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CHAPTER - VI

DEFENCE R&D LABORATORIES IN HYDERABAD 1. Introduction There are six Defence R&D Laboratories in Hyderabad as follows : (i) Defence Research & Development Laboratory (DRDL), Hyderabad – 500058 (ii) Research Centre Imarat (RCI), Hyderabad – 500069 (iii) Advanced Systems Laboratory (ASL) Kanchanbagh P.O. Hyderabad - 500 058 (iv) Defence Metallurgical Research Laboratory (DMRL), Hyderabad – 500058 (v) Defence Electronics Research Laboratory (DLRL), Hyderabad – 500058 (vi) Advanced Numerical Research & Analysis Group (ANURAG), Hyderabad –500058 DRDL, RCI & ASL have been designing & developing the missiles and related systems for Defence Services. DMRL has been working for the development of critical materials to meet the requirements of Defence. DLRL has been working for the development of advanced electronic systems for Defence. ANURAG has been developing the super computers. 2. Brief Details of Products & Facilities - Defence R&D Laboratories 2.1 Defence Research & Development Laboratory (DRDL), Hyderabad - 500058, A.P. 2.1.1 Introduction Defence Research and Development Laboratory is a multi-disciplinary Missile System laboratory with thrust on design, development and flight evaluation of various types of Missile Systems for armed forces. Right form conceptualization of the weapon system to production and induction into services, the laboratory has capabilities and the state of art infrastructure in terms of facilities and human resource. The laboratory is ISO 9001: 2000 Certified. Realizing the importance of guided missile weapon systems in the modern warfare, a Special Weapon Development Team (SWDT) was formed in 1958. This team was later expanded into DRDL, a full-fledged laboratory in June 1961 at the campus of Defence Science Centre, Delhi. The laboratory was moved to Hyderabad in Feb' 1962, from where starts the story of guided missiles in India.

During the initial phase, the laboratory successfully developed an anti tank missile system and indigenous rockets and proved them through flight trials. IBM 1620 was installed in DRDL as early as in 1965, which was used, for flight simulation studies.

In 1972, Project Devil, a medium range Surface-to-Surface Missile was initiated. A large number of infrastructure and test facilities were established during this period. The main facilities established during this period included Aerodynamic, Structural and Environmental test facilities, Liquid and Solid propulsion facilities; fabrication and engineering facilities; Control, Guidance, FRP, Rubber and computer centers, ground and flight instrumentation and onboard power supplies development facilities. The development of components / systems for Project Devil formed the technology bricks for the future IGMDP Programme.

1982 onwards DRDL took a quantum jump by taking design and development of various

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types of missiles systems simultaneously leading them to limited series production under Integrated Guided Missiles Development Programme (IGMDP). Prithvi- a surface to surface missile system, Trishul- a quick reaction short range, surface to air missile system, Nag- a third generation anti tank missile system and Akash- a medium range, surface to air missile system, besides Agni- a technology demonstrator were taken up under the Programme.

In order to meet the growing demands of development, integration, testing and quality assurance, three establishments namely Research Center Imarat (RCI), Composite Products Development Centre (CPDC), and Interim Test Range (ITR) came out under the parenthood of DRDL and a separate qualification agency Missile Systems Quality Assurance Agency (MSQAA) were established during this period. Later these establishments acquired independent status. In the year 1999 another laboratory called ‘Advanced System Laboratory’ was carved out of DRDL to meet the specific requirements of long range systems. This group of laboratories is now called Missile Complex.

Today DRDL, along with other Missile Complex Laboratories is the pioneer Missile Research Institutes in the country.

2.1.2 Vision

Be a design and development house for missile based weapon systems required for tactical applications from multiple platforms.

2.1.3 Mission Develop the state of the art infrastructure and technologies required for different classes of missiles. Transfer the technology to production agency for guided missile products. 2.1.4 Quality Policy

Design, Develop and lead to production cost effective guided weapon systems of assured Quality and Reliability with continual improvement, meeting the safety standards and time schedules. 2.1.5 ISO 9001 - 2000 Certification : Design, Develop and Lead to Production of “Guided Weapon Systems” Encompassing : System Design, Flight Structures, Propulsion, Aerodynamics, Computational Fluid Dynamics, Instrumentation, Range Systems, C4I Systems and Fabrication. 2.2 Facilities Available 2.2.1 Design facilities CAD / CAM As the Computer Aided Design emerged in eighties, DRDL was one of the first in the country to establish an integrated CAD/CAM facility. CAD / CAM center since its inception in 1987 was providing centralised service for entire DRDL for Computer Aided Design. CAD/CAM system comprising of six servers connected over a Local Area Network (LAN). The software capabilities covers application like Wireframe, Solid and Surface modeling with Assembly, Interference checking, Mass property checking, Visualisation, Computer Aided Manufacturing (CAM), Sheet metal, Piping, Cabling, and Detailing. The facility was complemented with analysis packages for Finite Element (FE) and for multi-body dynamic simulation. A Direct Numerical Control (DNC) link is also established between CAD/CAM

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and manufacturing facility. 2.2.2 Aero test facilities 2.2.2.1 Axi – symmetric and 2D supersonic wind tunnel The Axi-symmetric Supersonic Wind Tunnel facility and two Dimensional Supersonic Wind Tunnel were commissioned in 1980. Aerodynamic Forces and moments acting on scaled down missile models are tested in these facilities. Surface Pressure distribution, Hinge movement measurement, Performance evaluation of various subsystems such as isolated and installed air intakes were carried out. This facility is also used for wall-mounted model testing. 2.2.2.2 Aero ballistic range (ABR) Aero Ballistic Range - A Free flight test range where Aerodynamic parameters can be obtained without any interference were setup. The test model along with a sabot is launched from a gun at Supersonic speeds covering an instrumented range of 100 meters. Several cameras are located in the range take orthogonal pictures of the flying model at discrete intervals to get the required aerodynamic parameters. 2.2.3 Structural Test Facility 2.2.3.1 Static structural test facility To meet the requirement of structural strength tests, a closed type rig was developed. The rig is used to test integrated missiles. A number of actuators are used to apply structural load, axial force to the missile to simulate the desired bending moments as experienced by the missile during the flight. To observe the behavior of the missile during the test, extensive measurements are carried out. 2.2.3.2 Ground resonance test facility

A facility was set-up to find structural dynamic characteristics of integrated missile experimentally. The facility has been upgraded into a state of the art facility with multiple shakers and software for modal testing. This facility determines the oscillatory response of a vehicle to external forces.

2.2.3.3 Thermo structural test facility

Thermo - Structural Tests essentially are to simulate aerodynamic heating on ground to evaluate the performance of the missile structure as well as to ensure the thermal stability of the airframe of the missile.

2.2.3.4 Acoustic emission testing

This test facility is used for Evaluation of Structural Integrity of Pressure Vessels, Composite and Metallic Structures of various missile systems.

2.2.3.5 Material testing facility

This facility deals with all kinds of Tensile, Compressive and Shear testing of specimens of different materials like Aluminium Alloys, Mild Steel, Low Carbon Steels, Maraging Steel, Composites, etc.

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2.2.4 Propulsion Test Facilities

2.2.4.1 Horizontal test facility (HTF)

Horizontal Test Facility was indigenously developed to test Liquid Propulsion (L.P.) engines in horizontal mode using pneumatically operated control panel. This facility was utilized for testing various L.P. engines configuration.

2.2.4.2 Vertical test facility (VTF)

Vertical Test Facility was indigenously designed and developed to test LP engines. The control panel of this facility is electrically controlled from a remote location. This facility is used for testing the propulsion stages to prove the functional integrity.

2.2.4.3 Integral rocket ramjet test facility

To develop air breathing propulsion system for a flight vehicle, it is essential to have a test ground facility which can simulate the flight conditions. An integral rocket ramjet test facility was created for design verification & performance evaluation of ramjet propulsion systems.

2.2.4.4 Engine development facility (EDF)

The Engine Development Facility performs fabrication of components such as Reaction Control System components, Nozzles, orifices and adapters for Flow calibration facility, Hydraulic, Pneumatic, seals, flanges and test components for different Missile Systems.

2.2.4.5 Hydraulic flow calibration facility

To calibrate and adjust some of the internal parameters of an LP engine, so that the engine delivers its intended performance within the allowed tolerance band.

2.2.4.6 Vacuum brazing & welding facility

Vacuum brazing is a flux less process which involves removal of tenacious oxides, exposure of bare metal and promotes efficient wetting of the filler material resulting into an efficient joint. The Furnace is essentially consists of a heating chamber, which is evacuated to the required vacuum and maintained at that level throughout the operation. Vacuum heat treatment promotes degassing of the components (Which are already present on their surface) and avoids contamination with other harmful gases during the whole process.

2.2.4.7 Welding facility

Engine Development Facility of Liquid Propulsion Division has well established welding facility, intended for metal joining, cutting. etc for L.P. Engine and other auxiliary propulsion systems. The facility includes TIG welding machines and Air plasma cutting machines and portable TIG welding machines that employ non-consumable tungsten electrode with an envelope of inert shielding gas (argon, helium) to protect both the electrode and weld pool from the detrimental effects of surrounding atmospheric gases.

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2.2.5 Non-destructive Evaluation Facilities

2.2.5.1 Industrial computed tomography (ICT)

Computed Tomography is a radiological imaging technique that generates an image of a thin, cross-sectional slice of a test object. DRDL has setup the facility that is the biggest facility in India for scanning large objects.

