In this projects i will be demonstrating Full component modeling and assembly of American chopper in a sequence. The explanation inclused the components descriptions and How i made it in the Solid work enviroment One by One.

Components modeled in the solid work environment.

1.Transmission belt

2.Kick Stand

3.Front Fender

4.Rear fender

5.Chain .

6.Oil tank

7. Pedal

8.Front Wheel.

9. Rear Wheel.

10. Front Fork.

11. Chasis .

12. Engine.

13. Gas tank.

14.Assembly.

Components Discription and How it's made.

1. Transmission belt. - Belts is Used to transfer power from the Engine output shaft to the Gear box                                       Input shaft. Generally it is made polyster material with the layes or kevlar and                                      sandwich of metallic wires . It's a combination of diffrent elements which is                                        giving it Strength to transmit maximum horse power generated form engine to                                     gear box.

Explanation= the tools and features used to create the belt is :

1. Sketching
2. Use of sketching constraints ( tangent , coincident constraints)
3. Smart dimensioning
4. Use of offset tool to offset the figure externally by 3.5 mm
5. The extrude by 88.00 mm
6. Fillet of 1mm on the side edging externally only.

first i sketched the component and then using offset tool made a copy of my existing sketch about externally about 3mm , and then with the use of extrude command the 3-d component wad made after ,that fillet tool was used and by intelegent suface selection i selected upper palne surface so that all the external side edges was select and fillet was performed on the edge sucessfully.

 Rendered image:-

2.Kick Stand:-It's a supportivr accessories for the chopper which helps it to park a bike anywhere . It supports all the body of american chopper. material is steel .

EXPLANATION= THE PROCEDURE TO MAKE a model  IS ILLUSTRATED IN THE IMAGES BELOW ,And the tooling features are :- 

1. fundamental to create an ellipse on the front plne and apllying constraint and using smat dimenssion provide necessary dimenssion .

2.now sketching of a spline on the mid/ right palne (the spline is straight angled in the leftward direction) with desired dimensiion and also there is , need to edit the lower points of splines 

3. by creating a plane on the end point of the spline we have to draw an another ellipse (dimenssions anr in image) . 

4. using of lofted/boss base command join the those ellipse using spline as centerline parameter ..

5. using dome command on both the ends ..

6. using cut extruse command to make a slot on the upper end for mounting on the chopper, the cutting slot dimenssion was 28*8 mm.

7. then creating a mounting boss/ cylindrical body inside the splitted face of upper end using sketch and bos extrude.

8. using fillet tool to provide fillet on  the side edging of mounting side of kick stand.

 3.Front Fender:-Fenders are used to avoid spattering of dirt over the bodies and driver while driving. It is generall made up of lighter material. mainly aluminium.

EXPLANATION = the images shown for the suport of dimenssing and tooling features in solid works. and the procedure used to make front fender is as follows:-

1. using revolve command the component is modeled very easily ... firstly the sketch was created based on the dimenssion aquired from the pdf file attached to the video lectures.

2.the sketch was sketched on the front plane , along with a referance axis was drawn for performing an command of revolve.

3. The components was not fully revolved ,as it is a front fender we have to provide the direction of revolving in both left and right direction i.e, 5 degree and 130 degree.

4.on the center plane we have to create a sketch as shown in the image , the dimensions are given, here we used dynamic mirror option to create similar spline on both side .using this sketch we had to make / split the upper end of front fender to give a fancy look.

5. using split tool , split the revolve geometry. as shown..

6. again we are creating the splined sketch on front/ vertical plane for extrude cut the lower part of fender to make it fancy .

7. The using fillet command providing a 10mm fillet on the side edges .

4.Rear fender:- having same illustration as front fender.

Rendering:-

 5.Chain .:- Chain is power transmitting unit , It transmit power from Gearbox output shaft to the sprocket attached to the rear wheel. It is constant velocity drive . Manufactured by using various materials the general material for chain is low carbon steel.

explanation=  AS THE MODEL IS HAVING VARIOUS CRITICAL STEPS , MAXIMUM PORTION IS ILLUSTRATED BY THE IMAGES INCLUDING DIMENSIIONS AND TOOLING FEATURES USED. THE PROCESS I CARRIED OUT FOR MODELING THE CAIN ARE AS FOLLOWS:-

1. by renaming the planes as ; front plane= mid plane chain; top plane =center plain chain; rightplane = front plane chain. sketching on the mid plane / front plane(the dimenssion and featuring along with constraints as shown in the image.

