Monday, 29 January 2018

Ugly Duckling, Swan or a hunt bird in hand? The JF 17- an open source assessment.

The assessment of a rival’s warplane suffers from a primary lacunae in that the information is secret. There is perforce reliance on secondary sources but this is inevitably heavily dosed with rivalry, jealousy, envy, disdain, NIH ( not invented here!) racialism and similar human failings. The task therefore becomes difficult and the output subjective. To illustrate my observation I will mention the case of two very well known warplanes.
The existence of the Mitsubishi Reisen ( Zero) first came into US knowledge almost a year before Pearl Harbour. The American Volunteer Group (AVG) Flying Tigers sent back reports from China of an astonishing Japanese fighter with unimaginable maneuverability and range. The US experts discounted these frontline reports because such a fighter could not exist. One can sympathize with the experts. Going by their lights such as aeroplane could not be designed. They did not know that the Japanese had got rid of everything which the West would consider “essential”- armour, bullet proof windscreen, self sealing tanks radios etc to produce the ultimate dogfighter that swept everything before it. It is an illustration of how human emotions cloud judgment that when the first wrecks were examined after Pearl Harbour much time was spent and much evident satisfaction gained  on “identifying” what part of the Zero was copied from which American aircraft! In fact this copy allegation was so sustained that much later, Jiro Hirokoshi, the Zero’s Chief Designer was to say, perhaps with testiness, Japanese style “The Zero was a copy of all the aircraft before it!” Even today there is a persistent view that the Zero had erred by sacrificing protection for performance. This misses an important point. Battle damage resistance would have improved pilot survivality but given the Zero’s phenomenal long range and the fact that it operated over the ocean and over tropical jungles did Japan have the resources to ensure pilot recovery? Without pilot recovery battle damage resistance is less meaningful. Note that when the fighting was over the homeland the later versions of the Zero was given a fair measure of battle damage resistance- it was not all Bushido and Banzai as is popularly believed. The real weakness in the Zero was it had to fight an enemy industrially ten times as big. Putting it in another way if Japan had the Corsair and the Hellcat and it was the US which had the Zero the outcome would still be the same. This, by the way, is an argument for maintaining large forces. It pays on the long run.
One would think that things would have improved with time but the MiG 21 case is illustrative. To the Indian Air Force used to the fit and finish of the Mystere IVA, the MiG 21was “brute force supersonics” possibly because it was at the time of its induction the most powerful fighter in IAF service. The truth is both the MiG 21 and the Su7 were the lowest powered aircraft in their categories though one must add the Soviet aircraft often had no exact equivalent because they were designed for different scenarios. In 1966 an Iraqi MiG 21 F 13 defected to Israel and very soon afterwards a leading US Aviation Magazine carried a very detailed examination of the aircraft. Much of the focus was on the poor fit and finish of the aircraft and the mushroom head rivets ( discoloured) used in the rear fuselage. The three shock two position translating cone intake ( the mighty EE Lightning had a fixed cone and encountered intake buzz problems during development) and the semi encapsulated SK ejection seat ( surely the best for high altitude supersonic ejection) must have been covered but the overriding impression one carried away was of gaps and discoloured rivets on the aeronautical equivalent of a combine harvester. Generally the MiG 21 s lack of F104 and F4 Phantoms level of avionics and long range missiles were disparaged. Unfortunately the Viertnam War started in earnest soon after and it was the Americans who had to go back to school- the excellent Red Flag ,the F 15 and F 16  being a typical energetic US effort to correct things.
The point of citing the above is to accept that assessing a rival’s warplane is difficult not only because of the lack of information but also because of the “schooling” one has gone through.  I sometimes envy the Chinese in that they generally know less English and being “unschooled” look at things in their own pragmatic Chinese way.
 With that as both a caution and as disclaiming any infallibility the following is a very personal assessment of the Sino /Pak JF 17.
Enter the (JF 17) Dragon
 Wikepedia carries a review of the JF 17 Xiaolong ( Fierce Dragon) with several pages of references. The figures cited below are drawn from this review and I will presume that the reader has access to the Net to avoid total repetition. I am therefore confining myself to a commentary. Because both aircraft originated as MiG 21 replacements comparison with the LCA is inevitable.
 The Chinese have made so many MiG 21 based derivatives that one can be forgiven for initially thinking it was yet another derivative with a nose job like the Qiang JiJi 5 ,surely one of the ugliest jet as I ever wish to see. This impression is quickly corrected by looking at the Table.
The JF 17 is no MiG 21 clone. It is altogether a more potent aircraft, reminiscent of the Northrop F 20 Tigershark. Though Yang Wei, the Chief Designer, did not have access to the F 20 he may have had opportunity to examine ex Vietnam Air Force F 5A aircraft or airframes and why not-only an arrogant fool will not “flatter” a good piece of engineering by imitating? Mitchell of Spitfire fame was “inspired” by the Heinkel He 70 Blitz’s graceful lines and Yang Wei may have been similarly “inspired” by Welko Gasich/Lee Begin’s work on the F5/F20 series. Northrop of course threw the game away by adding 80% more power and 20% more weight without changing the wing which remained the same as the F5 series. The figures of the wing loading speak for themselves. Digressing for a moment one sees the same reluctance in BAe to design a proper light strike aircraft using perhaps the Hawk systems in a Gnat derived airframe ( see Vayu III/2016- Going against the Wind) instead of trying to fob off native Air Forces with an inappropriate airframe too big for the job.
It would seem that the JF 17’s able Chief Designer Yang Wei carefully studied the F 20 concepts and made very well thought out “nips and tucks” type bespoke tailoring of the F20 design so that the JF 17 did not carry an extra ounce of fat or skin. Comparing the lengths the JF 17 is 0.53 mts longer but that is largely the difference between the F 404 and the RD 33 engine lengths. The empty weight of the JF 17 is 622 kgs. heavier but again if you factor in the weight differences of the two engine types and the additional 5.8 sq.mts of wing area that the Sino/Pak fighter carries the weight is commendable. The weights indicate that either the weight control supervision on the JF 17 was up to US/International design standards or Shri Wang Wei had enough domain expertise to tell the powerful PLAFAF faction where they got off regarding equipment fit standards of the JF 17! One can recount that when the US Navy wanted any additional equipment on the little A4, Douglas’s Ed Heinmann would reputedly take off fuel of weight equal to the additional equipment requested. Of such stories is aviation is made. One final point on weights that should make us think: The JF 17 is a larger aeroplane with a heavier engine and with an all metal structure and yet it is “as near as dammit” the same weight as the largely composite and smaller LCA Mk 1. That is an indication of how much we have erred and how much we can correct.
Having accomplished his weight control Wang Wei pulled off the first of his two coups de main in that the generally conservative approach to the Northrop- like design was modified to a mid wing layout of increased wing area. Despite the weight penalty of longer u/c struts and ring frames to carry through the wing bending loads- an additional 42 kilos somehow comes to mind for the frames-it cured several big problems. The F 20 suffered in that though the warload was increased by twenty percent the low wing meant that fitting the store and the Ground clearance certifications must have been nail biting. The mid wing of the JF 17 avoided this easily and the larger wing area meant that the high induced drag of the F 20’ in high “g” turn and the increased CDo caused by the higher AoA, was lowered and dog fighting and general handling improved significantly. The F 20 gave the later F 16s a hard time during fly off competition and the JF 17 should be very much better. One will also note that sweet handling aircraft e.g. Hunter, MiG 21 and the Lightning were mid wing layouts which reduces or eliminates roll coupling and the JF 17 is a beneficiary. The second of his “coups de Main” was the introduction of the DSI after seven years of parallel preliminary work. DSI reduced weight and drag. Summing up: a very competent airframe has been designed on the lines of the Northrop F 20 but as with the F22/F31 resemblance the Chinese design somehow manages to look more elegant and dainty! There has been some gloating references on the Indian Net circles to the fact that Yang Wei has been recently severely criticized  for the shortcomings of the J 20   ( AMCA team beware!).The Gloaters have missed the significant point. Weapons development Programmes are of National Importance and there is no room for fellowship if things are not delivered. “You fail; you go” is the grim rule for running successful programmes-outside of India.
Programme Management: Hare and Tortoise
The Diagram 1 shows the difference between the timelines of the JF 17 and the LCA. The Sino/Pak team started eight years after us and reached where we are today i.e. a handling flight of three aircraft ten years ago (nota bene!). To rub the salt in properly they did it at one third to one fifth the cost calculated at Present Day Value PDV. Below is my conjecture as to how they did it:
i)                    They chose an utterly conventional layout. That way they could “decouple” any delay of FBW development.
ii)                  They chose no “glamorous” technology and were almost sanction proof from the word go. Being all metal the prototypes could be built faster- the shop floor people were dealing with a material they knew from infancy- and also airframes could be modified faster if things did not work out as predicted. Remembering Boeing’s problems with production of the 787’s composites it is clear that the Chinese by choosing all metal could focus entirely on the airframe development without being harassed by how to do it. As they say in the backwoods “if you are up to your ass in alligators it is difficult to remember that what you had actually set out to do is to drain the swamp!” 
iii)                The Chinese chose a pitch only FBW. This is less “advanced” than a four channel all axis FBW system.There is a size limit below which FBW becomes “doubtful”. To illustrate: would you fit FBW onto a Cessna 172 club trainer? Theoretically yes but in actuality the FBW weight and complexity would kill the bird. In my view an aircraft like the LCA is just teetering on the brink of this size limit. The “pitch only” FBW. This is a very good example of “engineering”  approach. If you think about it, pitch control benefits maximum from FBW in reducing trim drag; roll and yaw have less scope for “improvements” in “performance”.  The Chinese solution is not “brochure glamourous” or exciting but as the inventors of the Panhard-Levassor gearbox said so long ago “C’est brutal mais ce Marche!” – It is rough but it works! As if to add insult to our Injury the Chinese the FBW software was written in C++ and not the more elegant ADA language. The Chinese have reached a stage where they are very respectfully examining what is going on and then instead of being overawed they are doing there own thing. It is this arrogant (and I use it as a compliment!) self confidence that must be noted carefully in assessing any Chinese defence technology product.