2.2.5.2 Micro-focal real-time radiography

This is used for tight cracks and finer defects in small systems and sub systems. The facility is established for real time applications.

2.2.5.3 Infrared thermography

Infrared thermography is a non-contact and non-invasive test method that utilizes a thermal imager to detect, display, and record thermal patterns and temperature distribution across the surface of an object.

2.2.5.4 Magnetic particle testing

Magnetic Particle Testing detects the flux leakage due to the surface and sub-surface discontinuities in components made of ferromagnetic materials. It is used to detect surface & sub-surface defects in raw materials.

2.2.6 Computing Facilities

The simulation of the complex aero-propulsive flows requires enormous computing power and memory. To meet the increasing demand from the designer, various high performance- computing platforms have been established for generating 3-D CFD solutions for various missile configurations. Number of PIV based cluster computer with sustained speed of 0.5 terraflop have been established in DRDL.

2.2.7 Networking Facilities

2.2.7.1 DRDL intranet (D-Net)

Dnet is a 100 Mbps gigabit fiber optic local area network connecting all the buildings & Technology work centres. The facility is available on 24 x 7 basis. DRDO Rapid Online Network Access (DRONA) is also accessed by all the officers through this network. With more than 40 in-house developed on-line applications and 50 knowledge portal, DRDL intranet has become a very powerful tool for Communication and Knowledge Management for more than 1600 users from DRDL and 300 users from RCI and ASL.

2.2.7.2 Internet facility

A separate fully secured internet connectivity is also available in DRDL on 24x7 basis. More than 100 nodes are provided all across the lab through a 2 Mbps leased line connection.

2.2.8 Achievements

2.2.8.1 Integral ram rocket (IRR) propulsion systems

Fuel-efficient air breathing propulsion system was developed exclusively for Project Akash. IRR propulsion system provides powered range right up to target intercept enabling high

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maneuverability and tail chase capability unlike solid rockets.

Following subsystems were developed ab initio for realizing IRR propulsion system. • Light weight, high pressure rocket motors using indigenous maraging

steel, an indigenous high strength alloy steel. • Secondary chamber liner / thermal protection system using carbon phenolic fiber. • Composite propellant booster grain in free standing configuration. • A special grain with variable burn rates was developed and productionised at OF,

Itarsi which is also specific to Akash application. • Air intakes and caps are designed for ramjet application.

The IRR propulsion system is first in the country & it has potential application for long range air launched missile systems for air-to-air and air-to ground role. Not many countries have worked in the complex area of ramjet propulsion.

2.2.8.2 C4 I system hardware & software for air defence application

Akash medium range surface to air for area defence weapons system employing Group mode functioning. A group head quarters is a C4 I center which controls and coordinates the air defence activity over area against the airborne threats.

2.2.8.3 Dual control digital autopilot & guidance

Akash missile uses tail and wing control simultaneously for stabilization and maneuver. Digital autopilot controls six actuation channels in closed loop for achieving the missile control. The autopilot uses adaptive gain scheduling technique to maximize the control effectiveness for entire trajectory of the missile for various target engagement condition.

The autopilot is implemented in high-level language in the onboard computer. The latax control is through the two wing channels in both pitch and yaw planes. The rate stabilization is through two pairs of TCP channels. Roll control is through differential deflection of four TCPs. The control strategy for stabilizing both roll and rates using same TCPs employ dynamic sharing logic to effectively utilize the available maximum TCP deflections.

During boost phase of the missile, attitude hold is implemented to minimize the missile dispersion about the nominal launch attitude for assured gathering by Radar at designated position in space. The autopilot has been extensively flight tested for various regimes of missile kill zone and proved to be very effective and robust.

2.2.8.4 Superplastic formed HP air bottle

High pressure air bottles are used to store moisture and oil free compressed air at 400 KSC to provide regulated supply of air for electro pneumatic actuators of control system of Akash missile. Air bottles are made out of Ultra high strength titanium alloys. Conventional manufacturing techniques are not suitable for forming of hemispheres. Raw material is heated to plastic stage and specially designed tools are used to form hemispheres having very low d/t ratio. The entire process has to be carried out in controlled atmosphere to avoid oxidation at elevated temperatures.

The air bottles have been used in all the flight vehicles flight tested so far and reliability of the performance has been established.

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2.2.8.5 Tandem warhead system

The ‘NAG’ warhead is an indigenously developed shaped charged Tandem warhead for antitank role. It consists of two shaped charges namely the Precursor Charge and the Main Charge.

The Precursor Charge is designed to defeat the Explosive Reactive Armour (ERA) protection and the Main Charge is designed to neutralize the main armour of the tanks. The warhead is provided with an Impact Sensing Mechanism (ISM) and a Safety Arming Mechanism (SAM). On impact of the missile on the target, the impact sensing mechanism generates a command, which initiates the charges through safety arming mechanism. The Safety Arming Mechanism ensures safety during storage, handling & missile firing. It enables arming of the warhead at a safe distance and detonates warhead on impact of missile on target. In shaped charge, Warheads High Speed metal jet produced by the collapse of a metallic cone under explosive loading inflicts the desired target damage. This metallic jet acts as a carrier of energy and transports portion of explosive energy to the target.

2.2.8.6 Thermo stable liquid fuel charging technology

The BrahMos Missile is propelled by two stage propulsion system of liquid and solid propellants. For the Liquid Ram Rocket Engine, there is an essential need to fill in a highly purified gas free liquid fuel of exact volume into the fuel tank. The conditions applied for this are very stringent for the gas concentration in the fuel. The de-gasification process is carried out by Nitrogen gas purging and spring methods.

To ensure this, a system has been indigenously developed in DRDL with complete indigenous design and manufacturing technology. The system consists of double wall tank for de-gasification of liquid fuel within the stipulated time. This fuel is also being used in hydraulic actuation systems. The total fuel processing and charging procedure is carried out under vacuum conditions to avoid contamination during the process.

2.2.8.7 Fire control systems

BrahMos Fire Control System, known as BFCS is indigenously designed and developed for BrahMos Supersonic Cruise Missiles. It aids the user in planning the trajectory, Pre-Launch preparation and Launch of missiles. It has an option to introduce waypoints in the trajectory for better exploitation of BrahMos system. The FCS can be configured to launch the missiles in either single or salvo mode with an option to program the launch interval.

Two versions of FCS have been designed and developed: Ship Borne FCS for Indian Navy and Shore Based FCS for Indian Army.

2.2.8.8 Evolution of aerodynamic configuration of hypersonic air breathing vehicle

The crucial requirement for the hypersonic vehicle is the stability at cruise and positive thrust margin. Satisfactory performance has been achieved under power on and power off conditions. The aerodynamic configuration is non-circular (octagonal), which is non-conventional too. The performance enhancement has been obtained by incorporating fences at forebody and rearbody. Cowl extension at the nozzle improved the stability of the vehicle at cruise.

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2.2.8.9 Design of hypersonic air intake

External compression in the forebody and internal compression in the air-intake have been achieved for the hypersonic flight. Analytical and computational methods have been developed for the design of air-intake enhancing pressure recovery and minimizing loss. The starting performance has been evaluated through CFD. Suitable experiments are designed and conducted. Starting of isolated intake and integrated intake using suitable air intake cowl opening mechanism have been designed and realized. Enhancement of the performance with boundary layer bleed has also been attempted.

2.2.8.10 Development of scramjet engine test facility

The scramjet engine development is the critical path towards realization of the HSTDV. The Engine is designed for hydrocarbon (Kerosene) fuel combustion, which would make the hypersonic vehicle economical for the service usage. Connect pipe test facility with elaborate instrumentation and data logging capability has been established. The operation of the facility is fully automated through PLCs and other control devices.

Two versions of scramjet combustors viz., strut based fuel injection and ramp cavity based fuel injections are being developed. Half width model combustor static tests (10 Nos.) have been conducted so far. Extensive CFD analysis has been carried out for half width model and full scale model combustors. The full scale engine is being realized for conducting static tests in the connect pipe facility.

2.2.8.11 Manufacturing process for the scramjet engine

The scramjet engine construction is a double wall construction with special alloy used for the inner wall facing combustion region and the outer back up of another special alloy to provide the structural strength. These two alloys have to be joined continuously along the surfaces of their contact. The explosive welding gives the quickest way of joining these materials effectively. The explosive welding trials were done. This manufacturing process has been established to realize engine hardware for subsequent testing.

2.2.8.12 Design of aerospace mechanisms for the hypersonic vehicle

The HSTDV mission is mechanisms intensive. They are viz., the air intake flap mechanism, separation mechanism, unfolding mechanisms for the wings and tails of the cruise vehicle and the nozzle flap mechanism. The design of these mechanisms in the high temperature environment of the hypersonic flight is realized.

2.2.8.13 Control guidance algorithm for CLOS guidance

In order to achieve shortest possible range of a weapon system, it is essential to develop CLOS guidance scheme in which missile is guided to the LOS in the quickest possible time. This technology has been developed for the first time in the IGMDP. Trishul system has been developed using this technology and it was demonstrated through 80 flight tests using various kinds of platforms. Required miss-distance (» 10 mtr.) has been demonstrated repeatedly through live firings against targets.

