AMERICAN CHOPPER

AIM:

To sketch and model a solid work model of an American chopper.

 

Objective:

American chopper is one of the most classical retro bikes. In this Skill-Lync provided tutorials of solid works, we the enrolling students are taught the basics and advanced commands of sketching, modelling and rendering required to model an accurate and professional model of an American chopper. 

To finish this course of Solid works, we are required to model the entire bike by modelling individual parts and then assembling them. The parts involved are: 

 

Design and Modelling:

 

Parts to modelled:

1. Transmission Belt.
2. Kickstand
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.

 

  As the course progress, the difficulty level raises from simple closed sketch containing straight line to spline having many midpoints and using multiple curves to achieve a single curve having desired dimensions at the required position, multiple solid bodies joined together to achieve the desired final solid model. The first 5 parts are relatively easier than the rest, with the chain be difficult, as in understanding the theory behind the modelling rather than the actual modelling. The Engine, chassis and gas tank requiring advance 2d sketching and 3d modelling.

 

Commands in solid works:

1. 2d sketch: 2d sketch is the basic command which takes one to the sketching template. It is here where we make the sketches required to make solid body or part. We have to select a plane from 3 predefined planes namely Front Plane, Top Plane and Right plane.

 

2. 3d sketch: In 3d sketch, we make a sketch in a 3dimensional space rather than in a 2dimensional plane.

 

3. Straight Lines: Under Options, select:

 

4. Circles:

                        

 

5. Splines: The SOLIDWORKS software supports two types of splines, B-splines and style splines. You can use B-splines to create complex curves. You can define and modify them using several controls, including spline points, spline handles, and control polygons. A single B-spline can have multiple through points and spans (the region between through points). You can apply curvature constraints at each endpoint. At each point, you can weigh the tangency vector and control the tangency direction. Style splines, based on Bezier curves, are a good option when it is important to have a smooth curve (that is, to assure curvature continuity). You define and control the curves using control vertices. The control vertices form a control polygon or hull of the curve. There are no through points, so a style spline has only one span between the endpoints. You can inference style splines for tangency or equal curvature. You can constrain the points and dimension the curves' sides. These curves also support mirroring and self-symmetry.

 

6. Rectangles:

 

7. Sketch Fillet: The Sketch Fillet tool trims away the corner at the intersection of two sketch entities to create a tangent arc. This tool is available for both 2D and 3D sketches. The Fillet tool on the Features toolbar fillets entities such as edges in parts. The two corners of the rectangle are filleted with the same radius and with Keep constrained corners selected.

 

8. Ellipse: The Ellipse tool to create a complete ellipse. Use the Partial Ellipse tool to create an elliptical arc.

 

9. 3point Arc

10. Slots:

 

11. Fillets: Fillet/Round creates a rounded internal or external face on the part. You can fillet all edges of a face, selected sets of faces, selected edges, or edge loops.

 

12. Sketch Fillets: The Sketch Fillet tool trims away the corner at the intersection of two sketch entities to create a tangent arc. This tool is available for both 2D and 3D sketches. The Fillet tool on the Features toolbar fillets entities such as edges in parts. The two corners of the rectangle are filleted with the same radius and with Keep constrained corners selected.

 

13. Boss Extrude: creates a solid based on the sketch.

 

14. Cut Extrude: make a cut out of the existing solid body.

 

15. Revolve Boss: evolves add or remove material by revolving one or more profiles around a centreline. You can create revolved boss/bases, revolved cuts, or revolved surfaces. The revolve feature can be a solid, a thin feature, or a surface. The sketch must a 2d sketch not a 3d sketch. Axis of revolution can be 3d sketch.

 

16. Revolve Cut: does a cut w.r.t an axis of rotation according to sketch made.

 

17. Sweeps: Sweep creates a base, boss, cut, or surface by moving a profile (section) along a path. A sweep can be simple or complex. To generate the swept geometry, the software creates a series of intermediate sections made by replicating a profile at various positions along the path. The intermediate sections are then blended together. Additional parameters can be included in the sweep feature such as guide curves, profile orientation options, and twist to create a wide variety of shapes.

 

18. Loft: Loft creates a feature by making transitions between profiles. A loft can be a base, boss, cut, or surface. You create a loft using two or more profiles. Only the first, last, or first and last profiles can be points. All sketch entities, including guide curves and profiles, can be contained in a single 3D sketch.