The emphasis in flying the thing!
The Chinese flew the first prototype on 25 August 2003 i.e. within four years of funds being sanctioned. They had little faith in that if you calculated enough you would get the thing right first time! Once the third prototype (9/04/2004) was flying they built another three introducing a modified LERX (which needed enlarging) an enlarged Inlet (the RD 33 was smoking like a juvenile delinquent!) and the second significant improvement, a diverter less intake (DSI)  with the first modified prototype flying on 28/04/2006. It must be acknowledged, howsoever grudgingly, the Chinese/Pakistani team got their fighter in Squadron service in two iterations, six prototypes and within seven years of funding. The alarm bells are ringing here! We are being out developed and the advantage of a big economy is being neutralized by Pakistan through sheer efficiency and better organization!
The LCA Mk 1 still needs major redesign about 35-40% before it will be fit for service. I guess that the slow production is a cover to buy time to effect the changes. Those readers who have seen the dramatic cover of Vayu I/2017 with the LCA will have noticed and disapproved of the deep boundary layer diverter plates and the bleed off channels (which would have reduced the local lift fields). The Chinese were working on the DSI since 1997 and introduced it in 2004 claiming reduction in weight, cost and drag. Seventeen years after the first flight the LCA fore fuselage and the merging of the intake bulges with the centre fuselage still requires considerable refining. It is bemusing to compare with the undershot of the JF 17 (Vayu III/2016 p 94). Similarly if one compares the front views of the two aircraft the LCA’s excess of reentrant corners and deep channels indicate excess wetted areas and drags. Out of curiosity I estimated the distance from the rear pressure bulkhead and the tip of the radome for the two aircraft and the JF 17’s figures are 5382 mm compared to the LCA’s 4661 mm. If correct it indicates the effort and care taken ab initio in getting the forebody drag right. Visually the cross sections of the LCA’s forebody have a squarer section compared to the JF 17s and this increased cross section will tell on the transonic drag.  Incidentally the JF 17’s radome works out to 690mm compared to 648mm of the LCA, both in the plane of the antennae but the longer nose length compensates.
The Avionics
Reading so far one would think it was the Chinese who had done everything but that would be injustice to Pakistan’s contribution. Though clearly the Chinese were in the driver’s seat w.r.t. the airframe, Pakistan played a very competent and independent role in the development of the JF 17 particularly in customizing the aircraft for PAF use. Using it’s better networking and contacts with the West, Pakistan took what amounted to an independent charge of the avionics development for its aircraft, the Chinese going in for their own aggregates which were always on offer to Pakistan. It is noteworthy for example that Pakistan chose a Martin Baker PK 16LE seat over the Chinese model. Though the Chinese had launched the JF 17 project in 1991 Pakistan came on board in 1995 and the funding for the actual aircraft development was signed as a contract in 1999. Hit by sanctions- as with us-the Chinese/Pakistan- decided to decouple the avionics development in 1999 and it speaks well of the level of teamwork and the “can do” spirit that both sides were willing to re-engineer the design as and when needed. It will again be noted that choosing an all metal structure for prototypes must have been a great help Today ,with its West Asian connections Pakistan or perhaps the PAF is an “owner “ of the Project and bids fair to do a good job of Marketing. They did what we should have done with the PAKFA. Given our experience with the DARIN mods, clearly the expertise and ability were not lacking; aims and organization were.
The JF 17s Blocks 1&2 equipment fit is more than adequate for the job- HOTAS, MFD/EFIS, Holographic HUD, HUMS, VHF,UHF, ATE. The leading edge and trailing edge flaps are computer controlled to ensure controllability at high AoA. The FBW of production machines has quadruplex FBW in pitch and duplex in roll and yaw. The defensive aids include RWR, MAWS with 3600 scan, chaff flare dispenser and there is a provision for a jammer. Block 3 design was finalized in September 2016. The only sardonic cheer for us is having got a decent fit the PAF is now trying to load it with “goodies” such as IR targeting systems etc. God speed is my wish!
Propulsion
Soviet origin engines were always derided in the West. One remembers that when HAL was trying to see if the HF 24 could be fitted with the Tyumanskii RD 9F the story (probably untrue) went around that the engine was so surge prone that it would flame out on the test bench if someone so much as coughed at the other end of the Bangalore factory. The actual reason was that the Compressor stress limit was Mach 1.4 and the Soviets point blank (naturally!) refused to redesign it for Mach 2 which was our “must have” specifications at that point of time! Shows how fashions dictate “sacred” specifications and opportunities are lost. I mention the RD 9F  because when the Chinese laid their hands on the RD 9F they re-engineered the first stage of the compressor, put in a variable angle inlet stator, completely redesigned the hot section and put in a new afterburner stabilizer of reduced losses. It is possible that the variable inlet stator details were inspired by the close examination of the wrecked J 79s available to the Chinese during the Vietnam era. The fact is that the Chinese Wopen 6 of the F6 fighters did not give the PAF any more than the usual problems in service. This tradition of sensible engineering to improve a base product means that the Taihang WS 13 based on the RD 93 will probably emerge an acceptable engine though it may not have the 4000 hr service life demanded of Western engines. Such design targets are dishonest for countries like us. It is much better to design for quick engine change.
The cost and the prices
Cost consciousness is important because if there is a significant lowering in the cost of projects as has happened with the JF 17 , it means that there is more money to go around for other projects- bullet proof jackets or Infantry assist vehicles for example. Unchecked spending without results can cause a ‘drought” which will wither other possible and vital projects. The current asking price for the JF 17 is roughly $25 M which works out to $3800/kg compared to the $17,000-$21,000 per kg for current Western aircraft. The usual explanation is that these prices are “political/friendship” prices. This is wrong. One’s own considerable experience in the Industry confirms the following:
a)      The only cost really known for certain is the RM (raw materials) and the BOC (bought out complete) costs.
b)      When it comes to the labour costs escalation starts from the shop floor supervisor and goes right up the chain, though everyone concerned will scream blue murder and horror at the merest suggestion of downwards revisions.