2. FIRSTLY I CREATED A PATH FOR THE CHAIN ELEMENTS SHOULD FOLLOW ..

3. AGAIN BY SELECTING MID PLANE CREATED A THROUGH WAY SKETCH , THESE SKETCHS MAKES A BLOCK THAT WOULD BE STORED IN THE INTERNAL DIRECTORY ,SO THAT WHEN WE NEED THEM WE CAN EASILY ACESS THEM .

4. I CREATED TWO BLOCKS IN THE BLOCK INTEFACE. ( NOTE = ALL THE EXTRUDE DONE HERE BY DESELECTING THE MERGE OPTION)

5. NOW AGAIN BY SKETCHING OPTION RETRIVE THOSE BLOCK AND ALLIGN WITH THE PATH CREATED EARLIER, COMMAND USED ( COINDIDENT RELATION, CONCENTRIC, ALIGN RELATION ).

6. NOW EXTRUDING THE PIN AREA FIRST , AND ALSO EXTRUDING THE LINKS ELEMENTS ACCORDINGLY , AND PERFORMING < CURVE DRIVEN PATTERN > . 

7. AS THERE ARE 4 CONTOURS WE HAVE TO  MAKE A USE OF CURVE DRIVEN PATTERN FOUR TIMES . SO THAT THE PATERRN FOLLOW SMOOTH CURVING POSITION.

8. SIMILARLY DOING FOR ALL THE CURVES. AND EXTRUDING THE BLOCKS ACCORDINGLY,

9. AT THE END THE LAST LINK , WAS NOT MERGING WITH THE FIRSTLY CREATED LINK. SO THAT WAS MADE MANUALLY .SHOWN IN THE IMAGES.

10. AFTER THAT SEPERATE THE PINS AND ITS RELATING ENTITIES IN ASINGLE FOLDER AND ALSO SEPERATE THE ELEMENTS IN THE DIFFRENT FOLDER.

11. THEN MIRROE THE LINK ELEMENTS BY TAKING REFERANCE AS MID PLANE CHAIN .

12. THEN GIVING A APPERANCES TO THE CHAIN BLOCK..  

IN THIS WAY I CREATED CHAIN MODEL...

Renderings:-

 6.Oil tank:-

explanation = THE DIMENSSIONS ILLUSTRATED ON THE IMAGES BELOW . AND THE PROCESS FOR MODELING CAD MODEL ARE AS FOLLOWS:-

1. BY EDITING THE NAME OF FRONT PLANE AS MID PLANE OIL TANK ,I SKETCHED  A REFERANCE CONSTRUCTION LINE ON THE TOP PLANE ALSO A POINT VERTICALLY DIATANCE IS 146MM FROM THE ORIGIN.

2. THEN I SKETCHED THE LINE AND ARC USING DYNAMIC MIRROR OPTION ON THE EXISTING PLANE BY TAKING THE CONSTRUCTION LINE AS REFERANCE , AND ALSO APPLIED COINCEDENT RELATION (BETWEEN ARC AND CONSTRUCTION LINE) ------------SHOWN IN THE IMAGE BELOW.

3. NOW USING BOSS EXTRUDE OPTION , I EXTRUDED THE PART INBOTH THE DIRECTION AS 170 AND 10 MM.

4. NOW SKETCHED ON MID PALNE AS PER DESIRED DIMENSSIONIN THE IMAGE .

5. NOW EXTRUDING THAT SKETCH ON BOTH THE DIRECTION BY DESELECTING MERGE OPTION.

6.  NOW BY GOING TO INSERT>FEATURE>COMBINE >OPERATION TYPE> COMMON 

7. GIVING IT A REFERANCE APERANCE AS PAINTER> CAR> SIENA.

8. NOW BY USING SHELL OF 3MM WITHOUT SELECTING ANY OF THE EDGES, THATS REMOVING THE MATERIAL INTERNALLY WITHOUT AFFECTING EXTERNAL APPERANCE .

