DESIGN & ASSEMBLY OF AMERICAN CHOPPER

DESIGN & ASSEMBLY OF AMERICAN CHOPPER

Objective:

The objective of this project is to learn and understand the different tools and commands in SolidWorks.
To create a Model of different parts.
To assemble the different parts in the assembly.
To Render and make.realistic view in the SolidWorks Visualize and PhotoView 36O.

Part Modeling:
In part modelling first, sketch the Part and build the Part with some graphical visualisation.

Parts Modeled for Chopper:

The following Parts of the Chopper are Modeled and assembled in SolidWorks
1. Transmission Belt
2. Kick Stand
3. Front Fender
4. Rear Fender
5. Oil Tank
6. Chain
7. Pedal
8. Front Wheel
9. Rear Wheel
10. Front Fork
11. Chassis
12. Engine
13. Gas Tank

1. Transmission Belt

The Transmission Belt in the Chopper is used to transmit the Power from the Engine to Gear Box

Features used to create a transmission belt:

Sketch
Offset
Extrude
Fillet
Appearances

Sketch:

The sketch is a two-dimensional representation of the model There are different sketch options in the SolidWorks like Line, Arc, Circle,
Rectangle, Spline. These are known as Entities

Offset

Offset one or more sketch entities, selected model edges, or model faces by a specified distance. For example, you can offset sketch
entities such as splines or arcs, sets of model edges, loops, and so on. You can offset finite lines, arc, and splines

Extrude:

Extrude is a type of feature available in SolidWorks to convert a 2D sketch into the 3D model

Fillet:

Fillet/Round creates a rounded internal or external face on the part. You can fillet all edges of a face, selected sets of faces, selected edges,
or edge loops.

The procedure to create a model of Transmission Belt:

First, Open the SolidWorks. Then, click on the new part to start modelling
Before creating the sketch change the names of the planes.
Front Plane Front Plane Transmission Belt
.Top Plane Top Plane Transmission Belt
.Right Plane Right Plane Transmission Belt
Then, select the front plane to start the sketch.
. The 2D sketch is created in the front plane by giving it dimensions, relations to fully define a sketch. while sketching, the offset
command is used to duplicate the sketch to some distance.
After this process, the sketch is closed. Then, the extrude command is used to convert a 2D sketch into a 3D model.
.Then, the fillet is given to the belt as per the requirements. The model of the transmission belt is created.
.The model is saved with the name of Transmission Belt.

2. Kick Stand:

The Kick Stand is used to support the chopper. It is also known as Side Stand.

Features used to create Kick Stand:

Sketch
Loft
Dome
Extrude Boss
Extrude cut
Fillet
Split
Appearances

Loft:

The loft feature in SOLIDWORKS allows you to generate complex geometry in a single feature. It does this by interpolating surfaces
between various cross-sections of a model. These cross-sections can be sketches, faces or edges. In the loft-interface, these cross-sections
are considered as "Loft Profiles"

Dome:

Select one or more planar or non-planar faces. You can apply domes to faces whose centroid lies are outside the face. This allows you to
apply domes to irregularly shaped contours

Extrude cut:
Extrude cut is another great feature which helps to remove material from the 3D model It is just the opposite to extrude boss/base feature,
because it cuts a sketch profile while extruding. You can cut it in both directions and mainly used for creating holes, channels, slots etc

Split:
The SOLIDWORKS Split Line tool is used to project an entity (sketch, solid, surface, face, plane or surface spline) onto other surfaces or curved/planar faces. You are also able to split faces on multiple bodies with one command.

Procedure to create a model of Kick Stand:

.First, Open the SolidWorks. Then, click on the new part to start modelling
.Before creating the sketch change the names of the planes.
.Front Plane - Front Plane
Top Plane - Top Plane
Right Plane Mid Plane
.Then, the mid-plane is selected to start the sketch.
The 2D sketch is created in the front plane by giving it dimensions, relations to fully define a sketch. While sketching we used the
spline and trim commands.
There are two new planes created and the ellipse are drawn in the new plane as per the requirement
Then the loft command is used to create a loft for the Kickstand.
The extrude cut command is used to cut the parts which are not required for the stand.

3. Front Fender:

The Front Fender is a part mounted on the fork above the wheel to protect the rider and the chopper other parts from debris and
foreign particles.