c)      When it comes to overheads it runs riot and again figures are padded up just to be safe. For PSU’s this practice is safe but drives up project costs which finally affect local development.
d)     In technology transfer a five- fold reduction in costs is usual.
This is not the entire picture. Thanks to our colonial past there were rules that were actually designed so that India would NOT develop a local aeronautical capability. Some of these were:
i)                    An import duty structure that allowed complete aircraft to be duty free, accessories had a substantial duty and raw materials were prohibitively taxed.
ii)                  A system of “aircraft quality materials” (AQM) was the norm where the sources of this AQM was invariably from the Home Country.
These laws and there were many may or may not have been repealed but the spirit lives on and the Bureaucracy with nothing to gain and not tamed by the National Leadership, staunchly obstructs any attempt to reform. One will hear many arguments for maintaining status quo but there has been little reasoned debate as was done in China and Russia who do not have this anachronism. Finally with PSU’s operating at a cost plus 15% basis and Western Weapons Suppliers with a stock of horror stories if any initiative inimical to their interests it is we who have been “schooled “ into believing what should be the price of warplanes. The Sino Pak prices are realistic and can be reduced further.
An estimate of performance
Readers are referred to Vayu (I/2015) in which I had said that the LCA Mk1 would not be able to outperform the JF 17 as a fighter. It can be used as a strike aircraft but the outcome of any dogfight would be in favour of the FC17. I have not seen anything in the past two years that need me to make a drastic revision of that view. The only parameter the LCA Mk1 potentially is superior to the JF 17 is in TO performance The JF 17 will need a 25% longer run but even that difference will be reduced as this is not corrected for the CD0 and the reported lower engine installation efficiency for the LCA. Readers may raise the point that an aircraft with a sprightlier take off should perform better but this is not so because at combat speeds the CDo drag of the LCA will be much higher. Incidentally I did compare the TO values for the LCA and the Harrier and assuming equally efficient intake design and CDo s .The LCA should be marginally better/similar to the Harrier in the STO mode. If the Navy’s disappointment is purely technical than the weight and drag problem in the LCA is still significant.
What perhaps HAL should do is to take a deep breath and clean up the entire fore fuselage with particular attention to the blending of the front fuselage with the mid fuselage. The clutter is visible from afar and must be worse in detail! If ADA is ready with the DSI, (only if!)  it should be brought forward. They should do it in metal to begin with so as to get the prototype right quickly rather than have a nice sub project of making it in composites! With the clean up and the weight reduced the LCA stands a very good chance but not as things stand at the moment. C’ne marche pas! The LCA is unlikely to be clear for production until 2019-2020-if that!
Like the LCA,  the JF 17 was a MiG 21 replacement but it is now something more – nearer to a F 16 supplement at one fifth/one sixth the price and no threats of being sanctioned in which the PAF has much experience!.It has potential to become “fashionable” i.e. over equipped .What the JF 17 lacks it does not need and Pakistan should leave the aircraft well enough alone. Summing of this section:
i)                    The LCA has the potential to have significantly better field performance even at the current empty weight of 6650kg.
ii)                  In low level OAS the small size and the 5% better fuel fraction (internal fuel/ installed cold thrust) the LCA may be a better choice.
iii)                In any close combat as of the present the LCA is inferior. ( See Vayu I/2015)
iv)                Thanks to more power and a bigger ( by about  52 mm ) antennae the JF 17 is the better BVR platform but I think it is stupid to fit BVRs simply and just because they can be fitted on an aircraft of this size. BVR capability is a specialized capability which ruins general capabilities to install.
v)                  The current availability (raw figure)  of the JF17 is 113hrs/aircraft/year as of 2016. There has been two accidents in 19,000 hrs which is close to the 1 per 10,000 hrs for “bedded down” equipment and indicates  reliability,
vi)                Production has now moved to Block 2 and about 90 airframes are delivered or on the slipway.
At this point of time the JF 17 is the better aeroplane and the LCA is not even achieving its potential in the areas where it has the potential to be better! Sadly the comparisons are academic. At this point the PAF can fly 200-250 OAS sorties per day on the JF 17. The LCA?
Exports
Any Asian product is bad mouthed. The twelve Hindustan HT2s supplied to Ghana were routinely disparaged by the foreign instructors seconded to the NAF. The sturdiness, low prices and the fact that they served the IAF for over thirty years “faults and all” was overlooked. The more recent case of the ALH refers. The Chinese are in a better position. Over the years they have exported fair numbers to European, African and Asian Customers and have acquired useful skills in marketing, selling and sustaining a product on the field.  The FC17 has attracted the attention of about 21 customers with Myanmar, Nigeria and Saudi Arabia as confirmed customers. The weak link was the RD33/93 engine of Russian origin but if the Russians refuse the engine because of fears of the JF 17 cannibalizing MiG 29 sales they have little choice because the Chinese will develop the WS13 Taihang. Even if the TBOs are not quite upto the ‘international standards” their prices will be extremely attractive and ‘international standardsare not an operational necessity. I would not have minded buying the JF 17 myself. The Chinese have exported over two thousand aircraft and the FC17 bids fair to add to those numbers and customers list.
The reason why
The JF 17 is either an unremarkable warplane or a coolly brilliant piece of engineering improvisation superbly managed. The judgment will depend on one’s “schooling” but what cannot be denied is that the Sino Pak team has raised five squadrons on the type. There is an old adge  “ An engineer is a person who can do for sixpence which any fool can do for six shillings”. The JF 17 demonstrates that. The LCA’s so called “technical superiority” has been its undoing and If we confine ourselves up to correct the technical shortcomings of the LCA Mk1 then we shall be setting ourselves up to fail in the AMCA. The present situation is bleak and near collapse. I do not see any evidence of the energy and the interested management that is the need of the hour.

