Design, Modelling and Assembly of an American Chopper.

Introduction: All parts of the Chopper were modelled individually and assembled in the SOLIDWORKS 2018 Version.

Objective: To model an American Chopper bike in the SOLIDWORKS software and render it.

Parts that were Modelled:

1. Chain
2. Chassis
3. Engine
4. Front fender
5. Front fork
6. Front wheel
7. Gas Tank
8. Kickstand
9. Oil Tank
10. Pedal
11. Rear fender
12. Rear wheel
13. Transmission belt

The following process describes how the above-mentioned parts were built.

Chain

Procedure:

• First the 2D sketch is drawn using sketch feature with appropriate dimensions.
• One side of the chain is produced using features such as Boss/Base Extrude, Fillet, Curve Driven pattern.
• Using the Curve Driven pattern, the outer plates, inner plates and extruded pins were patterned along the sketch.
• Through Mirror feature the other side of chain is produced.
• Appropriate appearances were applied.

Chassis

Procedure:

• First the 2D sketch is drawn using sketch feature with appropriate dimensions with reference to the sketch picture & the planes.
• The chassis was built using features such as projected curves, mirror, Boss Extrude, Cut Extrude, Sweep, Dome, Split, Revolve, Combine.
• Fillets, Chamfers were applied at required areas.
• Some sections such as sweep base & pedal holder were mirrored to the other side.
• Appropriate appearances were applied.

Engine

Procedure:

• First the 2D sketch is drawn using sketch feature with appropriate dimensions with reference to the sketch picture & the planes.
• The Engine setup was built using features such as projected curves, mirror, Boss Extrude, Cut Extrude, Sweep, Dome, Split, Revolve, Combine, circular pattern, linear pattern, composite curve.
• One of the engine cylinders was built & mirrored to the other side.
• Fillets & Chamfers were applied at required areas.
• The exhaust pipes were built using the projected curves & composite curve features.
• Appropriate appearances were applied.

Front fender

Procedure:

• First the 2D sketch was created with appropriate dimensions with reference to the axis & the planes.
• The sketch was revolved using revolve feature & was cut appropriately using split feature.
• Fillets were applied along the edges.
• Appropriate appearances were applied.

Front fork

Procedure:

• First the 2D sketch was created with appropriate dimensions with reference to the axis & the planes.
• One side of the part is produced using various features such as Boss Extrude, Cut Extrude, Sweep, Dome, Revolve, Combine, circular pattern, linear pattern, projected curves, Cut Revolve.
• Fillets were applied at required areas.
• Appropriate appearances were applied.

Front wheel

Procedure:

• First the 2D sketch of spider web design of the rim was created carefully with appropriate dimensions.
• The frontwheel was created using features such as Boss Extrude, Cut Extrude, Revolve, Combine, circular pattern, Cut Revolve.
• Fillets and Chamfers were applied at required areas.
• The rotor & caliper were created at proper position.
• Appropriate appearances were applied.

Gas Tank

Procedure:

• First the 2D sketch was created using splines with appropriate dimensions with reference to the sketch picture & planes.
• The body of gas tank was built using the features such as Surface sweep, Surface trim, Surface loft, Boundary Surface, Surface knit, split, Surface Extrude, Cut sweep, Shell.
• One side of the gas tank was created and then mirrored to the other side.
• Fillets were applied at required areas.
• Appropriate appearances and decals were applied.

Kickstand

Procedure:

• First the 2D sketch was created using ellipses at the ends. Then using Surface loft feature a solid surface was created along the sketched ellipses.
• The ends were rounded using Dome feature.
• At the bigger end of dome shape, a slit type of cut was made between the upper & lower side.
• A cylindrical structure was created in between them which serves as a joint with the vehicle. The surface of bottom end of smaller dome was made flat using split feature.
• Finally, fillets were applied at required areas.

Oil Tank

Procedure:

• First the base of the oil tank was 2D sketched using lines and arcs with appropriate dimensions.
• The body oil tank was built using the features such as Boss extrude, Combine, Shell.
• Fillets were applied at required areas.
• Appropriate appearances and decals were applied.

Pedal

Procedure:

• First the 2D sketch was created using splines, lines & circles with appropriate dimensions with reference to the sketch picture & planes.
• The body of pedal was built using the features such as Boss extrude, Revolve, Dome, Linear pattern.
• Fillets & Chamfers were applied at required areas.
• Appropriate appearances were applied.

Rear fender

Procedure:

• First the 2D sketch was created with appropriate dimensions with reference to the axis & the planes.
• The sketch was revolved using revolve feature & was cut appropriately using split feature and then shell feature was used.
• Fillets were applied along the edges.
• Appropriate appearances & decals were applied.

Rear wheel

Procedure:

• First the 2D sketch of spider web design of the rim was created carefully with appropriate dimensions.
• The rearwheel was built using features such as Boss Extrude, Cut Extrude, Revolve, Combine, circular pattern, Cut Revolve.
• Fillets and Chamfers were applied at required areas.
• The rotor, caliper & sprocket wheel were created at proper position.
• Appropriate appearances were applied.

Transmission belt

Procedure:

• First the 2D sketch was created using lines & semi circles with appropriate dimensions and then extruded using Boss Extrude feature.
• Fillets were applied along the edges.

American Chopper assembly

Procedure:

• Open an assembly file & import all the part files into it.
• Then fix the parts manually at appropriate positions using various mates such as Concentric, Coincident, width, angle, distance, parallel, tangent.
• Now the assembly of the American Chopper was completed and it was rendered using PhotoView 360 & Solidworks Visualize and the images were shown below.