2.2.8.14 Height lock loop guidance algorithm

Trishul is the first indigenous supersonic missile having capability of flying 5 meters above the sea-surface. This has been possible by design of a sophisticated height lock loop guidance

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algorithm using a precision Radio Altimeter as a height sensing device. The sea-skimming capability of Trishul missile has been demonstrated through a large number of live firings from Naval Trishul Shore Installation at INS Dronacharya.

2.2.8.15 Lithium thermal battery

Lithium Thermal Batteries have high power density and very long shelf life (in excess of 20 years). Trishul missile borne lithium thermal batteries have been indigenously developed, qualified & produced in large numbers.

2.2.8.16 Dual thrust rocket motor

Dual Thrust Rocket Motor has been designed and developed indigenously for Trishul missile. Smokeless composite propellant has been indigenously developed for this Rocket Motor. Rocket Motor has been flight tested several times without any flaw.

2.2.8.17 Launch container

Trishul missile is delivered as ammunition in a FRP canister. This launch container has been indigenously developed with various mechanisms like automatic umbilical retraction, transport-locking mechanism etc., along with its electrical interfaces.

2.2.8.18 Folding fin technology

In order to have minimum dimension of the launch container to accommodate more number of missiles on the launcher, folding fin mechanism has been developed for Trishul missile. All the four fins are folded when the missile is within the launch container. They automatically are deployed as soon as the missile moves out of the launch container. Design and implementation of the fin folding Mechanism has been a real challenge. Folding fin mechanism has been qualified through large number of flights tests without any failure.

2.2.8.19 Flow forming technology

Novel manufacturing technique called flow forming has been established for manufacturing of Trishul airframe structures. This technology has been successfully utilised for manufacturing of maraging steel rocket motor tubes, and other airframe structures of Trishul. This technology has played crucial role in reducing the hardware weight of Trishul missile.

2.2.8.20 Materials for hypersonic vehicle

The materials have to be chosen to retain the required strength levels at the elevated temperatures. The short duration mission materials are required for the engine walls to withstand high temperatures, another special alloy as a structural back-up to the first alloy, a Titanium alloy for airframe and carbon composites for high temperature regions. These materials with appropriate coatings would be suitable for the short missions. The thermal barrier coatings (TBCs) bring down the surface temperature levels to the ones within the capability of the materials. Many TBCs were tried out by thermal tests and erosion tests and it is found that ceramic based coating developed which is best suited for the application. The technology development is done in various work centres. Based on the testing and feebback from the designer, the technologies will be improved.

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2.2.9 Areas of Work 2.2.9.1 System design and engineering Mission Analysis, System Design, Simulation and Post Flight Analysis of various tactical and Ballistic Missiles, are done starting from system definition and feasibility study, specification of different subsystems and finalisation of system configuration. All the above were successfully completed for all IGMDP Missiles, AD (exo and endo atmospheric Interception), SF and ASTRA projects.

Various guidance algorithm including command guidance, midcourse/terminal guidance, seeker based guidance and control system design have been developed. Very important contributions were made for trajectory and missile design, performance analysis, mission clearance and post flight analysis for these missile projects. Many specialized softwares on multi-sensor data fusion algorithm, weapon system algorithm for command and control, nonlinear autopilot design, trajectory optimization, aero parameter estimation etc., have been developed.

2.2.9.2 Aerodynamics

Aerodynamic design and characterisation of different tactical and ballistic flight vehicles are carried out using analytical, computational and experimental methods. Rapid prediction methodologies are applied in the conceptual and preliminary designs which are further refined using CFD and wind tunnel tests. Enhanced aerodynamic configuration design of all missiles are carried out using state-of-art-design features like near neutral stability, Low aspect ratio wings and control surfaces, Hypersonic aero-thermal characteristics etc.

Multi Disciplinary Design Optimization (MDO), Grid Fin Technology is also studied for design improvements. Aerodynamic data generation for complete flight envelope, estimation of load distribution for airframe design, estimation of control efficiency and hinge moment, Store/stage separation studies for air launched missiles and multistage vehicles, air intake design and characterization ramjet/scramjet propulsion system etc., are carried out for different missile systems. Various aerodynamic testing facilities like supersonic wind tunnel, aero ballistic range, hydro basin, shock tunnel, Ludwig tube and hypersonic wind tunnel have been established.

2.2.9.3 Propulsion

Propulsion Systems with varying thrust are developed for various missile programmes using liquid and solid propellants. Development of Bipropellant liquid rocket engine, Bipropellant Reaction Control System and Velocity Trimming Package (VTP), Divert and Attitude control system, Cold gas reaction control system are some of the notable achievements in liquid propulsion system. Programmes for the development of Liquid Fuel Ramjet and pulse detonation engine are currently under progress.

Development of important solid propulsion systems includes integrated solid fuel Ram rocket, solid propellant booster (4 fin finocyl grain configuration) with Jet vane thrust vector control, Dual pulse solid propellant rocket, safe and arm ignition system for rocket motor, and EPDM based thermal insulation system etc. Number of different test facilities such as Liquid Propellant Engine development facility, horizontal and vertical test facility for band rocket engine, and Liquid ramjet test facility has been established for testing various liquid engines.

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2.2.9.4 Computational dynamics

If we like to study the vortex formation over missile, (ii) Missile separation from aircraft and (iii) Flow field over Jet Vane - the experimental investigation and flight testing is very costly both in time and money; hence numerical simulation of external and internal flow field on complex missile configuration is playing an increasing role in estimating accurate aerodynamic and propulsive characteristics for the design of missile system.

DRDL has developed a host of advanced industry standard 3D Euler and RANS codes using kinetic schemes to deal with both in viscid and viscous flows encompassing complete Mach number and angle of attack regime of the flight. These codes have been extensively validated against reliable experimental results and are used routinely as a design tool. Use of the advanced numerical methods in the missile design can reduce the development cost and time very significantly. Recent developments in CFD include 3-D q-LSKUM software to estimate control characteristics of aerodynamic surfaces and store separation dynamics. A new unsteady CFD solver KFMG has been developed and being applied to computational aero elastic analysis. An Euler- Boltzman coupled solver has also been developed for low-density reentry flows.

In the Computational Combustion Dynamic area competence has been developed in numerical simulation of turbulent reacting flows. Propulsion systems of various ongoing and future missile projects are being designed and analyzed using the commercial CFD softwares. Such as SCRAMJET combustor flow field simulation, JET VANE flow field simulation, TIP - TO – TAIL aero propulsive simulation of air breathing missiles, Exhaust plume and free stream interaction at base region, Conjugate Heat Transfer studies etc. Various advanced topics like ignition modeling, atomization modeling, turbulence – chemistry interaction and large Eddy simulation (LES) are being pursed in-house and also in collaboration with academic institutes.

2.2.9.5 Flight structures

DRDL has got expertise in the area of Structural Design and Development of Missiles. Present thrust areas are the design for elevated thermal environment and design for dynamic environment. The design starts with evaluation of both structural and thermal loads. The airframe sections are designed to withstand these loads. Thermal loads play a very important role at higher Mach number of the missiles.

This load dictates the selection of proper material, selection of thermal barrier coatings and evaluation of thermal stresses. Design of aerodynamic surfaces and associated mechanisms to deploy these is another important area of work. Opening mechanisms can be active or passive. The design is governed by the deployment time and the aerodynamics loads at the time of deployment. Dynamic characteristics of the missiles are also evaluated theoretically and validated experimentally by this group. Ground response test facility can handle mode shapes. Multiple excitations can be given and the accelerometers data is processed to get the dynamic characteristics.

All the structures are tested to validate the design. This group has facilities for material testing and structural testing. The structures can be tested in the combined environment of structural loads and external pressure load and also at elevated temperatures. The thermo-structural testing facility has been set up to simulate flight conditions. Efforts are on to develop the set-up for combined elevated temperature, structural and external pressure loads.

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2.2.9.6 Computer & communication

The DRDO Computer Center became functional in 1983. Since then the group has been contributing to various programmes through its evolving computer setup. Today this group is responsible for activities in the areas of C4I and Independent Verification and Validation (IV&V) of mission critical softwares. C4I system is Command Control Center, which provide Commanders at all echelons with accurate, timely and credible information for decision-making. They provide a means to process, display and evaluate the developing situation. The C4I systems have been designed to handle the multi target scenarios arriving from multiple directions. The efforts of this group have resulted in development and realization of C4I system for various missile programmes.

An Independent Verification & Validation Group has been functional since the inception of the IGMDP programme. The objective of the group is effective validation of mission critical software as per customer requirement and reduces the number of bugs in any software developed to the level of at least 6 sigma. The IV&V of DRDL team has validated all the mission critical software of all projects and also projects from other DRDO laboratories. Several in-house tools have been developed in addition to use of commercial tools for software evaluation and validation.

2.2.9.7 Engineering & fabrication

First off development of hardware for Missile subsystems before the technology is transferred to external agencies is fabricated at DRDL. The product spectrum ranges from a small intersection fastener to high technology Seeker Guidance system. DRDL engineering & fabrication facilities are capable of developing Integrated Products and Processes using state of the art technologies, productionise and deliver world-class missile system hardware.

DRDL employs a strong Quality control and Quality assurance policy with well established quality practices and state of-art in house infrastructure for non destructive testing and evaluation, assembly testing and qualification of Missile systems and sub systems.