The organization for effective development is not the present topic but that is the crux. What the Sino /Pak team achieved with the JF 17 they can do in AFVs and submarines and rifles and every item required in warfare. We shall be out resourced and out timed- and out gunned! India’s weapons development programmes are in the “fire and forget “mode which will not work in a hundred years. By preoccupation with other “priorities” The Politician, the Bureaucracy and the Armed Forces have abdicated their role of leadership in weapons development to the technocrats.. None of the above, singly, can manage a Weapons anymore than the blind men could “see” the elephant. Yet the solution lies in them working as a team with respect for the undoubted competence there is in each organization. Unthinkable in our bureaucracy dominated committees, Pakistan had serving Air Marshalls in charge of the project who reported directly to the Air Chief whereas we had the IAF actually ‘shorted out” so that the LCA project could be “Fast tracked”! The Cheek of it! Left to themselves the Technical people went on a Technical Picnic!
The Armed Forces whose responses have been clumsy and indignant rather than studied and moral (why did it accept pressure when things were obviously out of control and so much is at stake? Recall Air Marshall Dowding’s stand just before the Battle of Britain: He stood up to that old steamroller Churchill. Of course he paid the price but he saved Fighter Command for the Battle. The Bureaucracy’s sniping of the Military- I think the business about Batmen being one of the latest must stop or be regulated. If the Batman must go so should the Chuprassi!. This tribal warfare between the Bureaucracy and the Forces has to be tamed and yoked by the Political Leadership. The country must form a WEDOG (weapons development Group) so that realistic threat scenarios are generated for the next say ten years that we need to become sanctions independent. China used its large Armed Forces and its nuclear deterrent to buy the ten years it needed. Given our large armed forces and our nuclear capability we have those ten years. We have the expertise to do so-if we work in a team. Realistic threat identification will lead to realistic specifications. Realistic specifications will reduce technical challenges and prioritize weapons programmes. Close monitoring will stop shocking wastage and ensure timeliness. We may yet surprise the World.

