DESIGN AND ASSEMBLY OF AMERICAN CHOPPER

SONU
updated on Apr 24, 2020, 05:03am IST

Objective:

• The objective of this project is used to create a model of different parts of the Chopper using Solidworks.
• To assemble the different parts modeled for the chopper.
• To create a Photorealistic model of the chopper and Render the model using Solidworks Photoview 360 or Solidworks visualize.

Part Modeling:

• Part Modeling you can create a part from a conceptual sketch through solid feature-based modeling, as well as build and modify parts through direct and in- tuitive graphical manipulation.

Parts to be modeled for chopper

• The following parts of the chopper
are modeled in Solidworks and as-
sembled together.
1. Transmission Belt
2. Kick stand
3. Front Fender
4. Rear Fender
5. Oil Tank
6. Chain
7. Pedal
8. Front Wheel
9. Rear Wheel
10. Front Fork
11. Chassis
12. Engine
13. Gas Tank

1. Transmission Belt :

• The Transmission Belt in the chopper is used to transmit the power from the Engine to the Gearbox.

Features used to create Trans-mission Belt

• Sketch
• Offset
• Extrude
• Fillet
• Appearances

2. KickStand:

• The Kick Stand is also known as Side Stand. It is used to support the chopper.

Features used to create KickStand:

• Sketch
• Loft
• Dome
• Extrude Boss
• Extrude cut
• Fillet
• Split
• Appearances

3. Front Fender :

• The Front Fender is a part moun- ted on the fork above the wheel to protect the rider and the chopper other parts from debris and foriegn particles.

Features used to create Front Fender

• Sketch
• Offset Entities
• Trim entities
• Revolve
• Dynamic mirror
• Split
• Appearances

4. Rear Fender:

• The use of the rear fender is the same as the front fender. The rear fender is mounted on the chassis
of the rear part above the Rear Wheel.

Features used to create Rear Fender

• Sketch
• Offset Entities
• Trim entities
• Revolve
• Appearances

 5. Oil Tank:

• The Oil tank is one the part of the Chopper. Oil tank is used to store the oil required to run the Engine. Oil tank is the Hollow one. The thickness of the oil tank is given as 3mm in our chopper.

Features used to create Oil Tank

• Sketch
• Boss Extrude
• Combine
• Fillet
• Shell
• Appearances

6. Chain :

• Chain is a type of transmission system that is used to transmit a power from the Engine to the Rear
Wheel. Chain is made of steel. The Sprocket is used to transmit the power to the chain. The sprocket is
connected with the Shaft with the help of a key.

 

Features used to create Chain

• Sketch
• Trim
• Fillet
• Blocks
• Extrude
• Patterns
• Appearances

7. Pedal :
• Pedal is the external part attached to the chassis. The pedal is used to place the leg on top of that. To
give comfort to the rider pedal is used.

Features used to create Pedal

• Sketch
• Extrude
• Fillet
• Linear pattern
• Dome
• Chamfer
• Appearances

8. Front Wheel :

• A wheel is a circular block made of the Steel/Alloy material. On the top of the wheel the tyre is covered. The tyre is made of Rubber and it has thin wires within it.

Features used to create Front Wheel

• Sketch
• Revolve
• Trim
• Fillet feature
• Boss/Base Extrude
• Revolve Cut
• Linear pattern
• Chamfer
• Circular Pattern

9. Rear Wheel :

• A circular object that revolves on an axle and is fixed below a vehicle or other object to enable it to move easily over the ground.

• The disc and sprocket are attached with a rear wheel.

• The chain is connected between the Engine and the Rear Wheel. Chain is a positive drive. Compared to the belt it will be more efficient and losses in the chain will be less comparatively.

 

 

Features used to create Rear Wheel

• Sketch
• Revolve
• Trim
• Fillet Entities
• Boss/Base Extrude
• Planes
• Revolve Cut
• Linear pattern
• Chamfer
• Fillet Features
• Cut Extrude
• Circular Pattern
• Appearances

10. Front Fork:

• Most motorcycles today use telescopic forks for the front suspension. The forks can be most easily understood as simply large hydraulic shock absorbers with internal coil springs. They allow the front wheel to react to imperfections in the road while isolat- ing the rest of the motorcycle from that motion.

Features used to create Front Fork

• Sketch
• Extrude
• Trim
• Revolve
• Split
• Plane
• Convert entities
• Move/copy Body
• Dome
• Mirror
• Combine
• Curve (Project Curve)
• Sweep
• Appearance

11. Chassis :

• A chassis or frame forms its skeleton. All the components of a motorcycle, like the suspension, wheels, fuel tank, seats, handle- bars etc, are attached to this base structure which lends a motor- cycle its strength and ability to handle well.

Features used to create Chassis

• Sketch
• Offset
• Convert entities
• Project Curve
• Trim
• Plane
• Sweep
• Split
• Revolve
• Cut Extrude
• Fillet
• Combine
• Appearance

12. Engine :

• Engine is the prime mover for the Bike. The engine converts a Chemical energy into the Heat energy
and then the heat energy is converted into mechanical work. The mechanical work in the engine
is rotational motion. This rotation is converted to the wheel with the use of the chain and sprocket
through the gearbox and clutch.

Features used to create Engine

• Sketch
• Convert entities
• Trim
• Revolve
• Boss extrude
• Cut extrude
• Offset
• Dome
• Fillet
• Project curve
• Composite curve
• Sweep
• Mirror
• Circular Pattern
• Split

12. Gas Tank:

• Gas tanks are used to store the gas. To give the gas to the engine whenever it's required.

Features used to create Gas Tank

• Sketch
• Trim
• Project cuve
• Convert entities
• Sweep Surface
• Loft Surface
• Fill surface
• Surface trim
• Surface knit
• Sweep cut
• Fillet
• Appearances

Assembly of Chopper :

• Initially, the Chassis part is inserted in the assembly by using insert parts in the option. After that the
part is inserted in the assembly environment and clicked ok to fix the chassis.

• After that the other parts of the chopper are inserted into the assembly and given possible mate
conditions.

Features used to assemble Chopper

• Mates
• Insert part

Rendering:

• Rendering is the process of creating realistic images of the Photorealistic model with the environment.

• Rendering has been done in two ways in solidworks. The following are the two ways, Photoview 360 or Solidworks Visualize

• In the photorealistic model some of the mate conditions and positions are changed to render realistic models.

• Then the photorealistic model is rendered into realistic images with different views

 

Conclusion :

• The parts of the chopper are modeled.

• The parts are inserted into the assembly environment and the chopper is assembled.

• The realistic image was rendered with the use of the Photoview 360 & Solidworks visualize.

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