Modeling and Assembly of American Chopper

Objective:

• To design various parts of American chopper using Solidworks under part modeling
• To assemble the parts of chopper in assembly environment
• To render and create photorealistic view of chopper using Photoview 360

Modeling Tools:

The following are the tools used for modeling parts of chopper

2D Tools: Line, Spline, Circle, rectangle, polyline, fillet , Chanfer, smart dimension, sketch pattern, Trim, offset entities.

3D Modeling Tools:

Extrude Boss: It converts the 2D sketch into 3D object.

Extrude Cut: It is used to make holes/ cut the 3D object.

Revolve: It to used for creating revolved profile with referance to the sketch and axis of rotation.

Lofted Boss: It is used to create 3D solid of different cross-section.

Pattern: Patterns are various types like linear pattern and circular pattern. It is used to create required number of identical parts in a certain pattern/ sequence.

Mirror: It is used to create the mirror part object.

Shell: It is used to convert the solid object to hallow.

3D Sketch: It is used to create a 2D sketch between two different planes

Fillet, Draft, Shell, Combine, Intersect, Sweep Boss, Split boss are also some of the 3D tools used for modeling.

Surface Tools:

Sweep surface: It is used to generate surface from sectional curve positioned along path

Filled Surface: It is used to fill the gap between the two surfaces by generating the surface path along the boundary of the two surfaces.

Surface Trim: It is used to cut the extra surface.

Surface Knit: It is used to join the two surfaces and reduces the gap between the two joined surfaces.

Parts of Chopper:

The following are the parts to be modeled.

1. Transmission Belt
2. Kickstand
3. Front Fender
4. Rear Fender
5. Fuel Tank
6. Chain
7. Pedal
8. Front Wheel
9. Rear Wheel
10. Front Fork
11. Chassis
12. Gas Tank
13. Engine

Transmission Belt: It is used to transmit power from engine to gearbox

Commands Used:

• Sketch
• Trim
• Boss Extrude

Kickstand: It is provides support to the chopper

Commands Used:

• Sketch
• Sweep
• Boss extrude
• Cut extrude

Front Fender: Its primary purpose is to protect the chopper from sand, mud, stones and other dirt particles.

Commands Used:

• Sketch
• Offset entities
• Trim entities
• Revolve
• Split

Rear Fender: It is also used for same purpose as front fender but it is mounted on the rare wheel

Commands Used:

• Sketch
• Offset entities
• Trim entities
• Revolve
• Split

Fuel Tank: It is used to store the fuel which is used to provide power to engine

Commands Used:

• Sketch
• Boss extrude
• Combine

Chain: It is used transmit the mechanical power from gearbox to the wheels.

Commands Used:

• Sketch
• Trim
• Fillet
• Blocks
• Extrude
• Pattern

Pedal: It is the footrest attached to the chassis for the riders comfort.

Commands Used:

• Sketch
• Boss Extrude
• Linear pattern
• Dome
• Chamfer

Front and Rear Wheels: It is one of the most important part for any automobile.

Commands Used:

• Sketch
• Revolve
• Trim
• Fillet
• Extrude Boss
• Revolve cut
• Linear pattern
• Chamfer
• Fillet
• Extrude cut
• Circular pattern

Front Fork: It is used as a handle of the bike. It connects the front wheel and axle to the frame. The front suspension are also incorporate in the front fork.

Commands Used:

• Sketch
• Extrude
• Trim
• Revolve
• Split
• Convert Entities
• Mirror
• Dome
• Shell
• Combine
• Projected curve
• Sweep

Chassis: It is the frame part of the chopper which supports the every part of the bike. Parts like engine , Pedal, fuel tank kick stand are mounted on it. It is designed to distribute the loads equally.

Commands Used:

• Sketch
• Offset
• Convert Entities
• Project Curve
• Trim
• Sweep
• Split
• Revolve
• Cut Extrude
• Fillet
• Combine

Gas Tank: It is used to store the fuel.

Commands Used:

• Sketch
• Trim
• Project curve
• Convert Entities
• Sweep surface
• Loft Surface
• Fill Surface
• Surface trim
• Surface knit
• Sweep Cut
• Fillet

Engine: It is the heart of the automobile. It converts the thermal energy into mechanical energy.

Commands Used:

• Sketch
• Convert entities
• Trim
• Revolve
• Boss Extrude
• Cut Extrude
• Offset
• Dome
• Fillet
• Project Curve
• Composite curve
• Sweep
• Mirror
• Circular pattern
• Split

Assembly and Rendering:

• The assembly of chopper is done in assembly environment by inserting the modeling parts and assembly is done by giving required mates.
• Rendering can be done by using photo view 360 or solid works Visualize

Project Link: https://drive.google.com/open?id=1whzKqfF0B1eKBeVYwiK5t8Yc4JyZ8VOW