Table 1.


Parameters
JF 17
F20
LCA Mk1
F 16
F7
Length
14.93
14.4
13.2
14.52
 13.86
Target Volume
1.34
1.03
1.0
1.44
0.866
Wing Area
24.4
18.6
37
27.87
23
Empty Weight
6586
5964
6580
6857
5275
Internal Fuel ( KG)
2350
2450
2458
3162
2080
Disposable Load
5914
6510
6680
9200
3825
Wing  Loading Clean/MTO
312/ 512
485/ 670
256/ 356
372/ 576
306/408
Fuel Fraction
0.45
0.5
0.502
0.47
0.47
Dish Dia.
 ( estimate)
690mm
n.a
648
n.a
n.a
Nose Tip to rear pressure bulkhead
5382
n.a.
4661
n.a.
n.a.
TO Run
1.27
1.84
1.0
1.49
0.91

1.      Pakistan has an excellent replacement for the F7
2.      The LCA’s 10% higher disposable load should be noticed. With drag reduction and weight improvement it should be quite respectable but there is no evidence of any timely addressing of these long pending tasks.



Table 2: Costs sanctioned ( Rs. Crores unless otherwise stated)  and PDV( present day value)
Sl
Date
Amount
PDV
Remarks
1
1983
560
17,920

2
1993
1628
16512
FSED
3
2001
3302
15172

4
2009
2475
5305


Total

54,969

JF 17 project





1998
$ 500M=2250 Crores INR
Rs. 13,065
Equally shared by Pakistan and China

Note: The above does not include Rs 1729 sanctioned by the Navy ( 2003) for the NLCA PDV ( Rs. 6512 crores)
This excludes Rs. 4353 (2432+1921) PDV Rs. 9331 crores sanctioned for LCA MK2.
If we further ignore the Rs 560 crores sanctioned in 1983 the comparison of costs on the common base of PDV is:
LCA ( 16512+15172+5305)= 36,989
JF 17 ( 13,065)= 13065
Financially we are being ‘ resourced” by at a rate of 2.83 :1 at least.

Readers will be interested to compare that the entire XST/F 117 stealth development programme was funded in 1973-1978 to the tune of 4997 crores PDV in small stages to produce the required cutting edge technology aircraft. Unless financial management is tightened we will not have the funds for local development.