Features used to create Front Fender:

Sketch
Offset Entities
Trim entities
Revolve
Dynamic mirror
Split
Appearances

Trim entities:

Select the trim type based on the entities you want to trim or extend. All trim types are available with 2D sketches and 2D sketches on 3D
planes. You can use any of the following trim options: Power trim.

Revolve:

To create a revolve feature: Create a sketch that contains one or more profiles and a centerline, line, or edge to use as the axis around which the feature revolve can be used.

Dynamic mirror:

Dynamic mirror is an important tool in SolidWorks. As you sketch the entities, they can be mirrored about the pre-selected sketch entity.

4. Rear Fender:

The use of the rear fender is the same as the front fender. The rear fender is mounted on the chassis of the rear part above the Rear
Wheel to protect the body from mud.

Features used to create Rear Fender:

Sketch
Offset Entities
Trim entities
Revolve
Appearances

Appearances:

An Appearance defines the visual properties of a model, including colour and texture. Appearances do not affect physical properties, which
are defined by materials. Every material is assigned to a default appearance that emulates the look of the material

5. Oil-Tank:

The Oil-tank is another part of the Chopper. Oil tank is used to store the oil required to run the Engine. Oil tank is the Hollow one. The
thickness of the oil tank is given as 3mm in our chopper

Features used to create Oil Tank:

Sketch

Boss Extrude

Combine

Fillet

Shell

Appearances

Combine
Combine feature is used to manually combine the two bodies into the one body

Shell:

The Shell Definition Property-Manager is used to define the thickness of thin and thick shell elements.

6. Chain:

Chain is used to transmit the power from the engine to the Rear Wheel. Chain is made of steel. The Sprocket is used to transmit the
power to the chain. The sprocket is connected with the Shaft with the help of a key.

Features used to create the Chain:

Sketch
Trim
Fillet
Blocks
Extrude
Patterns
Appearances

Blocks:

we can make, save, edit, and insert blocks for drawing items and sketch entities that We use often, such as standard notes, title blocks, label
positions, and many more. We can attach blocks to geometry or drawing views, and We can insert them into sheet formats.

To create blocks:

1. Create a sketch.
2. Click Make Block. (Blocks toolbar) or Tools Block Make
3. Select the sketch entities you want to make as a block for BlockEntities
4. Repeat steps 2-4 for each of the remaining sketch entities.
5. With the sketch in edit mode, add the necessary relations.
6. Save the part

Patterns:

The Curve Driven Pattern tool allows us to create patterns along a planar or 3D curve. We can base our pattern on an open curve, or a
closed curve, like a circle. In the chain part Curve Driven Pattern is used.

7. Pedal:

Pedal is the external part attached to the chassis. The pedal is used to rest the leg on top of that. For the comfort of the rider pedal is used.

Features used to create Pedal:

Sketch
Extrude
Fillet
Linear pattern
Dome
Chamfer
Appearances

Chamfer:

Chamfer is used to cut on the edge or corner of something that makes it slightly slope or rounded rather than being perfectly square or
straight.

Linear Pattern:
Linear pattern is also similar to the circular pattern. The features/bodies are patterned linearly. Pattern is a kind tool like Array available in
AutoCAD.

8. Front Wheel:

A wheel is a circular block made of the Steel/Alloy material On the top of the wheel, the tyre is attached. The tyre is made of Rubber and it
has thin wires within it. Wheel rotates to move the vehicle.

Features used to create the Front Wheel:

Sketch
Revolve
Trim
Fillet Entities
Boss/Base Extrude
Revolve Cut
Linear pattern
Chamfer
Fillet Features
Cut Extrude
Circular Pattern
Appearances

Circular Pattern:

Circular pattern is used to create a pattern of the sporks and the patterns (Grooves) available in the tyre. Also, it is used to create holes in the
brake discs of the front wheel The parent bodies/ features are used to create a different number of instances required to create the pattern
circularly.

9. Rear Wheel

A circular object that revolves on an axle and is fixed below a vehicle or other object to move it easily over the ground.
The disc and sprocket are attached with a rear wheel
The chain is connected between the Engine and the Rear Wheel. Chain is a positive drive. Compared to the belt it will be more
efficient and losses in the chain drive are comparatively less.

