AMERICAN CHOPPER- DESIGN, ASSEMBLY AND RENDERING USING SOLIDWORKS

OBJECTIVE:

To design an American chopper using solid works and rendering using visualize to obtain a more realistic view of the chopper.

With the design, the complexity of the model is analyzed, and key techniques are learned to design the parts, 3D design process, intuitive interface, create an assembly that is suitable for manufacturing using the least number of steps, and design standards.

INTRODUCTION:

The chopper is an American custom motorcycle using radically modified steering angles, frames without rear suspension and lengthened forks for a stretched-out appearance.

Chopper consists of various parts such as Transmission belt, kickstand, Front and Rear renders, oil tank, pedal, chain, Fuel tank, wheels, fork, Chassis, and Engine

Different factors such as seat height, handlebars placement, head angle, wheelbase, fuel injectors, intake and exhaust, and location of significant components are vital factors for consideration in the design.

The individual design of parts is integrated seamlessly within the bike.

DESIGN

1. TRANSMISSION BELT:

Belt type transmission is considered to transmit power. Belts run smoothly with little noise and vibration, needs no lubrication and minimal maintenance.

Modeling of transmission belt helped in understanding features like 2D sketch, identifying constraints, relations, extrude, fillet

Fig:1 - Transmission belt

2. KICKSTAND

Kick stand keeps the chopper upright and against leaning. It attached to the frame and pivot. A flat spot is made on the end that touches the ground, and it flips down to touch the ground

Modeling of kickstand helped in understanding features like 2D sketch, identifying constraints, relations, extrude, fillet, and extrude cut, loft, dome, and appearances.

Fig:2 - Kickstand

3. FENDER:

Fenders protect the chopper from mud, rain, and water which gets kicked up by the wheels and protects the chain and the body. Fenders are clamped to the fork. While designing the fender, we should make sure that there is sufficient clearance between a fender and the tire as tighter clearances can trap mud or snow entrained by the tire.

Modeling of front and rear fenders helped in understanding features like 2D sketch, identifying constraints, relations, revolve surface, fillet, shell, spline line and extrude cut, fillet, split, and appearances.

Fig:3 - Front Fender

Fig:4 - Rear Fender

4. OIL TANK:

Oil tank store the engine oil for the chopper. It is mounted/welded securely on the chopper to prevent spills.

Modeling of oil tank helped in understanding features like 2D sketch, identifying constraints, relations, extrude, fillet, combine, shell, and appearances

Fig:5 - Oil Tank

5. CHAIN:

A chain designed here is a roller chain, and it connects output shaft of the transmission to the rear wheel. It makes the rear wheel to turn. Chain and sprockets are the essential parts of chopper drivetrain.

Modeling of the chain is made by creating external and internal link plates, and a curve driven pattern is formed by using the link plates for both smaller and larger sprockets. The modeling helped in understanding features like 2D sketch, identifying constraints, relations, curve driven pattern, fillet, extrude, slot, blocks

Fig:6 - Chain

6. PEDAL:

The pedal is used as a support to rest the feet and helps in shifting the gears.

Modeling of pedal helped in understanding features like 2D sketch, identifying constraints, relations, extrude, revolve, dome, fillet, chamfer, linear pattern

Fig:7 - Pedal

7. WHEELS:

Front and rear wheels drive the motorcycle. It has a caliper, spokes, rim, brakes, and sprockets. Rear wheels play a crucial role during power transmission.

Modeling of wheels helped in understanding features like 2D sketch, identifying constraints, relations, extrude, extrude cut, thin extrude, revolve, revolved cut, fillet, chamfer, linear pattern, mirror, circular pattern

Fig:8 - Front-wheel

Fig:9 - Rear-wheel

8. FORK:

Front fork helps in the steering of the chopper and has connected the front axle to the frame. It has clamped front render, lights, handlebars, and holds the front wheel, front brake, and suspension modeling of front fork helped in understanding features like 2D sketch, identifying constraints, relations, extrude, revolve, fillet, sweep, mirror, dome, linear pattern, projected curve.

Fig:10 - Front fork

9. CHASSIS:

Chassis is the critical structure in which engine, oil tank, front fork are mounted on. And it also supports front and rear wheels.

Modeling of chassis helped in understanding features like 2D sketch, identifying constraints, relations, extrude, extrude cut, thin extrude, revolve, revolved cut, mirror, sweep, dome, fillet, chamfer, projected curve.

Fig:11 - Chassis

ENGINE:

The engine is the key component which converts energy from fuel to drive the chopper. It is a V-Twin engine with 45deg. It consists of parts like a motor, pulleys, starter motor, cylinders, Spark plug, inlet valve, exhaust valve

Modeling of engine helped in understanding features like 2D sketch, identifying constraints, relations, extrude, extrude cut, thin extrude, revolve, revolved cut, mirror, sweep, dome, fillet, chamfer, projected curve, linear pattern, composite curves

Fig:12 - Engine

11. FUEL TANK:

Fuel tank stores the gas, and it propels the fuel into the engine. And mounted on the chassis.

Modeling of fuel tank helped in understanding features like 2D sketch, identifying constraints, relations, surfaces

Fig:13 - Fuel tank

ASSEMBLY AND RENDERING:

The parts designed are assembled using mate feature. Mates like parallel, coincident, concentric,

Positions of the parts are defined using global positioning& defining angle and distance between the parts.

Fig:14 - Assembly - Chopper

Fig:15 - Chopper - Render with decals

Fig:16 - Chopper - Render with decals - RT 66