Prof.Prodyut Das

Sunday, 9 July 2017

Creating an Indian Weapons Industry- the Total Matrix approach

Successful weapons development programmes require the united efforts of the Political, Bureaucratic , Armed Forces and the Technological Establishments ( POBAT) . Individually none of them have the capability to develop a suitable weapon but together, as always, the whole is greater than the sum of its parts. The sustained poor performance of the Indian weapons development programmes is a result of a situation where the first three have abdicated their responsibilities to the Technical Establishment. Contrary to popular belief ,Technology, Facilities and funding are not the main constraints to developing a viable weapons Industry. Thinking in terms of a Matrix, as used in Mathematics to solve complex multi variation problems, India is repeatedly failing because it is focusing on the Technical sub matrix whilst ignoring the other critical sub matrices. The pursuance of the above model for the past seventy years has resulted in India perhaps the fourth largest economy in the World being leading importers of Weaponry. This can be changed by the total matrix approach.
The Indian Space Research Organization  (ISRO is not the most well funded of  Space Organizations.The performance of ISRO has been entirely satisfactory on counts such as utility and contribution to the nation building process, professionalism and credibility. It has evolved its own philosophy and path without aping others and is arguably the most cost effective of all such organizations with particular skills in long range telemetry and control e.g.the Mangalyan project. ISRO has earned the grudging admiration of its peers which is rare praise indeed. Unfortunately the same cannot be said of its sister Organizations engaged in Weapons development.
To the Indian Citizen this great difference in results is baffling. On one hand we have brilliant results on a modest budget in an area that is literally “rocket science” and on the other hand we have “performance “so pathetic it has the dimensions of a swindle. We have projects that have lingered for years despite considerable funding. There have been suggestions of involving the private sector and that delightful (to the recipients!) panacea of increased funding. This is putting the cart before the horse. Funding and private sector are necessary but not sufficient. Unless Systemic changes are made, involvement of the private sector may lead to wastage of trust. This contrasting performance in Space Research and Weapons development can only be explained by viewing the problem as a Matrix.
The Matrix Approach
In Mathematics a matrix is a series of factors arranged in rows and columns. These factors are “weighted” according to the influence it has on all the other factors and are used to solve complex multi factor situations. The point of the Matrix is all the factors have to be solved to arrive at the correct solutions. The emphasis is to identify and adjust for all the factors irrespective of the “visibility” or importance of the problem.
The HF 24 project is a good example of what happens when some “small” factor in the matrix is ignored. The Government of the day wishing to develop a supersonic warplane paid due attention to all the major problems of developing a supersonic warplane in India of the Fifties. Foreign design leaders were recruited, factories and facilities were built up, funding to the tune of several tens of Crores was sanctioned, but there was a fatal “oversight”. Prof.Kurt Waldemar Tank, the Chief designer had chosen the Bristol B.Or.12engine for the HF 24. It was a decision which even with hind sight can be faulted. The chosen engine had good prospects of being selected by NATO for its light fighter programme. The Bristol B.Or.3 Orpheus were already under production at Bangalore. The Bristol Siddely Company had completed the bench tests and had flown the uprated B.Or.12 engine for 150 hours on a Sabre test bed and had asked for a further one crore  per year  to complete the certification. This was refused by someone! The immediate result was that the HF24 was doomed to having only 55% of its design installed thrust- and that too in a tropical country where thrust and lift are both significantly eroded by the temperature.  The HF 24 was an aircraft of which a respected UK journal wrote that if the HF 24 can meet its technical objectives it could find an enormous market amongst the world’s smaller air forces for fulfilling the demand for a low cost ground attack aircraft with a supersonic dash performance. The cost of the loss of this opportunity cannot be computed. The further move to remove the core German team of about six Designers in 1969 just as the HF 24 squadrons were being built up resulted in the expected IOC related problems not being tackled and the aircraft had  limitations of gun induced vibration of the cockpit and control locking problems. The decision not to fund the 2 crores resulted in severely curtailing the potential of the investment of crores. The reason for the decision which sabotaged the entire project could be many –  political disinterest after 1962, ignorance by the concerned Ministry,  “covert” marketing by the existing weapons supplier or sheer corruption but it illustrates the need of  for sustained “weeding” of apparently trivial issues even after major  decisions have been made..
The TSR 2 story
The story of the TSR 2 programme of UK in the 1960s is relevant because it shows the typical “soft” problems that beset the development of an advanced weapons system. There are excellent references about the often painful details but the summary is as given below.
In the late ‘fifties the UK wished to have a submarine launched nuclear deterrence system ( SLBM) independent of the USA. With hindsight such a need was preposterous and an overreaction to a nonexistent Russian threat.
Due to the anticipated delays in the SLBM submarines programme it was desired to have an aircraft based nuclear delivery system- the Tactical Strike Reconaissance 2 system.
The RAF which wanted to have  the aircraft set about getting the specifications as different as possible from the RN’s Blackburn Buccaneer subsonic carrier borne strike aircraft. The Table 1 shows the successive increases of requirements were all “justifiable” but added exponentially to the cost. The last straw was that the bomber was required to take off from a grass “Dakota” aircraft airstrip because it was felt that the existing runways would be bombed. Whilst justifiable to design a “soft field” undercarriage with balloon type tyres  requires more airframe volume as opposed to thinner higher pressure tyres that are sufficient for concrete runways This increases weight and cost ! It is not surprising undercarriage resonance was one of the major problems encountered during development.  More capability can be justified but it may break the camel’s back often technically but certainly always in terms of cost and time!
There was competition between the Navy and the RAF. The Navy wanted funds for its super carriers and saw the TSR2 as a competitor for funds. Lord Louis Mountbatten, the First Sea Lord, played a role in this which was subsequently described as “beyond the limits of propriety”. He discouraged the Australians, who were initially interested in the aircraft to counter a perceived threat from the Indonesians about the prospects of the TSR2 thus helping to kill off its export potential which could have brought down its unit costs.
The Americans played a role by offering the UK the TFX which at that time was not even ready. They then offered the Phantom both for the RAF and the RN. Here the British made the mistake of insisting on a british engine, the RR Spey and much British avionics. The subsequent redesign of the airframe was a heavens sent opportunity for the Americans to jack up quoted prices by about 30%. This will have relevance in the way we negotiate our “Make in India” programmes.
The UK Government, reorganizing the British Aviation Industry under pressure from the Americans, formed the BAC consisting of the former Vickers Weybridge works because it had experience in large airframes ( civil Viscount airliners it may be noted!) and the English Electric Warton works which had actually designed the aircraft and had been building the Lightning Mach 2 interceptor but gave the programme leadership to Weybridge! The time and energy lost in overcoming initial cultural frictions and rivalries wasted time and money.