Features used to create the Rear Wheel:

Sketch
Revolve
Trim
Fillet Entities
Boss/Base Extrude
Planes
Revolve Cut
Linear pattern
Chamfer
Fillet Features
Cut Extrude
Circular Pattern
Appearances

10. Front Fork:

Most motorcycles today use telescopic forks for the front suspension. The forks can be most easily understood as simply large hydraulic
shock absorbers with internal coll springs. They allow the front wheel to react to imperfections in the road while isolating the rest of
the motorcycle from that motion. it filters the bums to give comfort to the rider.

Features used to create the Front Fork:

Sketch
Revolve
Split
Convert entities
Move/copy Body
Dome
Mirror
Combine
Curve (Project Curve)
Sweep
Appearance

Move/copy Body
Move copy body is used to move copy the body from one place to other places in the fork

Mirror

By using the mirror feature we can mirror body or part to the other side Mirroring bodies can be used whether in a single or multi body part
and allows you to select solid geometry instead of the features and faces in a body, n the fork part, the one part of the fork is created and
the other part is mirrored Then the parts are manually combined it helped me to save a lot of time

Project Curve:
Project curve is the kind of 3D curve which is projected based on the two different 20D sketches

Sweep:
With the Sweep feature, we can create a shape by moving a 2D sketch Profile along a 2D or 30 sketch Path

11. Chassis

The chassis or frame forms its skeleton. All the components of a motorcycle like the suspension wheels, fuel tank, seats, handlebars etc
are attached to this base structure which lends a motorcycle its strength and ability to handle.

Features used to create the Chassis

Sketch
Offset
Convert entities
Project Curve
Trim
Plane
Sweep
Split
Revolve
Cut Extrude
Fillet
Combine
Appearance

12. Engine

Engine is the prime mover for the Bike. The engine converts a Chemical energy into the Heat energy and then the heat energy
converted into mechanical work,
The mechanical work in the engine is rotational motion. This rotation is converted to the wheel with the use of the chain and sprocket
through the gearbox and clutch.

Features used to create the Engine

Sketch
Convert entities
Trim
Revolve
Boss extrude
Cut extrude
Offset
Dome
Fillet
Project curve
Composite curve
Sweep
Mirror
Circular Pattern
Split

12. Gas Tank

Gas tank is used to Store the fuel gas.Fuel gas is required to drive the engine.

Features used to create the Gas Tank:

Sketch
Trim
Project curve
Convert entities
Sweep Surface
Loft Surface
Fill surface
Surface trim
Surface knit
Sweep cut
Fillet
Appearances

Loft Surface:
Loft Surfaces are surfaces generated by multiple 3D Curves or existing edges creating a smooth tangency between the selected curves

Sweep Surfaces:
Sweep surfaces are surfaces that are generated from a section curve positioned along a path.

Filled Surface:
The Filled Surface feature constructs a surface patch with any number of sides, within a boundary defined by existing model edges
sketches, or curves, including composite curves.

Surface trim:
Primarily used to cut away material from a surface. and provides two modes: Standard and Mutual

Surface knit
Surface knit is used to knit the two free edges/open edges of the surfaces together. It also reduces the gap between the two edges of the
surface.

Assembly of the Chopper

First the Chassis part is inserted in the assembly by using insert parts in the option. After that the part is inserted in the assembly
environment and clicked ok to fix the chassis
After that, the other parts of the chopper are inserted into the assembly and given possible mate

conditions.

Features used to assemble the Chopper:

Mates
Insert part

Mates:

Mates create geometric relationships between assembly components As we add mates, we define the allowable directions of linear or
rotational motion of the components. we can move a component within its degrees of freedom. visualizing the assembly's behaviour

Rendering

Rendering is the process of creating realistic images of the Photorealistic model with the environment.

Rendering has been done in two ways in SolidWorks. The following are the two ways
1. Photoview 360
2. Solidworks Visualize

In the photorealistic model, some of the mate conditions and positions are changed to render realistic models.
Then the photorealistic model is rendered into realistic images with different views

Conclusion:

.The parts of the chopper are sketched and modelled in the SolidWorks.
.The parts are inserted into the assembly environment and by applying the mates chopper is assembled
The realistic image was rendered with the use of the Photoview 360 & SolidWorks Visualize

https://drive.google.com/open?id=1PCBbXbQOHmArIQNrrb3bJuayyv0WQroB