Designing and Modelling an American chopper using Solidworks

OBJECTIVE:

The objective of this project is to design and model an American chopper using solidworks and to assemble the parts and to create a photo realistic render of the chopper.

INTRODUCTION :

A chopper is a type of custom motorcycle perhaps the most extreme of all custom styles, often using radically modified steering angles and lengthened forks for a stretched-out appearance. Some of the characteristic features of choppers are long front ends with extended forks often coupled with an increased rake angle, hardtail frames (frames without rear suspension), very tall "ape hanger" or very short "drag" handlebars, lengthened or stretched frames, and larger than stock front wheels.

So the purpose of the project is to create a model of an American chopper using Solidworks.

PARTS :

• Engine
• Chassis
• Transmission Belt
• Kickstand
• Front fender
• Rear Fender
• Oil Tank
• Chain
• Pedal
• Front Wheel
• Rear Wheel
• Front Fork
• Gas Tank

DESIGN AND MODELLING :

Solid modelling was used predominantly for this chopper design expect for the gas tank, where the surface modelling was used.

1. ENGINE :

Engine is the heart of motorcycle. In chopper V-Twin engine is used and it is also called as V2 engine.It has a two-cylinder piston engine, where the cylinders share a common crankshaft and are arranged in a V configuration.

Commands used :

Sketch, Convert entities, Extrude boss,Trim, Revolve, Extrude cut, Fillet, Circular pattern, Dome, Chamfer, Linear pattern, Mirror, Split body, Combine, Swept boss, Project curve, Composite curve.

( Sketch includes commands like line, circle, spline, arc, ellipse, slot, rectangle etc. It also includes various sketch relations like parallel, perpendicular, tangent, equal etc ).

Extrude : It extrude a sketch or selected sketch contours in one or two direction to create a solid features.

Revolve : It revolve a sketch or selected sketch contours with respect to axis to create a solid features.

Extrude cut : It used to remove the 3D model of selected sketch.

Fillet : It used to connect two adjacent faces using a smooth tagent arc.

Chamfer : It used to connect two adjacent faces using an inclined line

Convert entities : Convert a selected model edge entities into current sketch segments.

Circle pattern : Pattern features, faces, bodies around an axis.

Linear pattern : Pattern features, faces, bodies in one or two linear direction.

Project curve : This features is used to project a curve onto a face or sketch.

Composite curve : Combine selected edges, curve and sketches into single curve.

Swept boss : This feature is used to sweep a close profile along an open or closed path to create a solid feature.

Fig 1 a. Engine

Fig 1 b. Engine Render

2. CHASSIS :

A motorcycle frame is a motorcycle's core structure. It supports the engine, provides a location for the steering and supports the rider and any passenger or luggage and the fuel tank is attach to the frame.

Commands used :

Sketch, Convert entities, Project curve, Swept boss, Mirror, Extrude boss, Extrude cut , Chamfer, Fillet, Dome, Split body, Combine.

Mirror : This allow to mirror the faces or bodies along a face or plane.

Dome : A rounded vault forming the outside face of a body typically with a circular base.

Combine : This feature is to combine two or more bodies together

Split body : This feature is to split bodies.

Fig 2 b. Chassis Render

3. Transmission belt :

Transmission belt is a loop of flexible material used to link the two rotating shaft mechanically.

Commands used :

Sketch, Extrude boss, offset entites, fillet.

Fig 3 a. Transmission Belt

Fig 3 a. Transmission Belt

4. Kickstand :

Kickstand is used to support the vehicle by making contact with ground while it parked .

Commands used :

Sketch, Loft boss, Dome, Extrude boss, Split body, Extrude cut, Fillet.

Fig 4 b. Kickstand

5. Front fender :

Front Fender is used to provide a support to wheel and also prevent dust, sand and other particals that enter the wheel

Commands used:

Sketch, Offset entites, Revolve boss, Split body, Fillet.

6. Rear fender :

Rear fender is also did same purpose like front fender but rear fender is attach with rear wheel.

Command used:

Sketch, Offset entities, Revolve boss, Split body, Fillet.

7. Oil Tank :

Stores the oil for lubrication and cooling purpose.

Command used:

Sketch, Extrude boss, Combine, Fillet, Shell.

8. Chain :

Chain is a way of transmitting mechanical power from one place to another. It is often used to convey power to the wheels of a vehicle, particularly bicycle and motorcycle. It is also used in a wide variety of machines besides vehicles.

Most often, the power is conveyed by a roller chain, known as the drive chain or transmission chain, passing over a sprocket gear, with the teeth of the gear meshing with the holes in the links of the chain. The gear is turned, and this pulls the chain putting mechanical force into the system.

Commands used :

Sketch, Block, Extrude boss, Fillet, Curve driven pattern, Mirror.

9. Pedal :

The pedal used for placing the foot, applying brake and shifting gears in a motorcycle.

Commands used :

Sketch, Extrude boss, Fillet, Revolve boss, Dome, Chamfer, Linear pattern.

10. Front wheel :

The front wheel consists of the unique spider web shaped rims, tyre, brake, rotor, and caliper.

Commands used :

Sketch, Convert entities, Trim Entities, Revolve boss, Extrude boss, Extrude cut, Revolve cut, Circular pattern, Combine, Fillet, Chamfer.

11. Rear Wheel :

The wider but rear wheel consists of the unique spider web shaped rims, tyre, brake, caliper and sprocket.

Commands used :

Sketch, convert entities, Extrude boss, revovle boss, Extrude cut, Revolve cut, Circulat pattern, Fillet, Chamfer, Combine.

12. Front fork :

The fork connects the front wheel and axle to its frame via york also known as triple clamp, which consists of an upper york joined to a lower york via steering stem, a shaft that runs throughthe steering head, creating the steering axis.

Command used :

Sketch, Revolve boss, Extrude boss, fillet, Linear pattern, Extrude cut, Dome, Revolve cut, Move/Copy body, Project curve, Swept boss , Mirror, Combine.

13. Gas tank :

Unlike other parts where solid modelling was used, gas tank is majorly designed in surface modelling, given in curve geomentry.

Commands used :

Sketch, Convert entites, Swept boss, trim surface, project curve, loft surface, boundary surface, mirror, knit surface, Split lines, Extrude surface, Fillet, sweep cut, Shell.

ASSEMBLY :

Assemblying is generally performed with certain relations like mate ( Coincident, Parallel, Tangent, Perpendicular), Advanaced mate ( Symmetric, Width, Angle ) and Mirroring.

Parts like kickstand and front fork needed a limiting angle which was set while applying mates. someparts had to be edited for respective geomentry into to appear good in assembly.

RENDERRING :

Renderring the model was done using Photoview 360 in Solidworks .

Decals were applied in the case of Oil tank, Gas Tank and Rear Fender during the final model rendering stage.

• Photoview 360 :Rendering using Photoview 360 involve setting the scene, Environment, Camera, Perspective and light by adjusting various parameters. Extra mates were added to give a realistic view of the scene. Colour adjustments were done if required.

CONCLUSION :

Thus, the exterior parts of an American chopper were designed, modelled, and assembled using Solidworks 2018 and photorealistically rendered using Solidworks Photoview 360