 

19. Chamfer: The chamfer tool creates a bevelled feature on selected edges, faces, or a vertex.

 

20. Shell: The shell tool hollows out a part, leaves open the faces you select, and creates thin-walled features on the remaining faces. If you do not select any face on the model, you can shell a solid part, creating a closed, hollow model. You can also shell a model using multiple thicknesses.

 

21. Dome: Creates a dome on the face selected.

 

22. Linear Pattern: The Linear Pattern Property Manager appears when you pattern one or more features along one or two linear paths.

 

23. Circular Pattern: The Circular Pattern Property Manager appears when you pattern one or more features around an axis.

 

24. Sketch Driven Pattern: Using sketch points within a sketch, you can specify a feature pattern. The seed feature propagates throughout the pattern to each point in the sketch. You can use sketch driven patterns for holes or other feature instances.

 

25. Split: You can split a sketch entity to create two sketch entities. Conversely, you can delete a split point to combine two sketch entities into a single sketch entity. Use two split points to split a circle, full ellipse, or a closed spline.

 

26. Combine:

• Combining Bodies – Add:

In a multibody part, you can combine multiple bodies to create a single body.

• Combining Bodies – Subtract:

In a multibody part, you can subtract one or more bodies from another body.

• Combining Bodies – Common:

In a multibody part, you can create a body defined by the intersection of multiple bodies.

• Combine Property Manager:

In the Combine Property Manager, you specify which bodies in a multibody part to add, subtract, or overlap.

• Delete/Keep Body:

You can select bodies to keep or delete using the Delete/Keep Body feature. This is useful in working with multibody parts with multiple configurations.

 

27. Extend: You can add to the length of a sketch entity (line, centreline, or arc). Use Extend Entities to extend a sketch entity to meet another sketch entity.

 

28. Convert Entities: You can create one or more curves in a sketch by projecting an edge, loop, face, curve, or external sketch contour, set of edges, or set of sketch curves onto the sketch plane.

 

29. Trim: Select the trim type based on the entities you want to trim or extend. All trim types are available with 2D sketches and 2D sketches on 3D planes.

 

30. Mirror: Select Mirror Entities to mirror pre-existing 2D sketch entities on a plane, and then select the entity about which to mirror. If you want to first select the entity about which to mirror, and then sketch the entities to mirror, select Dynamic Mirror Entities.

 

 

31. Sketch Picture: Sketch pictures are used as a reference to draw sketches.

 

32. Sketch Pattern: Create linear or circular sketch patterns using elements from sketch entities you intend to pattern or model edges.

 

 

33. Dynamic Mirror Sketch Entities: Select the Dynamic Mirror Entities tool to first select the entity about which to mirror, and then sketch the entities to mirror.

 

 

 Designing and Modelling:

parts to be modelled:

1. Transmission Belts:

Transmission Belt is a loop of flexible material used to transmit power by the means of pulleys. Belts transmit power efficiently through the pulleys. They are one of the cheapest means used power transmission. other advantages are noiseless working, shock absorption during working, no lubrication, minimal maintenance, high tolerance for misalignment. Transmission Belt is the first part taught in this ultimate SolidWorks tutorial.

 Commands used:

• 2d sketch:
• lines:
• Extrude: 
• Fillets: 
• Appearances:

 

2. Kickstand:

The kickstand is a device used to keep the bike in up-right position. It is a metal piece that flips down to touch the ground and provide support.

 

commands used:

• 2d sketch
• ellipse
• spline
• pierce
• loft
• cut extrude
• Boss extrudes
• split

 

 

 

3. Front Fender:

Fender is a part of automobiles that covers the wheel. The fender's function is to contain the various material such as stones, mud, liquids on the roads which otherwise would have sprayed itself on to the inside of the car or the pedestrian behind the car. The front fender is used for the front wheel and rear fender is used for the rear wheel. The fender is also known as a mudguard.

 

Commands used:

• 2d sketch
• 3-point arc
• offset
• Extend
• Trim
• Revolve
• spline
• Fillet

 

 

 

 

 

4. Rear Fender:

Fender is part of automobiles that frames the wheel. The fender's purpose is to contain the various material such as stones, mud, liquids on the roads which otherwise would have sprayed itself on to the inside of the car or the pedestrian behind the car. The front fender is used for the front wheel and rear fender is used for the rear wheel. The fender is also known as a mudguard.