9. ASO GIVE IT FILLET OF 10MM TO ALL THE EDGES .

 Renderings:-

 7. Pedal:- 

Explanation= SKETCHING PORTION AND CONSTRAINTS WITH DIMENSSIONS ARE ILLUSTRATED WITH THE HELP OF SCREEN SHOTS... AND THE PROCEDURE TO MAKE PEDAL ARE AS FOLLOWS:-

1. FIRSTLY I CREATED A SKETCH ON THE FRONT PLANE ,THEN PROVIDED THE NECESSARY DIMENSSION TO SKETCH ALONG WITH CONTOURS , 

2. THEN BY USING SAME SKETCH , I CREATED DIFFERENT 3D STRUCTURE ,SUCH AS PLATE AND PINS .

3. THEN I EXTUDED THE RIGHT HAND SIDE HOLE WHICH WAS CREATED PREVIOUSLY.ALSO BY SKETCHING ON THE TOP PLANE A USED REVOLVE COMMAND TO CREATED A MOUNTING PIN LIKE STRUCTURE.

4. THEN PROVIDED A DOME AT THE END OF PREVIOUSLY CREATED PIN. WITHOUT SELECTING MERGE ELLPTICAL OPTION.

5. BY SKETCHING ON A FRONT EXTRUDED FACE ,I OFF-SETTED THE CIRCULAR ENTITIES ,ON ALL THE PINS CREATED PREVIOUSLY.

6.  THEN I CREATED A OFFSET EXTRUDE OF THOSE SKETCHES , AND USED A LINEAR PATTERN  BY SPECIFYING THE CENTER DISTANCE AND NO. OF PATTEN AS 4.. 

7. THEN USING FILLET OPTION , I APPLIED A FILLET ON THE SHARPE EDEGEING SURFACES AS SHOWN IN THE IMAGES BELOW.BY FOLLOWING THE ABOVE SHOWN PROCEDURE I CREATED THE PEDAL MODELING

 Renderings.

8.Front Wheel.

THE MODEL IS COMPOSITION OF DIFFRENT PARTS . THE PARTS ARE AS FOLLOWS:-

- RIM OF WHEEL

-BRAKE ROTOR

- CALLIPER

- TYRE       (ALL THE PROCESS " HOW I MODELED WAS ILLUSTRATED WITH THE HELP OF SCREEN SHOTS  . THE DIMENSSIONS CONSTRAINTS , TOOLING FEATURES, AND ADVANCES COMMAND,

BY MODELING THIS FILE I GOT DEEP UNDERSTANDING OF THE USE OF VARIOUS SKETCHING TOOLS SUCH AS(CONVERTING ENTITIES, OFFSETTING ENTITIES ETC....

THE EXPLANATIONS IS ILLUSTRATED BELOW IN A PREDEFINED SEQUENCE:-

 ********************** RIM OF WHEEL***************************

1. BY SKETCHING ON THE RIGHT PLANE AND USING REVOLVE COMMAND I CREATED TWO ROUGH BODY REFERANCES , ALSO THERE IS A NEED FOR THE FURTHER ADDING AND REMOVAL OF MATERIALS.

2. THEN I CREATED SPOKES BY USING A CONSTRAINTS DRAWN SKETCH AND THE BOSS EXTRUDING (FOR EX TRUDE COMMAND I DESLECT MERGE OPTION.

3. THEN I REMOVED THE CURVED SHAPED MATERIAL BY EXTRUDE CUT ON THE CENTER PLANE BY TAKING THE REFERANCE GEOMETRY AS ROUGHLY EXTRUDED SPOKE ELEMENTS.

4. AFTER THAT I DRAWN A RIBS GEOMETRY TO CONNECT THE EXTRUDED SPOKES OF RIM . 

5. AFTER THAT FULLY GEOMETRY FOR THE SPOKES AND THE OUTER PERIPHERY WAS READY SO I USED CIRCULAR PATTERN > EQUALLY SPACED> 3 NOS. > BY TAKING THE REFERANCE GEOMETRY AS SPOKE ELEMENTS.

6. THEN BY GOING TO COMBINE FEATURE , I ADDED THE OUTER CIRCUMFERANCE AND SPOKES AND THE CENTER HUB . AS SINGLE BODY ELEMENT.