Main Capabilities in the area of Engineering & fabrication are:

• Prototype Development, Realisation & Productionisation Mechanism

• Design & Analysis of Special Equipment & Processes Development Tool

• Mould, Jig, Fixture Design and

• Fabrication, Integrated Manufacturing system software

• Different Welding Technologies

2.2.9.8 Range & instrumentation

Range Instrumentation group provides all necessary instrumentation requirements for work centers and for field instrument requirements. This group is recognized for conceptual design and implementation of static test facility of different types of propulsion systems. The following are the specific activities in this area:

• Six component static test for Thrust Vector Controlled Propulsion systems

• Evaluation of Flex Nozzle control systems

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• Instrumentation for development and testing of advanced propulsion systems like Scramjet/ Ramjet propulsion systems

• Performance evaluation of propulsion systems, which are designed and developed for missile programmes.

2.2.10 Projects

2.2.10.1 Akash

The supersonic surface to air missile ‘AKASH’ has a range of about 25Km and carries fragmentation warhead which is triggered by radio proximity fuse. The missile uses state-of-technology integral ramjet rocket propulsion system and the onboard digital autopilot ensures stability and maneuvers. The multi function phased array radar tracks the targets and guides missiles towards them. The weapon system has a network of radar sensors to effectively manage the air threats.

Salient Features

• Multidirectional, Multitarget Engagement

• Fully automated operation

• Targets – Fighter A/C, UAV, Helicopter, Cruise Missile

• All Terrain mobility

• All weather operation

• Advanced ECCM

• Custom configured to meet user requirements 2.2.10.2 Nag (third generation anti-tank missile) Third generation Anti-Tank Missile System ‘NAG’ has “fire and forget” and “top attack” capabilities. The Lock-on-before Launch Imaging Infra Red (IIR) homing provides capability for Day & Night operation. The Missile excels as a formidable support weapon for the Mechanised Infantry and Attack Helicopter formations. The Imaging Infra Red homing seeker has all-weather day and night capability. The Nag system is for deployment on “NAMICA”, a tracked vehicle and on a Helicopter. Top attack mode using the advanced homing guidance system and tandem shaped charge warhead is used to defeat heaviest armour. In addition, high energy, smokeless propellant, light weight, high strength composite airframe with foldable wings and fins, onboard real-time processor with fast and efficient algorithms, compact sensor package and electric actuation system, digital autopilot and high immunity to counter measures make this missile a state-of-art Anti-Tank Guided Missile System. Salient Features - RANGE-4.0Km - Fire & Forget capability in lock-on-before-launch mode

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- “Day & Night operation (imaging infrared seeker) - ‘Top-Attack’ capability - High SSKP (Single Shot Kill Probability - Capability to defeat futuristic tanks & other hard target. 2.2.10.3 Namica Salient Features - 8 Nos, ready-to-fire missiles on the turret - Option for additional 4 missiles in storage - 4 missiles can be fired in 1 minute - Mobility matching BMF-11 2.2.10.4 Astra ASTRA is a Beyond Visual Range (BVR) air to air missile indigenously designed and developed to engage and destroy highly maneuvering supersonic aerial targets. This highly agile and accurate missile can intercept high speed, highly maneuvering targets and can pull High level maneuvers. The kill boundary of this vehicle gives the enemy no chance of survival. This is one of its class with a low all up weight to have high launch range capability, this weapon system is meant for platforms like SU 30MKI, Mirage 2000 of Indian Air force and LCA developed by DRDO. Salient Features - Airborne Launcher adaptable to Different Fighter Aircrafts - Smokeless Propulsion - Inertial Mid-Course & Terminal Homing - State-of-art ECCM features - All weather capability - Launch Speed 0.4M to 2M - Launch Altitude SL to 20Km - Launch Range 80Km 2.2.10.5 PJ-10 BrahMos is a Supersonic Cruise Missile System developed by DRDL with foreign collaboration. DRDO's share of the work is being executed under the Programme PJ10. Salient Features - Integral Booster & High Performance Ramjet System - Fuel based Actuation System - Nose Cap Control Thrusters - Inertial Navigation System - Active Radar Seeker 2.2.10.6 Helina (Helicopter launched anti tank missile) A variant of NAG Missile to be launched from Helicopter is being developed under the Project named HELINA. The missile will have a range of 7 Km with all other features similar to NAG Missile system

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2.2.10.7 HSTDV (Hypersonic technology demonstrator vehicle) Project HSTDV is a technology demonstrator aimed to demonstrate autonomous Flight of a Scramjet Integrated Vehicle using kerosene. The related technologies are new not only for India but for the entire aerospace community in the world and have potential applications in the areas of civil, military and space sectors. A demonstrator flight vehicle has been conceptualised to demonstrate the Scramjet technology for a short duration of about 20 seconds. 2.2.11 Directorate of Human Resource Management (DHRM) The Directorate of Human Resource Management is headed by a Director. There are three Divisions under him as follows: (i) Human Resource Development, (ii) Knowledge Management Centre and (iii) Knowledge Centre, i.e. Library. Each of the above Division is headed by a Senior Scientist with full time responsibility of respective Division. Human resource development division The Human Resource Development Division in DRDL has taken the following initiatives for Human Resource Development: - Identifying training needs of DRDL personnel, - Preparing Training Bulletin / Planner every year, - Circulating Training Calendar/Brochures of various training organizations, - Placing Training Calendar/Brochures in DRDL Intranet, - Facilitating Mentoring programme for new scientists, - Conducting In-house Continuing Education Programmes for Scientists & Officers, - Conducting National & International Conferences & Workshops, - Nominating employees to External Institutes for training in identified areas, - Encouraging Scientists and Officers to present and publish papers at National Conferences/Seminars/Journals, - Arranging DRDL Facilities for B.Tech. & M.Tech. Project Work to the Children of DRDO employees, - Conducting training for Technical Staff of DRDO Hyderabad Zone. Knowledge management centre - Providing training to Users on usage of DRDL Intranet, - Introduced Idea Recognition System, - Managing DRDL Intranet, - Conducting Colloquium, - Providing Support for E-learning - Responsible for knowledge management in DRDL. - Providing Idea Recognition System for knowledge sharing - Introduced multi-user Document Management System to store documents by any user, at a central facility that can be accessed and shared between multiple users, across departments, multiple locations and the entire enterprise.

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2.2 Research Centre Imarat (RCI), Hyderabad – 500069, Andhra Pradesh

2.2.1 Introduction

Research Centre Imarat has been established in a sprawling campus of 2100 acres, in Hyderabad. Dr. Avul Pakir Jainulabhudin Abdul Kalam is the founder Director of Research Centre Imarat (RCI). The former Prime Minister Late Shri Rajiv Gandhi laid the foundation stone of Research Centre Imarat on 3rd August 1985 and was inaugurated by the former President of India, His Excellency, Shri R. Venkataraman on 27th August 1988. The area has been named as ‘VIGNYANA KANCHA’.

Research Centre Imarat, the premier institution of Defence Research & Development Organisation (DRDO) has been established to design and develop world class, state-of-the-art technologies which will produce precise and reliable indigenous weapon systems to strengthen country’s Armed Forces. RCI is pursuing research on Navigation, Control & Guidance, Imaging Infrared & Radio Frequency seekers, batteries and flight instrumentation technology areas. The other technology areas include Electrical and Mechanical Integration of systems and Reliability and Quality Assurance. RCI has also set up Environmental and EMI/EMC test facilities for Qualification and Acceptance testing of the mechanical and electrical airborne hardware.

2.2.2 Vision

To be the leader in the development of guided Missile Systems for our Armed Forces by developing the frontier Technologies, multi-disciplinary competence and state-of-the-art infrastructure leading to self-reliance.

2.2.3 Mission

Be a premier institute for developing Frontier Technologies in collaboration with Academic Institutions & industry. Foster Human Resources for professional Excellence, organise for the induction and production of the guided missile systems on to the Armed forces.

2.2.4 Areas Of Work

Research Centre Imarat ( RCI ) is a centre of Technological excellence in guided missile systems and variety of frontier technologies as follows:

(i) Missile System Engineering and Simulation, (ii) Control Systems, (iii) Guidance Systems, (iv) Seekers, (v) Navigation and Inertial Sensors, (vi) Missile Integration, (vii) Flight Instrumentation, (viii) Environmental Testing and Evaluation, (ix) Power supplies, (x) Micro-electronics, (xi) Micro-Electro-Mechanical Systems ( MEMS ), (xii) Reliability and Quality Assurance, (xii) Digital Simulation, (xiii) Hardware-In loop-Simulation ( HILS ) for tactical Missiles like, Surface to Air Missiles - Akash and Trishul, Air to air Missiles - Astra. 2.2.5 Technologies

2.2.5.1 Imaging infrared seeker technology

Short range homing guidance systems, visible CCD seeker, IIR seeker, Image processing system for scene matching techniques, missile interface electronics and signal processing techniques.

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2.2.5.2 Visible seeker

(i) Day seeker for anti tank missile guidance application featuring CCD sensor, servo stabilization system / real time image processor and (ii) Anti-tank missile applications.

IIR Seeker (Imaging Infrared seeker for antitank missile applications)

(i) Image processing algorithms and associated software & (ii) Optics with focus control.

2.2.5.3 MMW seeker

(i) Seeker with coherent transmitter receiver, (ii) Direct drive linkage based servo stabilization, (iii) Trans twist monopulse antenna and (iv) Signal processor.