 

 Commands used: 

• 2d sketch:
• 3-point arc:
• Extend:
• Trim:
• Revolve:
• spline:
• Fillet:
• Shell:

 

 

 

 

 

 

5. Oil Tank:

An oil tank is a safe container for flammable fluids. Though any storage tank for fuel may be so-called, the term is typically applied to part of an engine system in which the fuel is stored and propelled (fuel pump) or released (pressurized gas) into an engine. Fuel tanks range in size and complexity from the small plastic tank of a butane lighter to the multi-chambered cryogenic space shuttle eternal tank.

 

commands used

• Lines:
• 3-point arc:
• Boss Extrude:
• Combine:
• Fillet:
• Shell:

  

 

6. Pedal:

Foot pegs can be developed or manufactured from a variety of materials; some are made from aluminium, steel, and also titanium. Some of them can assume a stamped, cast, mechanized or forged form. Most of the above foot pegs are both heats treated, or they are anodized. The majority of the great foot pegs have been drilled polished or ground they are then floor and put together. We have main facets of foot pegs that aa the charge of mud retention. These are draft, thickness, nooks and crannies. Let us seem to be at each of them and how it influences the mud retention. Draft- when a foot peg has a fantastic draft it virtually potential that the lower opening is better than the one at the top. This implies that we are probable to experience minimal mud trap.

Thickness- normal foot pegs normally make use of extra manufacture material, this in most instances creates deeper cavities that lure a lot of mud. On the different hand, super-thin foot pegs best in seasoned circuit units. They are most desired here they are magnificent skinny and they, therefore, don’t supply any room for mud to be trapped.

Nooks and crannies- simplified difficult and crossbeams foot pegs do not entice any mud as antagonistic to their different counterparts.

 

Commands used:

• 2d sketch:
• Lines:
• Circles:
• Fillets:
• Revolve:
• Dome:
• Chamfer:
• Linear Pattern:

 

 

7. Chain Link:

The Chain drive is a mechanism to transfer power from one place to another, similar to a transmission belt. The chain drive is a positive drive mechanism since there is no slippage between the belt and gear. Drives are mostly made of metal, followed by plastic and rubber. They are very efficient in power transmission. Lubrication is one of the most important points since the drives wear out quickly without proper lubrication. Chain drives suffer from speed controlling since the drives are made from metal, they have significant self-weight which give rise inertia during rotation. Therefore, special care has to be taken to avoid such situations, which in turn will reduce the chances of vibration and increase the life of the chain drive. In most cases, either the shafts are accelerated and deaccelerated accordingly, or the sprocket is speed controlled. Chains are often narrower than belts, and this can make it easier to shift them to larger or smaller gears to vary the gear ratio. Multi-speed bicycles with derailleurs make use of this. Also, the more positive meshing of a chain makes it easier to build gears that can increase or shrink in diameter, again altering the gear ratio.

 

Commands used:

• 2d sketch:
• circles:
• 3point arc:
• Slot:
• Block:
• Fillet:
• Curve Pattern:
• Mirror:

 

8. Front Wheel: 

A wheel may be a circular block of a tough and sturdy material at whose centre has been bored a circular hole through that is placed Associate in Nursing shaft bearing concerning that the wheel rotates once an instant is applied by gravity or torsion to the wheel concerning its axis, thereby creating along with one in all the six straightforward machines. once placed vertically below a supporting platform or case, the wheel turning on the horizontal shaft makes it doable to move significant loads; once placed horizontally, the wheel turning on its vertical shaft makes it doable to regulate the spinning motion accustomed form materials (e.g. a potter's wheel); once mounted on a column connected to a rudder or a chassis mounted on different wheels, one will manage the direction of a vessel or vehicle (e.g. a ship's wheel or steering wheel); once connected to a crank or engine, a wheel will store, release, or transmit energy (e.g. the flywheel).

 

Commands used:

• 2d sketch:
• Straight lines:
• 3-point arc:
• sketch fillet:
• revolve:
• spline:
• extend:
• trim:
• cut extrude:
• offset:
• cut revolve:
• circular pattern:
• chamfer:
• fillet:
• corner centre point rectangle:

 

9. Rear-wheel:

A wheel may be a circular block of a tough and sturdy material at whose centre has been bored a circular hole through that is placed Associate in Nursing shaft bearing concerning that the wheel rotates once an instant is applied by gravity or torsion to the wheel concerning its axis, thereby creating along with one in all the six straightforward machines. once placed vertically below a supporting platform or case, the wheel turning on the horizontal shaft makes it doable to move significant loads; once placed horizontally, the wheel turning on its vertical shaft makes it doable to regulate the spinning motion accustomed form materials (e.g. a potter's wheel); once mounted on a column connected to a rudder or a chassis mounted on different wheels, one will manage the direction of a vessel or vehicle (e.g. a ship's wheel or steering wheel); once connected to a crank or engine, a wheel will store, release, or transmit energy (e.g. the flywheel).