The final and perhaps the most disgraceful act of the episode was that when the programme was eventually cancelled expectedly on grounds of cost the outgoing Labour Government ordered that not only would all  the 20 prototypes be destroyed or rendered unflyable but also the tooling and jigs were to be destroyed so that the project could not be restarted when the Tories came back to power! We in India condemn ourselves that we are unique in our chicanery!
The purpose of citing the above is to show that every country and not only India faces ‘subsurface” problems in the process of weapons development. The successful ones manage to solve them by painstaking diligence. as a National policy. Any of the components alone cannot do it and the old adage “The whole is greater than the sum of its part”!
It is necessary to illustrate what can be achieved by painstaking common sense from the example of France under De Gaulle who faced the identical problem of an independent nuclear strike force. France decided that the possession of the bomb was sufficient deterrence. A ‘viable” deterrence was adequate and affordable; an “unstoppable” deterrence whilst ideal was not. Accordingly they chose a much simpler profile of low altitude but not the terrain following tree top level of the TSR2 penetration and the aircraft was to operate from standard Armee d’l Air bomber bases. This simplified technical problems and costs. Accordingly they upscaled the proven Mirage 3 by 50% into a twin engine version using the same engines and much of the systems already proven. Led by Marcel Bloch Dassault with a team of fifty engineers and focusing on having the aircraft aerodynamics right,  the Mirage IV-01 prototype was flying within two years of signing of the contract. Though the aircraft was in every way technically inferior to the TSR 2 it fulfilled an identified need to a a tight timescale and budget. Such was the soundness of the decision and perhaps indicating how threats are routinely over assessed the aircraft was supposed to be in service for only ten years, the so called “inferior” solution,  actually remained in service for close to forty years.
To Indian readers there would be an uncanny similarity between the TSR 2 and what is happening in India. This is nothing to be surprised at rather it is that we should recognize that such problems are inherent in a democracy and having acknowledged the existence of the problem and acknowledging some additional problems as an ex-colonial country diligent efforts must be made to solve them. These problems are what constitute a sub matrix of the Indian Matrix.
The Indian Matrix.
Any weapons development programme will have a set of universal problems. These are Challenges of developing new technology, Inter services and intra services rivalry, Unrealistic assessment of threat etc.
There is usually a hidden sub-matrix of interactions on which any weapons development programmes run. These are, in India‘s case:
An overly powerful bureaucracy whose threat perception is: The Indian Armed Forces, Pakistan and then China -unfortunately -in that order of priority.
A political establishment, particularly post 1969 and the beginning of coalition politics, where political survival took priority over national interests.
Higher than usual levels of corruption which leveraged the ever present pressures   from the existing arms suppliers?
These resulted in efforts being vectored in different directions so the net vector was much smaller and weaker than sum of the efforts and resources put in.
Encouragingly however here have been very successful programmes run in the areas of missiles, sonars and radars, AWACs and helicopters. This would indicate that the malignant matrix is not overwhelming in strength. The pro and counter development strengths are in near equilibrium and corrections in even one of the above three could make significant changes in the situation. Corrections in all and we could surprise the world.
The malignant submatrix
It is said that a carpenter does not look at tree, he sees twenty chairs. Given the evident, long sustained and regrettable hostility between our bureaucracy and the Armed forces  our bureaucracy sees the demands for a mountain strike corps not only as complete waste of money on an unrealistic threat assessment but behind that lurks the fear of tanks clattering up the slopes of Raisina Hill. Not unrealistically, the Bureaucracy feels they would be the prime targets! They are therefore inimical to any suggestions from the Armed Forces for increases in effectiveness.
The Armed Forces ,long accustomed of getting a fraction of what the demand have made a habit of exaggerating threats and the consequent demands for funding. This is not granted and over the years of finally making do without, its credibility as an informed experts have been devalued.
The political element, habitually it seems, interested in its own personal well being has abdicated its role as the harnessers of these two powerful, competent and organized bodies resulting in bitterness and chaos. Indeed the possibility exists that the common ploy of playing of two very organized and powerful bodies to keep oneself in the seat may have happened.
All the above points can be discussed and debated but gives the crux of the real problem; the sub-matrix within the matrix. It is not funding and technical issues. ISRO is successful despite being literally “rocket science” but because much of this malignant sub matrix is not present in its sphere of activity.
Solving the Matrix.
Technical challenges are not the critical problems in Indian weapons development. All  serious technical challenges were met ,usually within time. Neither is funding. Though often used as an excuse never has a project actually ground to a halt solely because of running out of funds. There has been chaos because the political establishment failed to yoke the two others. This has resulted in each contender fighting its own perception of the problem with no respect for the others expertise rather than as a team working as a all arms battle group.
It is therefore not enough to form a CDS. That is a necessary secondary step. The relevant Ministries and the Armed Forces must be yoked to form a Weapons Development Group WADOG (by whatever name!). This task is cut out for the Political Leadership.
The benefits of a WADOG
Today we are shooting ourselves in the foot by trying to produce Weapons to International Brochure Specifications. It will take us no more than ten years to reach sanction free weapons capability.During this period the Armed Forces will suffer from covert sanctions to coerce us to continue imports. This is beyond the AFs competence and ability to resist.  The benefits of a Cabinet WADOG vis a vis of individual players as of now will be the following :
i)                    Clear, moderated, multi input identification of expected threats and their likelihood of requiring armed action.
ii)                  Planned action to contain such a threat
iii)                The National policy about our military posture for say the next ten years. It will f necessity be a defensive, tactical rather than any grandiose strategic global one.
This can only be done by the three (Political, Bureaucracy and the  Armed Forces PBAF) acting in coordinated concert with mutual respect for each other’s knowledge and competence. It is beyond the competence or the scope of any of the individual PBAF components to see the  full picture any more than the blind men could  “see” the elephant.
Once the likely threat and scenarios are identified and a realistic and curtailed war task is agreed with expert inputs from the PBAF the following consequences will flow.
i)                    Given the climatic and terrain conditions a significant two front threat is low in probability.
ii)                  The nature in warfare is different. Within limits of logic the defence of the Northern front will be labour intensive.
iii)                      Rather than numerical goals e.g. 45 squadron air force, address on priority the real       weaknesses which seems to be the tactical strike capability.
iv)                Nevertheless a large armed forces has a deterrent value well beyond the treasury costs
                  Toughness, the ability to continue to fight even after taking substantial losses can only come from a sizable force. It is necessary if not sufficient.
If the high level plans are carefully made we shall see realistic specifications emerging for our equipment. No country even super powers over equips its weapons as costs is always a constraint. The following examples will clarify.