2.2.5.4 Launcher based missile interface electronics

(i) State-of-the-art Processor with Missile Carrier NAMICA ( NAG Launcher), (ii)Handing over electronics, (iii) Ground Control Unit and (iv) Missile Control Unit

2.2.5.5 R.F. guidance systems

RF guidance subsystems and antennas for missile borne and ground applications :

Command guidance system : (i) Transponder, (ii) Command link system, (iii) Twin antenna switching and (iv) Hybrid MIC

2.2.5.6 Antenna systems

(i) Cassegrain Reflector Monopulse Antenna System, (ii) Monopulse corrugated horn and (iii) Light weight trans-twist monopulse antenna system. 2.2.5.7 Calibrated test and measurement facility (i) Antenna and radome evaluation, (ii) Radar reflectivity measurement and (iii) Microwave absorbers evaluation.

2.2.5.8 Inertial navigation systems (high precision)

(i)Dry Tuned Gas based strap down inertial navigation system for short and medium range tactical missile system, (ii) DTG / Laser based system, embedded computers, navigation algorithm and GPS-Inertial Navigation System, (iii) Quick reaction inertial navigation, (iv) Transfer alignment schemes and (v)GPS aided navigation.

2.2.5.9 On board computers

(i) Real time embedded computers for aerospace application carrying out navigation, Guidance, Control and Mission sequence functions withstanding dynamic, climatic and EMI environments; Onboard computers with distributed system architecture using MIL-STD-1553B bus which carries out Navigation, Control and Guidance functions; Real time embedded computer for IMU carrying out alignment and navigation function; Missile Interface Unit (MIU) using 16 Bit Micro Controller and Real time PC based test beds for hardware and software.

2.2.5.10 Control systems Control systems for control of tactical missiles in pitch, yaw and roll planes by incorporating

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autopilot, servo controller, actuation systems and software.

2.2.5.11 Autopilot

Analog and digital autopilots for Quick Reaction missiles; Control and Guidance computer for sensor inputs and actuator commands and Guidance algorithm for the missile systems.

2.2.5.12 Control actuation systems

Electro Hydraulic Actuation Systems: Electro Hydraulic Actuation Systems for aerodynamic, thrust vector, fin tip

Electro Pneumatic Actuation System: Low weight, medium power blow down Electro Pneumatic Actuation Systems for Surface to Air Missiles.

2.2.5.13 Flight instrumentation -tele-command and telemetry systems

PCM Telemetry System; 1553 based ASIC PCM encoder; Digital Telecommand System; C Band Transponder; S-Band Transmitter ( MMIC ); CDMA data link; Conformal Antenna System; S-Band Transponder

2.2.5.14 Power supplies

Power supplies for missile systems; Test facilities for batteries, NDT method to find out state of charge, Electroless plating technique for Copper plating on Non-Conductor, HR-5 Silver Oxide Zinc rechargeable battery; Primary Battery - Silver Oxide – Zinc Battery; Secondary Battery - Nickel – Metal Hydride Battery and Thermal Battery - Lithium thermal Battery 2.2.5.15 Environmental test facilities

Environmental test facilities for conducting specialized environmental tests and Vibro acoustic studies for meeting the stringent requirements of all missile and ground systems as per MIL and JSS.

Dynamic Test Facilities to test Tactical and other missiles : Shock; Centrifuge; Vibration – Sine, Random and sine on random; Bump; Acoustic noise

Multipoint Excitation Testing for Modal Analysis : Multi shaker; 32 channel data; Laser Vibrometer

Launcher Vibration characterization, Acoustic and Vibration Data Measurement during launch and analysis. Packaging for PCB’s and Electronic Sub-Systems : Static analysis, Dynamic analysis, Thermal analysis, Chassis design and Isolators Vibro Acoustics : Estimation technique for turbulent boundary layer noise and jet noise; Vibration response estimation using Statistical Energy Analysis(SEA) technique and correlation with experiments. Pyro Shock testing, measurement and analysis:16 channel, High frequency recording. Environmental chambers ( Small and Large Chambers ) : High Altitude Simulation, Rain and Icing simulation, Humidity and damp heat, Salt corrosion, Extremes of temperature

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( low & high), Combined environments & Tropical exposure

Kinetic Heating : Thermal and static loading, Multi channel strain and temperature and IR lamps and reflector assemblies.

2.2.5.16 EMI / EMC testing technology

Test facilities to evaluate the performance of the missile sub-systems and ground systems against operating EMI environment as per MIL-STD 461C. EMI hardening technology.

Modular shielded enclosure

Automatic EMI data collection system

Automatic EMI susceptibility measurement system

Radiated susceptibility

Electronic static discharge system

2.10 Hardware-In-Loop-Simulation

HILS test beds for design, development and validation of different classes of tactical missiles

Strap down Inertial Guidance System for all missiles with sensors, actuators and embedded software including flight systems.

Rapid prototyping of onboard and ground systems including interfaces like 1553, ARINC, VME and SCRAMNet. Test beds including seeker hardware ( CCD / IR / RF ). Modularized PC based test beds. Test beds with state-of-the-art computers, motion simulators and application software and tools. Simulations with van and ship to bring more realistic situation in HILS. Capability to find deficiencies in model, onboard hardware and embedded software. 2.2.6 Projects - Prithvi & its variants :

Prithvi is a Surface-to-Surface Battle field Missile. It uses a single state, twin-engine liquid propulsion system and strap-down inertial guidance with real-time software incorporated in the onboard computer to achieve the desired accuracy during impact. Prithvi has higher lethal effect compared to any equivalent class of missiles in the world. Prithvi is a unique missile today having maneuverable trajectory and high level capability with field interchangeable warheads. Its accuracy has been demonstrated in the development flight trials. Flight trails for Air force version has been completed. This system has also been configured for launching from ship, increasing its capability as a sea mobile system.

(i) It is a tactical surface to surface missile for field support

(ii) Air force version (Prithvi II) developed for deep interdiction

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(iii) Naval version (Dhanush) can be launched from ships. Stabilization platform designed

for ships enables launching of missile even during sea state 4

Features of stabilization platform :

- Stabilization controller interfaced with launch computer

- Launch stabilization achieved +/- 1o

Missile range and payload: Range Payload

Army version: 40 to 150 km 1000 kg

Air force version: 250 km 500 kg

Navy version: 250 km 500 kg

2.2.7 Human Resource Development Group The Human Resource Development Group in RCI has taken the following initiatives for Human Resource Development : - Conducting In-house Continuing Education Programmes for Scientists & Officers, - In-house Structural Training Programmes in Core Areas for Scientist’B’s for eight weeks duration and for Scientist’C’s & Scientist’D’s for two weeks duration, - Introduced Mentoring System, - Conducting National & International Conferences & Workshops, - Nominating employees to External Institute/IT Sectors for training in identified areas, - Nominating Scientists and Officers to International Conferences/Workshops at foreign countries in the areas for which training scope in India does not exist, - Scientists and Officers are encouraged to present and publish papers at National Conferences/Seminars/Journals, - The information about various training programmes is put in RCI Intranet, - The Papers presented and published by Scientists & Officers are being put in RCI Intranet, - Facilities are provided to sponsored Scientists of DRDO for M.Tech. Project Work, - Establishing Zonal Training Centre to train the personnel of Hyderabad Zone. The Head Human Resource Development (HRD) Group in RCI is a full time Scientist, looking after only HRD activities.

2.3 Advanced Systems Laboratory (ASL) Kanchanbagh P.O. Hyderabad - 500 058

2.3.1 Introduction

Advanced Systems Laboratory (ASL) was established in the year 2001 as a consequence of restructuring of the missile laboratories and the missile programs. Advanced Systems Laboratory is responsible for design, development and induction of long range ‘AGNI’ ballistic missiles and development of associated technologies and facilities. The three AGNI reentry technology demonstrators developed and test fired during 1985 to 1992 gave the impetus to design, develop and induct a series of long range missile systems of AGNI class (A1, A2, A3). AGNI I & AGNI II have completed the development flights and are being inducted in the Services. The long range AGNI III is under development and the hardware is under qualification for the first development flight.

