facilities are available for component manufacture conforming to international quality standards.

Software Facilities

  • Dedicated data management servers
  • High end windows workstations.
  • Mechanical CAD Softwares
        Unigraphics NX6
        CATIA V5
        AutoCAD Mechanical 2010
        AutoCAD Inventor
  •     Structural Analysis Softwares
        ANSYS
        LS Dyna
        DyRoBeS
  •     Aerodynamic Analysis Softwares
        ANSYS CFX
        Concepts NREC - Compal, Axial, Axcent
        GasTurb
  • Large format heavy duty plotting facilities.
  • High speed internet connectivity.
  • Video conferencing facility with high bandwidth.

Quality Assurance

Well established quality assurance procedure in conformance with military and civil airworthiness requirements
  •     ISO 9001-2008 Quality Management system
  •     Well equipped test facilities for carrying out the following test
    - Cleanliness of fuel and oil to NAS 1638 standard
    - Calibration of pressure gauges upto 450 bar
    - Calibration of Thermocouple
    - Calibration of RPM indicator
    - Calibration of Transducer
    - Mobile Spectro for instant chemical analysis of various materials.

Customer Support

We take up the design of small gas turbine engines and their components and provide consultancy on various problems related to aerodynamics, heat transfer, structures and fatigue.

We undertake engine test beds and accessories test rigs projects from feasibility studies to project implementation on "turn key" basis.

All projects handled by the Centre are backed by excellent product support and customer training.
General Manager-Aero Engine Research & Design Centre (AERDC)

Hindustan Aeronautics Limited
Post Bag No.9310
CV Raman Nagar Post
Bangalore- 560 093
Telephone: 080-22311143
Fax: 080-22311143