Any American aircraft will have to cross either the Atlantic or the Pacific before it can fire it weapons in anger. To cross the ocean Flight refueling is a must. Even the AT 37, an aircraft in the same category as out HJT 16 Kiran has FR capability. Is it for us as a general requirement?
i)                    To stage from Hawai to Wake Island the distance is 2600 miles and Wake Island is only twelve miles long. This requires a navigation accuracy of .00024 radians. Striking Sukkur Bridge over the Indus (only as an illustration, please) from Jaisalmer is a distance of 150 miles. The accuracy required is eight times less and this can make the difference between possible and impossible.Much simpler less accurate equipment can be used rather than ransoming our capabilities to sanctions.
ii)                  The B2 bomber has an endurance of 40 hours and has a crew of 4.Any conventional crew oxygen system would add to size and reduce performance. The OBOGS become critical if not essential. For us its development should have been lower priority.
iii)                Western aircraft are routinely certified to +/-50 centigrad. This requires special engineering and materials. Given our anticipated theater of operations should we change the temperature certifications to + 50/ - 25?
iv)                 
The point of citing these examples is to state that we could, if the choice was between being sanction proof during the take off stage of our weapons development and importing then clearly a lower than international standard but adequate for our anticipated task has to be accepted by everyone. We can significantly reduce our immediate technical challenges and loads. The fixing of battle scenarios by is thus the critical first step.
The Decline of Force levels.
Any country wishing to develop its independent weapons industry will run in into a decline of its force levels . This is because the existing suppliers of weaponery will be loath to lose a lucrative source of income and influence. Soviet Russia in the early 1920s by decree destroyed its imported war equipment. Such drastic action would be inadvisable in today’s context but Iran’s maintaining of pre-Islamic revolution American weaponry for fifty years through war and peace is both a source of inspiration and knowledge. Equally relevant is the case of the Chinese. Between 1960 and 1986 the Chinese faced to actively hostile superpowers without blinking by relying on the huge size (which we have) and its nuclear deterrence ( which we also have) to buy time until its four modernizations were in place. Today the calm patient Chinese have moved forward to the power projection phase.
Summary
The present “fire and forget” style of weapons development has not worked and willnot work in a hundred years. The development of weapons independence will need the active and sustained collaboration of the four constituents of the POBAT and that too in an atmosphere of mutual trust and respect. This Cabinet must lead and ensure.
Left to the politicians alone they will ignore it till too late.
Left solely to the Bureaucrat the threat will be downplayed in the name of looking for seeking diplomatic solutions.
Quite understandably, the Armed Forces, acting alone, will over prepare for a worst possible scenario.
Left to the Technocrat we will have we shall a technical chaos – an enjoyable technical picnic but too often very little by way of timely hardware in service.
Yet the solution lies in the combined efforts of all the four above. An important side benefit  of a combined ops type POBAT/WADOG is that it will eliminate the ability of an isolated individual  or group to sabotage by taking a malignant decision.
The first task will be to realize that t5hat any attempts to become weapons independent will take about ten years and during this period the country will be vulnerable to various coercive measures from those who are presently supplying weaponry. Relying therefore on the passive deterrence of a large Armed Forces and the possession of nuclear weapons the groupmust identify and quantify the following:
i)                    Forewarned is forewarned; The intelligence gathering and analysis systems must be augmented to be the best  in the world.
ii)                  Identify the possible threat scenarios during this time and plans for their  resolution as a total combined package.
iii)                Discuss the military stance of the nation which will be generally dissuasive and defensive during this period of weakness.
iv)                Make a holistic assessment of the forces level required. For example theAir Force has a serious weakness in tactical strike and CAS. The LCA has to have priority over AMCA.
v)                  If needed prioritize development programmes across the services.
vi)                Bring into focus the real needs and specifications. The superpowers specifications are actually minimalist- for their needs. Our specifications must also be minimalist for our needs.
vii)              The reduced technical tasks will lead  to swifter completion of projects and we shall see a reduction of expenditure of individual projects.



Prof. ( retd. 2014) Prodyut Kumar Das has thirty years experience in the Industry.

References:
1.TSR2  McCelland T, Ian Allen 2010
2. Not much of an Engineer. Hooker, Sir.Stanley, Airlife 2010




Table 1
The growth of the TSR 2 specifications compared with the Mirage IVA

Aircraft
Role
Max. Speed
Min. Altitude
Radius
Airfield
TSR2 1st
Nuclear
M 1.3
330mts
350n.m.
Normal
TSR2-2nd
Nuclear /Conventional
M1.5
150 mts
500 n.m.
Normal
TSR2-3rd
Nuclear/Conventional/Recce
M1.7
50mts terrain following
600@M0.9
Grass Dakota
Mirage IVA
Nuclear
M1.7
Low altitude penetration, high altitude dash to target
1000n.m with FR
Normal


It would be clear to any engineer how much more difficult it would be to develop the TSR 2 in 1960s. It is little wonder that this superior solution was unaffordable and finally cancelled.