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In addition to the AGNI program, ASL is working on many other Technology Development (TD), Mission Mode (MM) and infrastructure projects for LCA and other systems. There are about 240 Scientists & Officers and 250 Staff working in the Lab. 2.3.2 Technology Vision :

Development of Competence in Technologies for Long Range Missile Systems. 2.3.3 Technologies

- Solid propellant cast at SFC successfully static tested for daisy-I & ds-I

- Composite rocket motor casing 1 mt (dia) load tested

- Successful testing of underwater booster MK-II with C/SIC Jet vanes for 14 seconds

- Successful performance of variable thickness radome / C-C

- Brake discs in LCA development flights ( PV-01, TD-01, TD-02)

- Composite Drop Tanks - 800 lt & 1200 lts qualification tests completed

- Variable thickness radome (VTR) for LCA PV series – (Four radomes made)

- Carbon-Carbon brake discs with reduced wear rate developed (production through industry)

- Refurbished Carbon-Carbon brake discs – first phase aircraft trials on mirage 2000

- Developed portable C-Scan equipment and supplied to NAL

- Flex nozzle technology established

- Dual redundant launch computer with switch over logic

- Shell on shell technology established for RVS (Re-entry Vehicle Structure)

- Fine weave preform technology established (unit cell vol.15mm3)

- Carbon-Epoxy-Glass-Epoxy long composite canisters

- Carbon-Silicon Carbide Jet vanes for thrust vector control

- Propulsion technology (gas generator, underwater booster, Air booster) for Sub-Marine launched systems

- Developed boost coast motor with case bonded composite propellant and flight tested in ASTRA

- Dual thrust rocket motor with non- aluminised propellant to reduce RF attenuation – successfully flight tested

- Aerospace mechanisms (pyrogen igniters, launch release mechanisms)

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2.3.4 Projects

2.3.4.1 Agni I Medium range surface to surface missile Salient features: - Single stage solid propulsion - Carbon composite re-entry vehicle - Closed loop explicit guidance - Road mobile system - Range:700 km - Launch weight:12 T - Length :15 m

2.3.4.2 Agni II Intermediate range ballistic missile Salient features :

(i) Two stage solid propellant rocket motors (ii) Carbon composite re-entry vehicle (iii) Strap-down inertial navigation system (iv) Rail mobile launcher system (v) Range : 2500 km (vi) Launch weight : 17 T (vii) Pay load weight : 1 T (viii) Length : 20 m

2.3.5 Facilities

- Static test facilities at SFC commissioned

- Solid Propellant Plant at Jagadalpur is operational, daisy 1 processed

- Facility for testing flex nozzle established

- Functional test rig for drop tank

- Established 6 component test bed

- CNC piercing & insertion machine

- 0/ 90° winding machine

2.3.6 Areas Of Work

(i) Aerospace Mechanisms, (ii) Advanced Composites, (iii) High Temperature Composites, (iv) Solid Propulsion Technologies, (v) System integration, (vi) Composite Product Development and (vii) Reliability & Quality Assurance.

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2.3.6.1 Aerospace mechanisms

(a) Ultra low shock staging system, (b) Soft pay load release mechanisms, (c) Aircraft spin recovery mechanisms, (d)Nose cap jettisoning mechanisms, (e)Large booster ignition systems, (f) Simulation of mechanism dynamics, (g) Characterisation of eeds, (h) Productionisation of ordnance products, (i) Ignition transient predictions, (j) Miniaturisation of eeds, (k) Air crew escape system, (l) Laser initiation system, (m) Semiconductor bridge eed, (n) Torpedo release systems, (o) Deployable nozzle exit cone mechanisms, (p) Variable nozzle mechanisms and (q) Under water mechanisms.

2.3.6.2 Advanced composites

(a) Re-entry vehicle structure for AGNI Missile, (b) Shell-on-Shell technology for RVS, (c) Ablative components, (d) Canister Assembly, (e) LCA Radome development and (f) NDT of composites : Ultrasonic testing, Radiography & Thermography.

2.3.6.3 High temperature composites

(a) Carbon-Carbon Composites CCD : C/C products re-entry, C/C brake discs for LCA & C/C process technologies.

(b) Liquid impregnation (HIP/CVI/Thermal gradient) : Mulidirectional weaving / braiding, Fine weave blocks & cones, Material characterization, Oxidation resistant C/C composite, Indigenisation of process & Equipment / accessories.

(c) Ceramic Matrix Composites CMCD : Carbon - silicon carbide composites(Jet Vanes), Silica - silica composites (Radomes) & Functionally graded composites (FGM).

(d) Elastomers ELD

(e) Carbon - Carbon brake discs for LCA

(f) Process Technology improvements to reduce wear of discs

(g) Rubber components for missile programs

2.3.6.4 Solid propulsion technologies

(a) Rocket motors : Large rocket motors, Dual thrust motors, Boost-coast systems, Gas generators, Divert thrust motors & Motors with tailpipe.

(b) Auxiliary propulsion : Retro motors, Nose cone sep. Motors, Micro thrusters & Ullage motors

(c) Fabrication technologies : Maraging Steel , 15CDV6 & HE-15

(d) Testing & qualification : Six component testing, Flex seal testing & High & low temp. Soaking.

(e) Thrust vector control system : Flex nozzle control system & Jet vane control system.

2.3.6.5 System integration - long range systems

Integration and checkout of long range missile systems, involving complex mechanical and

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electrical systems, computer systems & high level of computerized information processing

- Design of portable checkout setup for testing missile at site

- Design of solid state relay based redundancy in powering of critical missile sub-systems

- Design of a long distance 1553B link through ethernet and fiber optics conversion

- Development of linux based embedded GUI

- Linux kernel configuration to port entire checkout program in 32/64 MB flash

- Realization of user access scheme for launch operation

- Realization of fixture for tilting large diameter sections

- Design of containers for large diameter missile system with long storage life

- Developing of handling equipment for use at different locations

- Realization of ground based primary battery pressurization scheme

- Design of dual redundant launch computer

- Design of dual redundant switching scheme including redundant power supply

- A dual redundant fiber optics link

- Incorporation of intelligent interface units in the missile

- Simulators developed to simulate all functions of missile

- Secured access scheme to the operation of launch computer

- Usage of open source operating system

- A standard procedure for the development of Software of real time systems

2.3.6.6 Composite product development

(a) Composite Rocket Motor Casings, (b) Flex Nozzles, (c) Ablative Liners, (d) Lattice Structures, (e) 800 Ltrs Drop tank, (f) 1200 Ltrs Drop tank & (g) Composite load bearing structures.

2.3.6.7 Reliability & quality assurance

2.3.6.7.1 Quality planning : User requirements/ specifications; Standards & QA plans; Test plans for Materials, Standard Products & Fabrication/ processing; QT/AT documents; Integration check lists and Software validation plans.

2.3.6.7.2 Quality implementation : Suppliers quality assessment; Quality control and Inspection & testing for Incoming, In process & Final; Records for Materials, Standard Products & Fabrication/ processing; Qualification & Acceptance Testing; Structural Tests; Environmental Tests; Environmental Stress screening; Functional tests and Phase checks.

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2.3.6.7.3 Reliability engineering

- Test data collection and reliability analysis,

- Apportionment,

- Prediction,

- Assessment and

- Reliability studies / Engineering

2.3.6.7.4 Software verification & validation

- Flight & Checkout software validated

- Test jigs – LIU test jig, MIU test jig, section vibration software

- SFC –testing, validation & clearance of DAQ softwares

2.3.7 Core Technologies

- Re-entry Technology

- Radome Technology

- Composite Rocket Motor Casing

- Nozzle Systems

- Solid propellant processing technology

- Multi directional preforming technology

- Carbon/ceramic composite processing technologies

- Design and analysis of composite structures

- Dual thrust solid propulsion system

- Case bonded large solid rocket propulsion system

- Hot gas generator Thrust vector control Pyro mechanisms and devices

2.3.7.1 Re-entry technology - Established Non-impact fastening of bulkheads

SHELL-on-SHELL Technology Established

Designed & developed tape wound CP shells

Bonding technique of CE / CP shells (Shell-on-Shell)

NDT techniques for Shell-on-Shell RVS sections

Completed Autoclave (small) control up gradation

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N2 pressurization system for 3 autoclaves

Civil works realized for RVS assembly facility

2.3.7.2 Radome technology

2.3.7.2.1 Technology achievements

- Composite Pitot Adapter Development for better EM performance

- Qualified Composite Pitot Adapter with Lightning Test on Full Scale Radome

- Standardized Painting Scheme for Blister Free Surface

- Established the process for achieving ±15´ Angular tolerance requirement on Pitot Adapter Holes

2.3.7.2.2 Project milestones/achievements

- Delivery of Radome Assembly with due Airworthiness Certification for PV1 Aircraft

- 4 VTR Mouldings for PV4, PV5 & 2 Flight Standby completed

- Coupon level Mech., EM & Environmental Tests for QTAT completed which will be followed by Full Scale Radome Level Tests

2.3.7.3 Composite rocket motor casing

Technologies Established for the following:

- Filament (wet) winding on Non-geodesic path with in-house software.

- Soluble mandrel (Ø1M, L-5M).

- Metal - composite joint with rubber shear ply.

- Metallic bosses with rubber encapsulation.

- Full scale CRMC development with industry participation.

2.3.7.4 Nozzle systems

Technologies established for the following :

- Thermal boot moulding

- Compression moulding / tape winding of liners

- Rosette lay-up for liners

- Integration scheme

- Bench test facility

2.3.7.5 Solid propellant processing activities

- Propellant plant commissioned for processing of large size case bonded solid rocket

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motors (HTPB-AP-AL)

- Raw material for 180T Propellant available

- Formulation with HTPB-XT completed and 3 daisy 1 segments processed

- Formulation trials without XT completed and processing of segments scheduled during Aug /Sep 03

- Tooling and handling accessories for 2m motors realised

- Captive facilities for HTPB & Ammonium Perchlorate established.