*****************************************BRAKE / ROTOR************ BRAKE CALLIPER 

1.BY TAKING THE FRONT FACE OF HUB AS AREFERANCE SKETCH PLANE I SKETCHED THE ROTOR DIMENSSION AND OFFSETTED THE EXTRUDE AWAY FRON THE HUB,

2.THEN I DRAWN A 8MM CIRCLE ON THE FRONT FACE / FLAT FACE OF THE EXTRUDED GEOMETRY, AND LINEAR PATTEN THAT HOLE AT >MOS3 > AND ANGLED DIMENSSION OF 142 DEGREE.

3.THEN USING CIRCULAR PATTERN I CRETED MULTIPLE COPIES OF THAT EXTUDED HOLE ON THE FLAT FACE .

4.THEN FOR CALLIPER I CRETED A CONTRAINED SKETCH ON THE PERVIOUS FACE , AND EXTRUDED THAT. BY MERGING WITH THE ROTOR GEOMETRY, AND GIVING BOTH FULLY DEFINED DIRECTIONS.

5.AFTER THAT CHAMFER WAS GIVEN >AS DISTANCE DISTANCE > BOTH DIRECTION  (8MM, 20MM).> BY TAKING REFERANCE AS TOP FLAT FACE OF CALLIPER.

6. FILLET OF 4MM IS PROVIDED ON THE SHARE EDGING AS SHOWN.

******

**************************************TYRE OF WHEEL ************************************

1.USING CONVERT ETITIES OPTION TAKE A REFERENCE OF RIM CURVE AND SKETCHING THE GEOMETRY OF TYRE ON FRONT WHEEL . 

2.BY CREATING THAT SKETCH MAKE REVOLVE OPTION TO CREATE OUTER PEREPHERY, THEN I CREATED THE TYRE TREADS...

3. THE TREADS ARE CREATED ON THE FRONT PLANE BY SKETCHING 4 RECTANGLES ON THE FRONT PLANE AND PROVIDING THEM THE SUITABLE RELATION AND ALSO THE PRISCRIBED DIMMENSSIONS ALONG WITH ORIGIN AND CONVERT ENTITY REFERANCE LINE.

4. THEN USING OFFSET EXTRUDE CUT 4MM OF MATERIAL FROM THE TYRE SURFACE .

5. AFTER TAHT USE CIRCULAR PATTERN AND PATTERN THE TREADS AS IN THE IMAGE.

IN THIS WAY I CREATED FRONT WHEEL ..

Rendering:-

9. Rear Wheel.

HE MODELING IS BASED ON THE SIMILAR PROCEDURE AS I CREATED FRONT WHEEL..ONLY ONE PART WAS ADDED HERE i.e, SPROCKET..

THE MODEL IS COMPOSITION OF DIFFRENT PARTS . THE PARTS ARE AS FOLLOWS:-

- RIM OF WHEEL

-BRAKE ROTOR

- CALLIPER

-SPROCKET

- TYRE     

 (ALL THE PROCESS " HOW I MODELED WAS ILLUSTRATED WITH THE HELP OF SCREEN SHOTS  . THE DIMENSSIONS CONSTRAINTS , TOOLING FEATURES, AND ADVANCES COMMAND,

BY MODELING THIS FILE I GOT DEEP UNDERSTANDING OF THE USE OF VARIOUS SKETCHING TOOLS SUCH AS(CONVERTING ENTITIES, OFFSETTING ENTITIES , PATTERN, REVOLVE , CHAMFER      ETC....

