Design of a Lightweight Gyrocopter
This project involved the end-to-end mechanical design of a skeletal-frame gyrocopter using CAD tools. The goal was to develop a structurally sound, lightweight airframe that integrates all key components: the main rotor mast, a rear-mounted pusher propeller, tricycle landing gear, and a tail fin for stability. The design focused on mechanical feasibility, proper load distribution, and maintaining a clear layout for future fabrication or testing. I paid close attention to aspects like frame geometry, bracing for structural rigidity, mounting locations for the engine and rotor assembly, and the positioning of the pilot compartment. The open skeletal design not only simplifies manufacturing and maintenance but also allows easy visualization of force paths and stress points.
Project Aim
The aim of the project was to sharpen my mechanical design skills while gaining hands-on experience with structural layout, weldment-based construction, finite element analysis (FEA), and identifying potential failure modes in lightweight aerospace structures.
Airframe Design and Considerations
The gyrocopter frame was designed using computational tools to optimize geometry and material usage for structural efficiency. A skeletal truss layout with triangular bracing ensured rigidity while keeping weight low. Lightweight aluminum tubing was chosen for its strength-to-weight ratio and suitability for weldment-based construction. Key structural elements were dimensioned for balanced load distribution and evaluated for stress and deflection using FEA
Gyrocopter Blade Pitch Control Mechanism
The main rotor blade pitch in the gyrocopter is adjusted using a control lever that changes the angle of attack of the blades via a pitch linkage. This allows the pilot to regulate lift generation during flight by altering the rotor’s aerodynamic response