- Provision for monolithic casting of Large motors upto 10m long

- Curing facility for large segments

- Multiple NDT & mixing facility

- Static test facilities

- Transit magazines

- Multiple curing ovens

Automated transportation in Process facilities

2.3.8 Facilities

- Autoclave (2.5m X 3.0lm, max. temp.300°c) installed and commissioned

- Co-ordinate measuring machine (l 3.0m X W 1.8m X H 2.4m, vol. Accuracy max. 90 microns) installation under progress

- Prepreg plant (speed 0.1 to 1.0m/min. Thyrister control, Automatic) installation under progress

- CNC piercing and insertion machine installed & commissioned

- Additional 4-D weaving fixture & fine weave fixtures fabricated

- Power supply unit cum control panel for graphitisation furnace indigenised and operational 150 KW / out put Frequency 1000hz Voltage 1650 V

- Compact / simple design single card / ac - dc converter diodes / no harmonic distortion

- High pressure vacuum impregnation system ( 60 bars ) commissioned

- Incoloy process chamber cum furnace for hip under fabrication Stitching machine developed

- Round the clock operation and maintenance of C/C facilities through O&M contract

- Static test facility for Solid Rocket Motors

- Six Component test bed

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2.2.7 Human Resource Development Group The Human Resource Development Group in ASL has taken the following initiatives for Human Resource Development : - Conducting In-house Continuing Education Programmes for Scientists, Officers & Staff, - Introduced Mentoring System, - Conducting National & International Conferences & Workshops, - Nominating employees to External Institute/IT Sectors for training in identified areas, - Nominating Scientists and Officers to International Conferences/Workshops at foreign countries in the areas for which training scope in India does not exist, - Scientists and Officers are encouraged to present and publish papers at National Conferences/Seminars/Journals, - The information about various training programmes is put in ASL Intranet, - The Papers presented and published by Scientists & Officers are being put in ASL Intranet, - Facilities are provided to sponsored Scientists of DRDO for M.Tech. Project Work. The Head Human Resource Development (HRD) Group in ASL is a full time Scientist, looking after only HRD activities and there is one Officer and two Staff.

2.4 Defence Metallurgical Research Laboratory (DMRL), Hyderabad – 500058, A.P.

2.4.1 Introduction Defence Metallurgical Research Laboratory (DMRL) was established at Hyderabad in 1963 to meet the needs of complex metals and materials required for modern sophisticated warfare weapons systems. Over the years, the Laboratory has acquired a special status as a premier centre for R&D in metals, alloys, ceramic and composites. Defence Metallurgical Research Laboratory (DMRL) was established at Hyderabad in 1963 to meet the needs of complex metals and materials required for modern sophisticated warfare weapons systems. Over the years, the Laboratory has acquired a special status as a premier centre for R&D in metals, alloys, ceramic and composites. Since its inception, the Laboratory has developed and established a number of frontline technologies in the area of metallurgy and material science. An infrastructure of advanced experimental facilities has been evolved over decades. The development at DMRL has led to creation of new technology and production centres in the country. They are – Mishra Dhatu Nigam (Midhani), Non-Ferrous Technology Development Centre (NFTDC) and International Advanced Research Centre for Powder Metallurgy and New Materials, all at Hyderabad and Heavy Alloy Penetrator Plant (HAPP), an Ordnance Factory, at Tiruchirapally. Today, they are nationally important institutions in their own right. 2.4.2 Vision

Be a center of excellence for providing total materials solutions for defence systems.

2.4.3 Mission

To pursue the development of innovative materials and process technologies, related product

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engineering, supported by research in the fundamental and applied aspects of materials.

2.4.4 Major Facilities

Many advanced experimental and simulation facilities have evolved over the past four decades in the laboratory. These facilities can be broadly categorised as below:

Titanium Metal Extraction Melting and Casting Processing Materials Structure and Texture Characterisation Tools Mechanical Property Characterisation Magnetic Property Characterisation Non-Destructive Testing Facilities Simulation and Modelling

2.4.4.1 Melting and casting Vacuum Arc Furnaces Air/Vacuum/Inert Atmosphere Induction Melting Furnaces Investment Casting facilities with Directional Solidification Capabilities

2.4.4.2 Processing Vacuum Hot Press Multi-purpose Forge Press Rotary Swaging Press Isothermal Forging/Extrusion Cold and Hot Isostatic Press Hot/Cold Rolling Mill Stretching Machine Straightening Machine Rapid Prototyping Machine Spex Mill Controlled Environment Sintering Furnace Rapid Solidification Vacuum Brazing Furnace Friction Welding Facility Electro Slag Refining Laser Processing, including Laser Engineered Net Shaping Plasma Spray Coating Facilities

2.4.4.3 Materials characterisation tools Optical/Stereo Microscopes Scanning Electron Microscopes Transmission Electron Microscopes High Resolution Transmission Electron Microscope Atom Probe Field Ion Microscope Electron Probe Micro Analysers Small and Wide Angle X-Ray Spectroscopy (SWAXS) X-ray Diffractometer Texture Goniometer Wet and Instrumental Analysis facilities such as AES, ICP, XRF

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Mossbauer Spectrometer Plasma Emission Spectromeer Polygraphic Analytical system Differential Scanning Calorimeter Differential Thermal Analyser Thermogravimetric Analyser Dilatometer BET Laser particle size analyser Molten Alloy Viscometer

2.4.4.4 Mechanical property characterisation Nanoindentation with AFM Universal Testing Systems Servo hydraulic systems for Fatigue and Fracture studies High Frequency Electromagnetic Resonance Fatigue Testing Machine Creep testing facilities Ultra High Velocity Gas Gun facility Instrumented Impact Testing System Sliding Wear and Solid Particle erosion test system

2.4.4.5 Magnetic property characterisation Vibrating Sample Magnetometer Hysterisis loop recorder

2.4.4.6 Non-destructive testing facilities Radiography Ultrasonics

2.4.4.7 Simulation and modeling • Work Stations and High End PCs • 8 nodes Cluster Computing / Grid Computing Facility • ANSYS-8.0 • GENSA-3.2 • IDEAS-6.0 • AutoCAD – Desktop-2000 • MATLAB • AutoDyn • DEFORM • Pro-E • UniGraphics

2.4.5 Achievements

Since its inception the laboratory has developed and established a number of frontline technologies in the area of metallurgy and material science. These are categorised as follows:

• Armour & Ammunition • Aerospace • Naval Applications

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• Other Functional Applications The major achievements in each of these categories are given below

2.4.5.1 Armour & ammunition

• Steel and Tungsten heavy alloy FSAPDS (leading to establishment of HAPP at Tiruchirapally)

• Jackal steel armour for armoured vehicles and personnel protection • Kanchan armour for MBT • Light weight armour for airborne vehicles

2.4.5.2 Aerospace • Brake pads for Aircrafts • Nickel based super alloys for aero engine applications • Super plastically formed air bottles for aerospace applications • High stiffness light weight Aluminium-Lithium alloys and high strength aluminium

alloys • Thermal barrier coatings • Investment casting technology for modern turbojet aerofoil castings • Investment cast components for jet fuel starter (JFS) of LCA “Tejas” • P/M (HIP stainless steel integral turbine rotor • Ultra high strength low alloy steel DMR 1700 for aerospace applications • Near alpha titanium alloy for aerospace applications • Titanium aluminides for aerospace application • Titanium sponge extraction from indigenous Titanium Tetra-chloride and electrolysis

of Magnesium from Magnesium Chloride

2.4.5.3 Naval applications

• HSLA steels for naval structural applications • Suspension band assembly for torpedo application • Light weight aluminium alloy castings for torpedo applications

2.4.5.4 Core competencies

• Product engineering, production support, and performance analysis of metals, alloys and composite parts

• Process development and surface engineering

• Design and development of specialty alloys intermetallics, ceramics and composites

• Knowledge base in process-structure-property-performance relationships

• Extractive metallurgy of Ti, Mg and rare-earth metals

2.4.6 Areas Of Work

The principal areas of research and development are

• Materials for armour applications

• Materials for ammunition applications

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• Materials for aerospace applications

• Materials for naval applications

• Functional materials such as advanced magnetic materials

• Emerging materials such as nanomaterials and smart materials

• Advanced materials processing technologies

• Surface engineering

• Advanced metal joining technologies

• Mechanical behaviour of materials especially at high temperatures, high strain rates and at small length scales.

2.5 Defence Electronics Research Laboratory (DLRL), Hyderabad – 500058, A.P. 2.5.1 Introduction

Defence Electronics Research Laboratory (DLRL) was established in 1961 under the aegis of Defence Research and Development Organization (DRDO), Ministry of Defence, to meet the needs and requirements of electronic systems of Indian Armed Forces. DLRL has been entrusted with the primary responsibility of the design and development of Electronic Warfare systems covering radar and communication frequency bands for the Indian Army, Air-force and Navy. In close coordination with various production agencies, other DRDO/National Laboratories and academic institutions, DLRL has designed, developed and produced a large number of ruggedised Electronic Warfare (EW) Systems meeting the State- of-the-art requirements of Army, Navy and Air-force in a dynamically changing operational scenario. Electronic warfare systems developed by DLRL have been inducted into the Services after rigorous field evaluation and user exploitation.

The testing and evaluation of EW systems demand huge infrastructure, test and evaluation facilities. To cater to this requirement, Electronics System Engineering Centre (ELSEC) was established in the year 1998 as an extension of the Defence Electronics Research Laboratory, Hyderabad. It consists of state-of-the-art infrastructure to meet the critical integration and evaluation requirements of ongoing and future programmes. Laid out in 180 acres of land, it is being extensively used for integration , and testing of complex Electronic Warfare Systems. Modern EW system simulation and modeling facilities are located inside ELSEC to carry out simulation of complex systems. 2.5.2 Vision

Be a Centre of Excellence in the Field Of Electronic Warfare

2.5.3 Mission

Design & Develop State of Art Integrated Electronic Warfare Systems for the Services and Achieve Self-reliance in Critical Technologies and Components.

