Defence Aerospace BU

Bharat Forge Ltd, a flagship company of Kalyani group has established a gas turbine & technology development Centre at Bengaluru. This centre works on ab-initio design & development of Gas Turbine Engines and technologies in India.

In Jan 2023, this centre has validated the performance of an indigenously developed 45 kgf thrust engine at the test facility of Bengaluru. Kalyani Gas Turbine 45 can develop thrust of 45 kgf at ISA Sea level static conditions. This engine can operate upto 8 kms of altitude and has best in class fuel consumption and thrust to weight ratio. The indigenous developed control system is a unique feature of KGT 45. This engine finds its application in UAVs, target drones, cruise missiles & range extender. The core team of renowned scientists and designers from aerospace industries have worked relentlessly to achieve this remarkable feat. The centre at Bengaluru has also developed a full-fledged test lab where young engineers mentored and encouraged to work on innovative ideas.

Bharat Forge will integrate the digital twin concept in these engines. This will help in digitising the maintenance culture. Bharat Forge Aerospace BU team dream is to produce the aeroengines in India with help from DRDO Labs and this is just a humble beginning.

Digitally Empowered End-to-End Capability

Development of small jet engines in the range of 40 to 200 kgf.


End use in unmanned aerial vehicles, target drones and cruise missiles.


State of art infrastructure for design and development


Concept to product realization

GTTDC CORE CAPABILITIES
Engine performance and cycle analysis
Compressor design and development
Combustor design and development
Turbine design and development
Mechanical design and integrity analysis
Engine control system
Engine assembly and integration
Engine testing
Engine performance and cycle analysis
Comprehensive Analysis of Requirements which impact cycle selection, performance, and operability.
Parametric study and thermodynamic cycle optimization at overall engine level support for design and development of engine
Design point cycle analysis for preliminary component design and estimation of engine sizes
Off-design cycle analysis
Compressor design and development
Design of Air intake
Design of centrifugal and Axial compressors
Design of Cross over and conventional diffusers
Compressors performance analysis and testing
Combustor design and development
Design of combustor flame tube
Design of fuel nozzles and ignitor systems
Combustor performance analysis
Turbine design and development
Design of Turbine stage
Turbine Performance estimation and testing
Design of Exhaust nozzle
Mechanical design and integrity analysis
Concept / preliminary design
Structural analysis and Computational Fluid dynamics
Detailed design and drafting
Manufacturing feasibility and preparation of Bill of Materials
Fit calculations, stack-up analysis
Selection and integration of accessories/LRUs
Inspection, Quality check and review
Engine control system
Development Open loop control system
Development of Closed loop control system using PID control
Development of input-output board
Analysis of System response
Failure mode analysis
Testing
Design and Development of Test Rig
Integration of Engine Control System with Engine
Integration of sensors for measurement of pressure and temperatures across various stage
Integration of load cell and speed sensors for thrust and speed measurement.
Perform engine testing
Concentric Ring Assemblies
Cold Flap Assemblies

Support to Indian Armed Forces through re-engineering for development of critical hot end assembly for use in Fighter Aircraft Aeroengine



Established new technology and developed vacuum investment casting, forming and welding in Cobalt and Nickle based super alloys for first time in India



Indigenous solution in collaboration with DRDO, Certification & Inspection Agencies and End User

Concentric Ring Assembly - Diameter 345 mm
Concentric Ring Assembly - Diameter 660 mm
Concentric Ring Assembly - Diameter 880 mm
Indigenisation solution – Cold Flaps Assembly - Inner
Indigenisation solution – Cold Flaps Assembly - Outer

Bharat Forge Ltd, established a Gas Turbine & Technology Development Centre at Bengaluru.


This center works on ab-initio design & development of Gas Turbine Engines and technologies in India.


This center engaged in developing Gas Turbine Engines up to 200 kgf


In Jan 2023, this centre has validated the performance of indigenously developed 45 kgf thrust engine


KGT 45 can develop thrust of 45 kgf at ISA Sea level static conditions.


This engine can operate upto 8 kms of altitude and has best in class fuel consumption and thrust to weight ratio.


The indigenous developed control system is a unique feature of KGT 45.


This engine finds its application in UAVs, target drones, cruise missiles & range extender.

KGT-45 Assemblies
KGT-45 Test Bench