THE EXPLANATIONS IS ILLUSTRATED BELOW IN A PREDEFINED SEQUENCE:-

 ********************** RIM OF WHEEL***************************

1. BY SKETCHING ON THE RIGHT PLANE AND USING REVOLVE COMMAND I CREATED TWO ROUGH BODY REFERANCES , ALSO THERE IS A NEED FOR THE FURTHER ADDING AND REMOVAL OF MATERIALS.
2. THEN I CREATED SPOKES BY USING A CONSTRAINTS DRAWN SKETCH AND THE BOSS EXTRUDING (FOR EX TRUDE COMMAND I DESLECT MERGE OPTION.
3. THEN I REMOVED THE CURVED SHAPED MATERIAL BY EXTRUDE CUT ON THE CENTER PLANE BY TAKING THE REFERANCE GEOMETRY AS ROUGHLY EXTRUDED SPOKE ELEMENTS.
4. AFTER THAT I DRAWN A RIBS GEOMETRY TO CONNECT THE EXTRUDED SPOKES OF RIM . 
5. AFTER THAT FULLY GEOMETRY FOR THE SPOKES AND THE OUTER PERIPHERY WAS READY SO I USED CIRCULAR PATTERN > EQUALLY SPACED> 3 NOS. > BY TAKING THE REFERANCE GEOMETRY AS SPOKE ELEMENTS.
6. THEN BY GOING TO COMBINE FEATURE , I ADDED THE OUTER CIRCUMFERANCE AND SPOKES AND THE CENTER HUB . AS SINGLE BODY ELEMENT.

*************BRAKE / ROTOR**AND** BRAKE CALLIPER***********************

1. BY TAKING THE FRONT FACE OF HUB AS AREFERANCE SKETCH PLANE I SKETCHED THE ROTOR DIMENSSION AND OFFSETTED THE EXTRUDE AWAY FRON THE HUB,
2. THEN I DRAWN A 8MM CIRCLE ON THE FRONT FACE / FLAT FACE OF THE EXTRUDED GEOMETRY, AND LINEAR PATTEN THAT HOLE AT >MOS3 > AND ANGLED DIMENSSION OF 142 DEGREE.
3. THEN USING CIRCULAR PATTERN I CRETED MULTIPLE COPIES OF THAT EXTUDED HOLE ON THE FLAT FACE .

    4 .THEN FOR CALLIPER I CRETED A CONTRAINED SKETCH ON THE PERVIOUS FACE , AND EXTRUDED THAT. BY MERGING WITH THE ROTOR GEOMETRY, AND                    GIVING BOTH FULLY DEFINED DIRECTIONS.

5. AFTER THAT CHAMFER WAS GIVEN >AS DISTANCE DISTANCE > BOTH DIRECTION  (8MM, 20MM).> BY TAKING REFERANCE AS TOP FLAT FACE OF CALLIPER.
6. FILLET OF 4MM IS PROVIDED ON THE SHARPE EDGING AS SHOWN.

***************SPROCKET**********************

1. I SKETCHED A DIMENSSIONAL ENTITIES BY TAKING REFERANCE OF ROTOR FRONT FACING ALSO OFSSETED THE ETITIES SO THAT IT COULD NOT MERGE WITH THE OTHER GEOMRTRY RELATING TO THE OTHER FEATURE.
2. THEN I PROVIDED THE FILLET OF 3MM ON THE SIDE EDGING OF THE EXTRUDED PART,
3. NOW USING THE FRONT FLAT FACE I CREATED TWO DIMENSSIONAL SLOTS USING CRIRCLE AND TRIM OPTION AND PATTERNED AS NOS 7.

***************************TYRE OF WHEEL***********************

1. USING CONVERT ETITIES OPTION TAKE A REFERENCE OF RIM CURVE AND SKETCHING THE GEOMETRY OF TYRE ON FRONT WHEEL . 
2. BY CREATING THAT SKETCH MAKE REVOLVE OPTION TO CREATE OUTER PEREPHERY, THEN I CREATED THE TYRE TREADS...
3. THE TREADS ARE CREATED ON THE FRONT PLANE BY SKETCHING 4 RECTANGLES ON THE FRONT PLANE AND PROVIDING THEM THE SUITABLE RELATION AND ALSO THE PRISCRIBED DIMMENSSIONS ALONG WITH ORIGIN AND CONVERT ENTITY REFERANCE LINE.
4. THEN USING OFFSET EXTRUDE CUT 4MM OF MATERIAL FROM THE TYRE SURFACE .
5. AFTER TAHT USE CIRCULAR PATTERN AND PATTERN THE TREADS AS IN THE IMAGE.
6. THEN BY RENAMING THE SOLID BODIES I CHANGED THE APPERANCE OF THE MODEL SO THAT IS WILL LOOK MORE REALSTIC

**

renderings:-

 Front Fork

 explanation= WHILE MODELING THIS COMPONENT I GOT SOME BASIC UNDERSTANDING OF SOME COMMANDS ( PROJECTED CURVES,SKETCHING ON THE VARIOUS PLANE AT THE SAME TIME ,MIRROR OF SOLID BODIES, USING OF MERGE ENTITIES , COMBINING BODIES....

