AMERICAN CHOPPER

AIM AND OBJECTIVE:

• To sketch and model every exterior part of the chopper under the part modelling environment using the Solidworks.

• To assemble the modelled parts in the assembly environment.

• To create a photo-realistic rendering of the chopper us Photoview 360.

WHAT IS PART MODELLING?

• Modelling in general means to create a virtual prototype of an item. It can be used for various purposes. Consider the engine of a car. Each part can be modelled separately and then can be assembled to get the engine's final form. This type of modelling is called part modelling.

PARTS TO BE MODELLED IN CHOPPER:

• Transmission Belt

• Kickstand

• Front Fender

• Rear Fender

• Oil Tank

• Chain

• Pedal

• Front Wheel

• Rear Wheel

• Front Fork

• Chassis

• Engine

• Gas Tank

1.TRANSMISSION BELT:

• The Transmission belt is used as a source of motion to transmit the power from one shaft to another.

Features used to create Transmission belt:

• Sketch

• Offset

• Extrude

• Fillet

Sketch:

• The sketch is a 2d representation of a particular from different views such as front view, side view, top view etc. The sketch comprises of commands like lines, arcs, circle etc.

Offset:

• The offset command is used to create a similar sketch in some distance as required.

Extrude:

• The extrude command is used to create a solid extrusion based on the selected sketch or contours. The extrusion can be made in either a positive or negative direction.

Fillet:

• In mechanical engineering, a fillet is a rounding of the interior or exterior corner of a part. The fillet is mainly done to uniformly distribute the stress in a specific area.

2.KICKSTAND:

• A component for supporting a bicycle or motorcycle when not in use, pivoted to the axle in such a way that it can be kicked down below the frame.

Features used to create Kickstand:

• Sketch

• Loft

• Dome

• Extrude Boss

• Extrude cut

• Fillet

• Split

Loft:

• Creates a 3D solid or surface by specifying a series of cross-sections. The cross-sections define the shape of the resulting solid or surface. You must specify at least two cross-sections. Loft cross-sections can be open or closed, planar or non-planar, and can also be edge subobjects.

Dome:

• Dome, in architecture, the hemispherical structure evolved from the arch, usually forming a ceiling or roof over the surface/face being selected.

Extrude Cut:

• The extrude cut feature is used to remove the unwanted material as per the modelled sketch. Based on the design of the sketch the material is removed.

Split:

• The split surface is used to split a single surface into multiple surfaces based on the sketch, by using the desired sketch split surface can be performed.

3.FRONT FENDER:

• The fender is the part which is used as a frame to the wheel. The fender does the work of blocking sand, debris from the surface.

Features used to create Fender:

• Sketch

• Offset Entities

• Trim entities

• Revolve

• Dynamic mirror

• Split

Trim:

• The Trim command can be used to remove the extra portions in the sketch the trim command works based on some reference point, edge etc.

Revolve:

• Revolve is the process of creating a revolved profile about the sketch and the axis of rotation. The profile can be created with the revolution up to 360 axis rotation.

Dynamic mirror:

• This tool allows the user to mirror a sketch about a line while the user is creating their sketch. Depending on design intent this tool can save an immense amount of time.

4.REAR FENDER:

• The fender is the part which is used as a frame to the wheel. The fender does the work of blocking sand, debris from the surface.

Features used to create Fender:

• Sketch

• Offset Entities

• Trim entities

• Revolve

• Shell

Shell:

• The shell command is used to create a thickened surface either it can be done in the interior or exterior surface.

5.OIL TANK:

• The oil tank is used as a reservoir to meet the oil requirements of the engine and to lubricate the parts.

Features used to create oil tank:

• Sketch

• Extrude Boss

• Combine

• Fillet

• Shell

Combine:

• The combine feature is used to merge two or more solid into a single solid.

6.CHAIN:

• A motorcycle chain is used to transmit the power from the engine to the rear wheel. It is used for power transmission.

Features used to create chain:

• Sketch

• Trim

• Fillet

• Extrude

• Patterns

Pattern:

• The pattern feature in the Solidworks helps us to create a similar geometry upto user-defined instances based on some reference edges, vertex etc.

7.PEDAL:

• The pedal is the extended surface from the chassis which is used for resting the feet to maintain balance and comfort while riding the vehicle.

Features used to create Pedal:

• Sketch

• Extrude

• Fillet

• Linear pattern

• Dome

• Chamfer

Chamfer:

• The chamfer command creates a bevelled feature on the selected edge, face and vertex etc.

