CREATING A MODEL OF AMERICAN CHOPPER USING SOLID WORKS

AMERICAN CHOPPER

AIM & OBJECTIVE :

• To sketch and 3D model each and every part of american chopper using solid works.
• To assemble modelled exterior parts with respect to environment
• To do photo realistic rendering by using solid works.

PARTS TO BE MODELLED ARE :

• TRANSMISSION BELT
• PEDAL
• ENGINE
• CHAIN
• GAS TANK
• OIL TANK
• FRONT & REAR WHEEL
• CHASSIS
• FRONT FORK
• KICK STAND
• FRONT FINDER
• REAR FINDER

1.TRANSMISSION BELT:

WITH HELP OF (2D SKETCH , EXTRUDE , FILLET & COLOR )CREATING TRANSMISSION BELT.

TO CREATE 2D SKETCH :

• click on new part file
• change metric from IPS to MMGS.
• select front plane for new sketch
• click on sketch select line option make harizontal line from orgin end the line and make an arc end it make a line tangent and make another acr and close it.
• changing relation to tangency, by dragging bottom to up and selecting tangent relation.
• adding dimension using smart dimension , by clicking on line and entering values in dimension box as for line 350mm , R70 & R60 as radius .
• cheack wether it is fully DEFINED

2) KICK STAND :

• MAKE PIERCE
• CREATE DOME
• TO CREATE BOSS
• FILLET

3) FRONT FENDER :

• new part file
• changing default plane as

VERTICAL PLANE FRONT FENDER

CENTER PLANE FRONT FENDER

MIDPLANE FRONT FENDER

• SELECT vertical plane

Start new sketch with 3point ARC above the origin.

• ADD RELATIONS
• OFFSET
• TO CREATE REVOLVE
• ADD COLOR
• DYNAMIC MIRROR
• SPLIT TOOL
• BACK EDGE
• ADDING RELATION AND DIMENTIONS
• SPLIT TOOL
• FILLET.

4) REAR FENDER :

• creat new part file
• change default plane as: vertical plane rear fender.

center plane rear fender.

mid plane rear fender.

• REVOLVE
• APPLY COLOR
• SPLIT TOOL
• FILLET
• SHELL

5.OIL TANK :

• Select new part file
• rename default top plane as mid plane oil tank
• select top plane and start the sketch.
• select line and make an construction line
• from origin to left in length 230mm .
• select sketch point locate vertically up on origin .
• make a length of 146mm from origin to sketch point .

DINAMIC ENTITES:

EXTRUDE:

SPLINE TOOL:

DIMENTION & RELATIONS :

EXTRUDE

INSERT>FEATURES>COMBINE> OPTION

* COMMON

* SELECT BOTH THE BODIES

* SHOW PREVIEW

* CLICK OKAY.

COLOR

FILLET

SHELL

6.CHAIN:

Open new document and rename default planes:

• minplane chain
• center plane chain
• front plane chain

create a OUTTER LINKS:

INNER LINK:

now to make the sketch fully defined rigth click on the link and select fixed tool.

make sure links are fully defined before exiting.

• CONVERT THE SKETCH TO BLOCK:
• EXTRUDE (rollers)
• EXTRUDE
• FILLET
• LINEAR PATTERN
• EXTRUDE
• LINEAR PATTERN
• FOLLOW THE SAME EXTRUDE , LINEAR PATTERN PROCEDURE FOR OTHER CURVES WITH SAME DIMENTION.
• MIRRIOR
• APPERANCE

7.PEDAL:

CREATE new part file

make another construction line up right

give dimension from end point of construction line to referance line = 255mm

now make that line about the lower edge of = 84mm.

ADDING SPLINE: UPPER AND LOWER SPLINE.

• UPPER SPLINE:

MOVE TILL CONSTRUCTION LINE make it tangency

activate upper handle and give an angle of =15 deg / away of 250mm

now click on lower handle and tangency of = 200mm

• BOTTOM SPLINE:

same procedure followed

activate upper handle give degree of 35 and 245mm away

lower handle of 545mm away.

cheack for good sweep.