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2.5.4 Areas Of Work

DLRL's core competence lies in Design & Development of Electronic Warfare systems, Technologies & Components. They are listed as under: 2.5.5 Systems

• Design of Electronic Warfare Systems (COMINT/ELINT/ESM/ECM)

• Development of hardware and software of sub systems

• System integration and evaluation on various platforms - vehicles, ships, submarines, helicopters, aircrafts, airborne pods

2.5.6 Technologies

• Multi octave band antennas and radomes

• Multi octave band Microwave/Millimeter Wave components & super components

• Narrow band/wide band intercept receivers

• Broad band high accuracy Direction Finding receivers

• High power transmitters for ECM

• Multi beam jammer transmitters

• Frequency Memory Loops & Digital Radio Frequency Memories for jammers.

2.5.7 Samyukta

SAMYUKTA is a joint DRDO and Army integrated EW programme. This programme, which is software and integration intensive, is meant to develop an indigenous production base for futuristic integrated EW systems. It has communication & non-communication segments and the whole system is meant for mobile, tactical battlefield use. The system comprising of about 140 entities has the capabilities for surveillance, interception, monitoring, analysis, recording, location fixing and jamming of all communication and radar signals (from HF to MMW band).

2.5.8 Sangraha

SANGRAHA is a joint EW Programme of DRDO and Navy. The system comprises of a family of EW suites for different Naval platforms capable of intercepting, detecting and classifying pulsed, CW, PRF agile, frequency agile and chirp radars. The systems employ modular approach facilitating deployment on a variety of platforms viz. helicopters, vehicles, small ships etc. Certain specific platforms apart from ESM also have ECM capabilities. State-of-the-art technologies like Multiple Beam Phased array jammers are employed in the system for simultaneous handling of multiple threats.

2.5.9 Divya Drishti

Divya Drishti is a joint SI Dte – DRDO programme, with the aim of interception, monitoring, direction finding and analysis (IMDFAS) of communication signals. The system will be installed at various locations on static and mobile stations. All stations will be connected

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through a satellite communication network. The system caters to the mission of building aircraft flight profile (Mission Analysis).

2.5.10 Sujav

Sujav is an integrated compact communication EW system, developed for various users in different configurations. It covers HF, VHF & UHF ranges and available in cluster configuration for Army use or in suite configuration for Navy’s ground as well as onboard usage. It has full capability to detect, locate & jam frequency agile communications as well as monitoring & recording of conventional signals.

2.5.11 Radar Finger Printing System

The system has the capability of providing ‘Unique Identification of emitters among a class of emitters’ based on intra-pulse analysis of Radar waveforms. The system measures the frequency, phase and amplitude variations within the Radar pulse. Intra pulse analysis extracts as many parameters (features) of Radar pulses as possible with fine grain accuracy. Self-reliance in this critical area has been achieved paving the way for installation of the system in various configurations on various platforms.

2.5.12 AEW&C (CSM)

It is a Communication Support Measures (CSM) system being developed for AEW&C programme. The system will have the capability to search, intercept, detect, direction finding, monitor, identification, record & analyse communication signals and can report of voice, data transmission in fixed frequency and frequency hopping modes.

2.5.13 Human Resource Development Group The Human Resource Development Group in DLRL has taken the following initiatives for Human Resource Development : - Conducting training programmes for Technical Staff of Hyderabad Zone as per the directives of DRDO Head Quarters, - Introduced Mentoring System, - Nominating employees to External Institutes/IT Sectors for training in identified areas, - Scientists and Officers are encouraged to present and publish papers at National Conferences/ Seminars/Journals, - The information about various training programmes is put in DLRL Intranet, - Facilities are provided to B.Tech. Students for Project Work. There is a five member Committee for Human Resource Development (HRD) in DLRL. The Head of HRD activities is a part time Scientist, he has got technical activities as main responsibility and HRD activities as additional responsibility. There are two Technical Officers and one Staff for HRD activities. 2.6 Advanced Numerical Research & Analysis Group (ANURAG), Hyderabad –500058

2.6.1 Introduction ANURAG was established on May 2nd 1988 to execute specific, time-bound projects/programmes leading to the development of custom designed computing systems and software packages for numerical analysis and other applications. To design and develop

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advanced computing systems, especially those based on state-of-the art concepts like parallel architectures as well as associated systems and sub-systems. To develop systems and application software packages for mission oriented tasks to build-up technology in these areas. To undertake forward-looking research and development in futuristic concepts and to create an environment and infrastructure which fosters such advanced research leading to the application of advanced computing concepts and technologies. 2.6.2 Facilities Available for Computing 2.6.2.1 Network of

• Sun Workstations

• Personal Computers

• Linux cluster based on dual Xeon Processor 2.6.2.2 Hardware development :

• Logic State analyzer

• Oscilloscopes

• Test and Measurement Equipment

• Spectrum Analyser

• Data Pattern Generator

• Hardware Emulator (VStation)

• Signal Analyser

• FPGA based prototype H/W 2.6.2.3 VLSI Design facilities:

• COMPASS Tools (Full Suite)

• CADENCE Tools (Full Suite)

• MENTOR GRAPHICS (Front-End Tools), DFT Tools

• HSPICE

• VHDL/Verilog Simulators 2.6.2.4 FPGA design tools :

• Synplicity Tools

• Leonardo Spectrum

• Xilinx tools 2.6.3 Achievements 2.6.3.1 Parallel processing technology

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Parallel processing technology has been widely used to develop High Performance Computers. ANURAG has used this technology to develop parallel computers. These systems have been built using VME-bus based Pentium processor boards, ATM switches and Reflective Memory communication hardware. Configurations up to 128-nodes have been developed. Such system can be used to solve computation of intensive applications such as Aircraft design, Weather forecasting, Molecular biology etc.

A 128-node PACE++ system, built using Pentium processor based VME boards installed at the Indian Institute of Science, Bangalore was dedicated to the nation by his Excellency, the President of India, Dr. A.P.J. Abdul Kalam in January 2004. The performance of this system is 50 Gigaflops (sustained performance). At present work is in progress on parallel processing system based on Linux clusters targeted to deliver 1 Tera FLOPS performance. 2.6.3.2 General purpose microprocessors ANURAG has designed and developed general-purpose microprocessors. ANUPAMA is a 32-bit RISC processor. ANUPAMA works at 33 MHz clock speed. The complete software development tool kit consisting of C compiler, assembler, linker, loader, debugger etc is available for application development. A single-board computer based on ANUPAMA is available for evaluation and software development. ANUPAMA is also available as an IP core.

ABACUS is a 32-bit processor for multi-tasking applications with virtual memory support. It is designed around ANUPAMA core with additions like MMU, two levels of cache, double precision FPU, SDRAM controller. The IP core of ABACUS is available in Verilog RTL code. This processor is suited for desktop applications. Complete software platform is available for ABACUS processor and a single board computer with ABACUS is implemented. Linux Kernel is ported. 2.6.3.3 DSP processors and arithmetic IP cores ANURAG has designed a 16-bit DSP processor. This processor is available as an IP core and the design is packaged in 120-pin CPGA. The other arithmetic cores that are designed and available with ANURAG include

• A floating-point co-processor that supports both 64 and 32-bit arithmetic operations.

• Multi channel Multiplier and Accumulator with user programmable 132 channels.

• Fast Multiplier Accumulator with 5-stage pipeline and 36-bit accumulator. It offers 16X16 multiplication.

• Polar to Cartesian and vice-versa conversion using CORDIC processor.

• A Complex Multiplier that allows the multiplication of complex numbers. All these are available as IP cores in and in chip form for use.

2.6.3.4 1- µ CMOS fabrication technology

Facility is available to fabricate designs targeted to 1µ technology with following features:

• Cell based designs upto 1,00,000 gates.

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• Design support option.

- Full contract design stating from functional description to physical design

- Full 'customer' design [upto GDS II tape stage]

• Die sizes upto 14 mm x 14 mm 2.6.3.5 ANAMICA (ANURAG's medical imaging & characterization aid) ANAMICA is a DICOM compliant three-dimensional medical visualization software for data obtained from any medical imaging system like MRI, CT and Ultrasound. The software has two-dimensional and three-dimensional visualisation techniques to visualize the images in various ways. Many three-dimensional visualisation techniques like Iso-Value surface, Cutout View, Arbitrary Planar Section etc. are available for the doctor for visualizing the medical data in three-dimension. The sequence of images obtained from any imaging system by scanning of a single patient is packed to form a three-dimensional grid. It is also equipped with a rich set of image processing and image manipulation techniques. Contrast and Edge Enhancement, Image Algebra, Pseudo Coloring, Spatial Editing are some of the two dimensional options provided in the software. The software is also modified for accepting data from Industrial CT systems. 2.6.4 Areas Of Work Parallel processing technology - System engineering, integration - General purpose microprocessors - 1-µ CMOS fabrication technology - Design and development of VLSI chips & SOC development - Processor related technology - System software development for custom made processors 2.6.5 Human Resource Development Group (HRDG)

The Human Resource Development Group (HRDG) in ANURAG identifies the training needs of various personnel in the Laboratory. HRDG prepares the training brochures with trainings available at different Institutes, based on the training needs of the Laboratory. It sends the training brochures to different departments of the Laboratory for nominating the employees for training. After getting the nomination from any department, Head HRDG sends the employees for training to the external Institute after approval by Director of the Laboratory. The Head Human Resource Development Group in ANURAG is headed by a Scientist whose main responsibilities are technical activities and HRD as additional responsibility.