 

Commands used:

• 2d sketch:
• Straight lines:
• 3-point arc:
• sketch fillet:
• revolve:
• spline:
• extend:
• trim:
• cut extrude:
• offset:
• cut revolve:
• circular pattern:
• chamfer:
• fillet:
• corner centre point rectangle:

 

10. Front Fork:

The element which connects the front wheel and axle to the rest of the frame is known as a front fork. The tripe clamp or yoke is one of the main parts of the front fork. The front fork contains a front brake and front suspension.

The fork and its attachment points on the frame establish the critical geometric parameters of rake and trail, which play a major role in defining how a motorcycle handles and dives during braking. While the standard telescopic fork arrangement is found with few major differences among mainstream street motorcycles since the 1970s, historically there have been many variations, including trailing or leading link, springer, Earles, girder, and others, as well as non-fork steering such as hub-centre steering.

 

commands used:

• 2d sketch:
• Straight Lines:
• Revolve:
• circle:
• Fillets:
• Linear Pattern:
• spline:
• Cut Extrude:
• Dome:
• Move Body:
• Curve:
• sweep:
• plane (ref geometry):
• mirror:
• combine:

 

 

 

11. Chassis:

A chassis is the load-bearing framework of an artificial object, which structurally supports the object in its construction and function. An example of a chassis is a vehicle frame, the underpart of a motor vehicle, on which the body is mounted; if the running gear such as wheels and transmission, and sometimes even the driver's seat, are included, then the assembly is described as a rolling chassis.

 

Commands Used:

• sketch pictures:
• splines:
• curves (ref geometry):
• mirror:
• boss extrude:
• cut extrude:
• chamfer:
• dome:
• split:
• revolve:
• combine:

 

 

 

 

 

12. Engine:

 

A motorcycle engine is an engine that powers a motorcycle. Motorcycle engines are typically two-stroke or four-stroke internal combustion engines, but other engine types, such as Wankel’s and electric motors, have been used. Although some mopeds, such as the VéloSoleX, had friction drive to the front tire, a motorcycle engine normally drives the rear wheel, power being sent to the driven wheel by belt, chain or shaft. Historically, some 2,000 units of the Megola were produced between 1921-1925 with front-wheel drive, and the modern Rokon, an all-terrain motorcycle with both wheels driven, has been produced since 1960. Most engines have a gearbox with up to six ratios. Reverse gear is occasionally found on heavy tourers, for example, the Honda GL1600, and sidecar motorcycles, such as the Ural. The rider changes gears on most motorcycles using a foot-pedal and manual clutch, but early models had hand-levers. More recently, some have automatic or semi-automatic gearboxes.

 

commands used:

• 2d sketch
• sketch pictures:
• straight lines:
• circles:
• boss extrude:
• fillet:
• revolve:
• plane (ref geometry):
• dome:
• circular pattern:
• chamfer:
• linear pattern:
• mirror:
• cut extrude:
• combine:
• mirror:
• curve:
• composite curve:
• spilt:

 

 

 

 

 

 

13. gas tank:

A gas tank (or petrol tank) is a protected container for flammable fluids. Though any storage tank for gasoline may additionally be so-called, the period is generally utilized to a section of an engine machine in which the gas is saved and propelled (fuel pump) or launched (pressurized gas) into an engine. Fuel tanks vary in measurement and complexity from the small plastic tank of a butane lighter to the multi-chambered cryogenic Space Shuttle exterior tank.

commands used:

• 2d sketch:
• spline:
• surface sweep:
• surface trim:
• surface boundary:
• surface loft:
• curve:
• mirror:
• surface knit:
• surface extrude:
• fillet:
• cut extrude:
• shell:

 

 

ASSEMBLY:

Manual Mating was done in case of the chopper. Standard mates such as coincident, parallel, tangent, perpendicular were used and advanced mates such as symmetric angle width were also used.

Limiting mates were added to make the model works as it would work in real life for kickstand and front fork. Every part is mated the midplane of the chassis to give the basic placing reference.

 

 

 

Rendering:

The rendering is done with photo view 360

Conclusion:

The American Chopper has been designed, modelled and assembled using solid works 2019, and photo realistically render using photoview 360.