• FILLET:
• EXTRUDE:
• FILLET:
• REVOLVE:
• CREATE AN PROFILE OF FOLLOWING DIMENSIONS
• INSERT > FEATURES > DOME > 3MM ( NOT ELIPITICALLY DOME)
• EXTRUDE
• CHAMFER
• EXTRUDE
• FILLET
• LINEAR PATTERN
• FILLET

8.FRONT WHEEL :

• Create new part
• select front plane
• ceate a line using midplane line from origin
• create an rectangle from it
• give dimentions as horizontal=110mm

vertical as=40mm

• CREATE REFERANCE GEOMENRTY
• REVOLVE
• SKETCH ON RIGHT PLANE
• DRAW SPLINE
• MIRROR
• EXTRUDE
• SKETCH RIGHT PLANE
• MIRROR
• EXTRUDE CUT
• EXTRUDE
• MIRROR:
• REVOLVE CUT:
• PATTERN:
• COMBINE:
• FILLET:
• TO CREATE ROTOR:
• EXTRUDE
• LINER PATTERN :
• MAKE EXTRUDE CUT:
• CIRCULAR PATTEN:
• EXTRUDE CUT:
• ADD 5MM FILLET INSIDE CORNERS.
• CREATE CIRCULAR PATTERN > SELECT SIDE EDGE > 10 INSTANCES
• CREATE AN CALLIPER:
• EXTRUDE
• CHAMFER
• FILLET
• TO CREATE TYRE FOR FRONT WHEEL
• FILLET
• EXTURDE CUT > FILLETS> CIRCULAR PATH > ANY EDGE> 14 instances

9.FRONT FORK :

sketch on front plane

• line from left of 1330mm
• close the end with 25mm
• make horizontal line
• check for fully defined

REVOLVE:

BOSS EXTRUDE:

FILLET:

EXTRUDE

EXTRUDE

TO CREATE HEAD LIGHT:

• front plane
• construction line fork of 61mm
• draw line above to right dimension of 18mm
• draw a perpendicular line from end
• 208mm from consruction line
• left angle of 28 degree
• create 3 point arc uper right to left
• construction line perpendicular to upper right
• and tangent with ARC
• FULLY DEFINED
• REVOLVE: deselect merge result
• insert>features>move/copy>select head line> z direction (-48mm)
• FILLET: 3mm on outside
• DOME: 7mm inside head light
• FILLET: 1mm inside edge
• curves
• fearures-sweep/bose:
• REVOLVE:
• Revolve :

new plane created

inside edge = 60deg

• right edge = 105 deg
• inside line = 54 mm
• outside line = 84 mm
• below horiz line = 175 , 70deg
• above 109 deg
• Extrude

• Fillet
• Curves
• Combine
• APPEARENCE

10.REAR WHEEL

sketch on front plane

• create mid point line finish it off as rectangle
• diimesion of 300mm x 45mm
• from horizontal line go down to left
• create an arc of radius R600
• back to line
• delete the tangent relation
• make line equal
• end point horizontal
• continue line with origin
• vertical line of 320mm out side
• away from origin of 273mm
• both side 75 degree.
• check for fully defined .
• APPLY REVOLVE.

• MIRROR :
• EXTRUDE:
• MIRROR ENTITIES:
• EXTRUDE CUT:
• BOSS EXTRUDE:
• MAKE IT COMBINE WITH COMBINE OPTION.
• MIRROR:
• REVOLVE CUT
• EXTRUDE CUT:
• REVOLVE
• ROTOR
• EXTRUDE
• EXTRUDE CUT
• FILLET
• EXTRUDE CUT:
• THREAD PATTERN:
• APPERANCE:
• TYRE = MATT BLACK
• RIM = CHROMIUME STEEL
• ROTOR = CHROMIUME STEEL
• SPROCKET = CHROMIUME STEELL

11.ENGINE

create a new part file

• create a 2d sketch
• insert chopper image > by selecting sketch tools
• rename sketch > blue print engine
• EXTRUDE
• EXTRUDE
• FILLET

• REVOLVE
• REVOLVE
• EXTRUDE
• CIRCULAR PATTERN
• EXTRUDE
• NEW SKETCH
• EXTRUDE
• CHAMFER
• FILLET
• FILLET
• SPROCKET BELOW
• EXRUDE CUT: Upto next
• REVOLVE for air intake
• EXHAUST FOR REAR CYLINDER
• PROJECT CURVE
• SWEEP
• FULL VIEW OF ENGINE

12.CHASSIS:

• Change default planes and rename: top plane as BOTTOM PLANE
• front plane as MIDDLE PLANE
• right plane as RIGHT PLANE

INSERT SKETCH PICTURE:

• SWEEP:
• MIRROR
• DIAGNOSE IF IT OVER DEFINED.
• EXTRUDE:
• MIRROR:
• COMBINE ALL BODIES.
• PLATE FOR LICK STAND:
• GIVE APPERANCE
• save the document as CHASSIS
• FULL VIEW OF CHASSIS

13.GAS TANK:

FRONT PLANE: midplane fuel tank.

TOP PLANE: bottom palne fuel tank.

RIGHT PLANE: front plane fuel tank.

PIERCE

SKETCH ON TOP PLANE

TRIM SURFACE

CREATE A NEW PLANE

referance geomentry > plane > front plane > vertex > hide plane.