Linear Pattern:

• The linear pattern is used to create a similar model either in linear XYZ directions. The pattern is created based on the reference edge, face etc.

8.FRONT WHEEL:

• A wheel is a circular block of a hard and durable material at whose centre has been bored a circular hole through which is placed a Front axle bearing about which the wheel rotates when a moment is applied by gravity or torque to the wheel.

Features used to create Front Wheel:

• Sketch

• Revolve

• Trim

• Fillet

• Extrude boss

• Revolve Cut

• Linear pattern

• Circular Pattern

• Chamfer.

Circular Pattern:

• The circular pattern is used to create a similar solid surface in a circular direction upto user-defined instances.

Revolve Cut:

• The Revolve cut command is used to cut a solid geometry by revolving about an axis. the axis may be the reference axis.

9.REAR WHEEL:

• A wheel is a circular block of a hard and durable material at whose centre has been bored a circular hole through which is placed a Rear axle bearing about which the wheel rotates when a moment is applied by gravity or torque to the wheel.

Features used to create Rear Wheel:

• Sketch

• Revolve

• Trim

• Fillet

• Extrude boss

• Revolve Cut

• Linear pattern

• Circular Pattern

• Chamfer.

10.FRONT FORK:

• A fork typically consists of two blades which are joined at the top by a fork crown. The crown is often at the front. Most suspension forks have an arch connecting the two side of the lower part connected to the axle.

Features used to create Front fork:

• Sketch

• Extrude

• Trim

• Revolve

• Split

• Move/copy Body

• Dome

• Sweep

• Reference Geometry

• Chamfer

• Fillet

Project Curve:

• The projected curve will be available under the features tab, the project curves command can be used to create a 3d curve. The 3D curve can be created by using the reference of two 2D curves.

Sweep:

• The Sweep command is used to create solid features by sweeping a closed profile along an open or closed path.

Reference Geometry:

• The Reference geometry is located in the features tab which is used for the plane, point, axis and coordinate system

11.CHASSIS:

• The Chassis is the rigid body and a supporting frame in every automobile the chassis incorporates the mounting of other parts and to keep the parts in their place rigidly.

Features used to create Chassis:

• Sketch

• Offset

• Project Curve

• Trim

• Sweep

• Split

• Revolve

• Cut Extrude

• Fillet

• Combine

12.ENGINE:

• The Engine in the motorcycle is the heart of the Engine. It drives the whole vehicle to move in a particular direction.

Features used to create Engine:

• Sketch

• Convert entities

• Trim

• Revolve

• Boss extrude

• Cur extrude

• Offset

• Dome

• Project curve

• Composite curve

• Sweep

• Mirror

• Circular Pattern

• Fillet

• Split

Composite Curve:

• The Composite curve is the combination of the two project curves.

13.GAS TANK:

• The Gas Tank acts as a reservoir to meet the fuel requirements of the chopper.

Features used to create Gas Tank:

• Sketch

• Extrude Boss

• Trim

• Surface Sweep

• Loft Surface

• Curves-Split line

• Knit Surface

• Sweep Cut

• Shell

• Fillet

Sweep Surface:

• Creates a surface feature by sweeping an open or closed profile along an open or closed path.

Loft Surface:

• Creates a lofted surface between two or more profiles.

Sweep Cut:

• The Sweep Cut cuts a solid model by sweeping a closed profile along a closed or open path.

ASSEMBLY OF CHOPPER

The chopper assembly is done in the assembly environment all the parts which are modelled before being inserted into the assembly environment by using insert component feature. The components are fixed in the assembly environment based on some references such as planes, mates etc.

MATES:

• Mates are used to creating a relationship among the parts being inserted into the assembly based on the one fixed part. Concerning the fixed part, all the parts can be mated.

• As you define the mates, you define the allowable direction of linear and rotational motion of the part in the environment.

PHOTOREALISTIC RENDERING OF CHOPPER

• Rendering is the process of converting a 3D model into a realistic image.

• In Solidworks, the rendering process can be done using SolidWorks add-ins such a photoview 360

• If photoview 360 is enabled it will enable the rendering tool, inside the render tools user can edit the appearance, scene and decals.

• By using the final render option one can predict how realistic the 3D model may look.

Conclusion:

• All the parts of the American chopper are modelled and assembled successfully using Solidworks 2019.
• The assembled chopper is rendered using the Photoview 360.

Outcome Of the Course:

• Understanding the basics of Solidworks and implementing it in part modelling and surface modelling.