NOW AT THIS END I AM VERY MUCH AWARE ABOUT THE INTERFACE AND MODELING THE COMPONENTS SO. 

1. I STARTED MODELING THE FIRST HALF PORTION OF THE FRONT FORK AS IN FURTHER WE CAN MIRROR THOSE ALL SOLID GEOMETRIES WITH REFERANCE TO FRONT FLAT FACING .

2. I CREATED SKETCH OF FORK AND REVOLVED THAT ALSO I CREATED HALF PORTION OF AXLE..AT THE BOTTOM SECTION,

3. THEN I MODELED SUPPORTING MEMBER BY SELECTING THE PRESCRIBED PLANE,

4. THEN I MODELED HEAD LIGHT (USING REVOLVE COMMAND ) BY APPLYING ALL THE OTHER FEATURES ON THE MODEL I SHIFTED THE SOLID BODY BY USING

5. DURING MODELING I ALSO CAME ACROSS THE CONCEPT OF PROJECTED CURVE , BECAUSE WE ARE NOT GETTING THE PLANE OR CURVE WHICH WOULD FOLOLW THE PATH FOR THE HANDEL BAR. BY CREATING 2 SPLINES ON THE FRONT AND RIGHT PLANE OPTION WE GOT THE SMOOTH CURVE FOR THE HANDEL BAR. USED

6. THEN I MADE HANDEL BAR , BY CREATING THE REFERANCE PLANE ON THE SWEEP AXIX, USING REVOLVE COMMAND.

7. THEN AGAIN I MADE THE USE OF SIMILAR PROCEDURE FOR PROJECTED CURVE OPTION, TO MAKE THE PATH FOR AN SWEEP OF BRAKE WIRE.

8. THEN I MIRROR THE SOLID BODIES. AND THE COMBINE THE NECESSARY COMPONENTS WHICH WAS NEEDED TO BE A SINGLE BODY 

9. THEN APPLIED DIFFERNT MATERIAL TO THE COMPNENTS ALSO APPERANCES,

10. AND GIVEN A SPECIAL APPERANCE TO THE HEAD LIGHT , BY GOING < APPERANCE> < ADVANCED> TO MAKE IT REALISTIC.

THE DIMENSSIONS OF SKETCHES ALSO THE COMMAND USED WAS ILLUSTRATED BY AN IMAGES BELOW.

Renderings:-

 12. Engine.

 EXPLANATION FOR ENGINE CAD MODEL= 

* WHILE MODELING ENGINE I CAME ASROSS MOST OF THE DIFFICITIES AND IT TOOK ME 12 HOURS TO COMPLETE.

* HERE I GOT THE BETER UNDESTANDING OF PROJECTED AS WELL AS COMPOSITE CURVES.

* I CREATED VARIOUS COMPONENTS SUCH AS

1 .MOTOR ,

2. STARTER,

3. PULLEYS,

4. SPROCKET,

5. ENGINE CYLINDER,

6. AIR INTAKE MANIFOLD

7. AND EXHAUST PIPE (THIS IS THE MOST CHALLENGING PART HERE , I CREATED VARIOUS SPLINE GEOMRTRY ON THE MULTIPLE PLANES TO OBTAIN THE SMOOTH PROJECTED CURVE ALONG THE PRISCRIBED PATH MENTION ON THE IMAGE.)

* THE DIMENSSIONAL SKETCHES, MODELING TOOL AND STEPS THAT I INCORPORATED WAS GIVEN BELOW WHILE WORKING ON THIS MODEL.THE IMAGES PROVIDED ARE THE STEPS HOW I CREATED THE MODEL.

Renderings:-

13. Gas tank._ fuel container Stores the fuel for the operation of Engine. 

material_- Steel sheets with seamless Welding.

While making Gas Tank i used surfacing options  From solid works,Also various features relating to surface trim, extrude and Surface lofting.

Rendering:-

 Assembly of American Chopper components in their prescribed position.

While making Assembly i used various constraints options,Such as Coinsident,Concentric,Tangents ,And distance.

I further applied the above listed constraints By considering the geometry modeling features (plane surfaces and vertices)

Renders:-