• FRONT PLANE
• PROJECT CURVE
• LOFT SURFACE
• PROJECT
• BOUNDARY SURFACE
• DIRECTION 1
• DIRECTION 2
• MIRRORS
• KNIT SURFACE
• OFFSET ENTITIES
• TRIM
• EXTRUDE
• FILLET
• BOUNDARY SURFACE
• SURFACE LOFT
• KNIT SURFACE
• FILLET
• SKETCH ON PLANE 1
• TRIM
• SWEPT CUT
• FILLET
• APPERANCE

ASSEMBLY:

Now insert components ( CHASSIS) :

• select chassis > select front plane chassis > front plane.

Now insert ENGINE:

• select engine folder and select the component
• select front plane of engine and front plane of assemble make it coincident
• select bottom foot face of engine and upper face of chassis make them coincident .

MATES :

select face front of engine and front face of plate chassis ? distance of 20mm inward .

CHASSIS & ENGINE EXHAUST INTEFFERACNE :

• Click on engine folder > sweep > composite curve > curve 1 > change dimention from 295mm to 300mm
• click okay and collaps items.

PEDAL:

• Select pedal and roughly place it
• make holes and boss extrude coincident.

EXHAUST & PEDAL INTERERANCE :

• engine > open part > sweep curve> sketch 28
• construction line > delete parallism > 80degree > 110 degree dimention
• close used part in document.

MIRROR COMPONENT :

• select pedal folder > linear component > across front plane of chassis > create opposite handle > create new files add suffix LH
• Rename it as MIRROR PEDAL

KICK STAND :

• open kick stand
• select mate option select upper face of extrude in chassis and inner face of kick stand
• make it coincident center extrude of kick stand cut the chassis boss extrude
• click advance mates
• minimum degree = 0.00
• maximum angle = 50 degree flip dimention

TRANSMISSION BELT :

• Insert transmission belt
• select innerface of bigger side and circular edge of larger pully make it concentric
• select side faces of transmission belt > makte > advance mate> width > tab selection > inner face pulley
• change radius of small pulley from 60mm to 61mm'
• mate apply belt and upper motor as 7 degree

OIL TANK:

• Select bottom face edge and fillet edge on motor face
• make them coincident
• select front plane of oil tank and front plane of chassis make it coincident.

REAR WHEEL:

INSERT COMPONENT:

• Rotate along y axis to get correct orientation
• select outer face of axle and select inner face rear wheel
• make them concentric
• select right palne of rear wheel and right plane of chassis and make them parallel

REAR FINDER :

• rotate about y axis z axis
• select edges of finder and select wheel make concentric
• select right plan of chassis and front plane of fender make it parallel

COLLAPES ITEMS

CHAIN :

BACK SPROCKET :

• select inner face link plate and outer face of sprocket and apply width option in mate.
• chain folder > sketch > show
• select back arc of chain and hub make it concentric

FRONT SPROCKET:

• select center point and inner circular edge of sprocket make them concident
• hide sketch.

SUPRESS LAST CONCENTRIC FOLDER

GAS TANK:

• select right plane and plane 2 of chassis make them coincident .
• select bottom plane fuel tank from chassis folder and topplane of fuel make them coincident
• select front plane & front plane of chassis make it coincident.
• apply 5mm distance in standard mate.

FRONT FORK :

• select face of stem & inner face of front section of chassis make them concentric
• mate: width mate> selection upper & lower > tab selection ? outer face of front section
• ANGLE : mini deg=-30 degree > maximum = 30 degree , fixed angle = 30degree
• select front plane of chassis & front palne of fork make it parallel.
• collapes items.

FRONT WHEEL :

• Select face of axle and inner face of wheel hub and make them concentric
• create referance plane on face of triple clamp rename it as front plane .
• mate: select right plane & fork midpalne make coincident
• unsupress parallel mates and then supress it

FRONT FENDER:

• Rotate about y axis to get correct oreintation
• select vertical plane & front plane of fender make coincident
• select right plane of wheel and fender make them coincident
• collapse items

WHEN INTERFERANCE HAPPENS BETWEEN CHAIN AND CHASSIS:

• edit chassis part > edit sketch of back face of chassis
• select vetrical edge convert entities and select outer edge convert entites ,
• make a horizontal line down , semi circle construction line make concident
• ISOLATE
• use split tool
• select the sketch
• click on consume cut bodies
• click okay
• apply fillet of 3mm
• chassis > collapse items
• FULL ASSEMBLY OF CHOPPER

CONCLUSION :

• Each & Every parts of american chopper are sketched and 3D modelled as per requirment by using solid works
• Modelled exterior parts are Assembled using Solidworks and Rendered using Solidworks Visualize.

DRIVE LINK :

https://drive.google.com/open?id=19JGKHjX6M3v8e84E78yufVE82oY_Wk64