American Chopper Modelling Using Solidworks

Objective :

• The objective of this project is used to create a model of different parts of the Chopper using Solidworks.
• Create an assembly of the different parts modeled for the chopper.
• Create a Photorealistic model of the chopper and Render the model using Solidworks Photoview 360 or Solidworks visualize.

What is Part Modelling ?

Modelling in general means to create a virtual prototype of an item. It can be used for various purposes. Part Modeling you can create a part from a conceptual sketch through solid feature-based modeling, as well as build and modify parts through direct and intuitive graphical manipulation. Consider the engine of a car. Each part can be modelled separately and then can be assembled together to get the engine's final form. This type of modelling is called part modelling.

Parts to be modeled for American Chopper :

The following parts of the chopper are modeled in Solidworks and assembled together.

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

Now we will see each and every Part one by one in detail.

1. Transmission Belt :-The Transmission Belt in the chopper is used to transmit the power from the Engine to the Gearbox.

Features used to create Transmission Belt

• Sketch
• Offset
• Extrude
• Fillet
• Appearances

Where as,

• Sketch : Sketch is the two dimensional representation of the model with respect to the plane/view from the outside of the model.In solidworks there are different sketch options available to create a sketch. These are known as Entities in solidworks. The following are the entities available in Solidworks LIne, Arc, Spline, Circles, Rectangle.
  
  
• 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, arcs, 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.

Procedures followed to create a model of Transmission Belt [Summary]

• Initially a Solidworks software is opened. Then, the new part is clicked to create a new model.
• Before creating the sketch the default plane names are changed as given below,
• Front Plane - Front Plane Transmission Belt
• Top Plane - Top Plane Transmission Belt
• Right Plane - Right Plane Transmission Belt

• Then, the front plane is selected to sketch.
• The 2D sketch is created in the front plane and dimensions,relations are given to the sketch 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 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 Part name i.e. Transmission Belt.

2. Kick-Stand :-
   
   It is nothing but a component for supporting a bicycle or motorcycle when not in use, pivoted to the axle in such a way that it can be kicked down below the frame.

Features used to create KickStand

• Sketch
• Loft
• Dome
• Extrude Boss
• Extrude cut
• Fillet
• Split
• Appearances

Where as,

• Loft : The loft feature in SOLIDWORKS allows you 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 “Loft Profiles”.
  
  
• Dome : Faces to Dome. Select one or more planar or non-planar faces. You can apply domes to faces whose centroid lies outside the face. This allows you to apply domes to irregularly shaped contours.
  
  
• Extrude cut : Extrude cut is another cool feature which helps to remove materials 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 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.

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 foriegn particles.

Features used to create Fender

• Sketch
• Offset Entities
• Trim entities
• Revolve
• Dynamic mirror
• Split
  
  Where as,
  
  
• 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 revolves. Click one of the following revolve tools.
  
  
• Dynamic mirror : Dynamic mirror is the important tool in Solidworks. As you sketch the entities, they are 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.

Features used to create Rear Fender

• Sketch
• Offset Entities
• Trim entities
• Revolve
• Appearances
  
  Where as,
  
  
• Appearances : An appearance defines the visual properties of a model, including color and texture. Appearances do not affect physical properties, which are defined by materials. Every material is assigned a default appearance that emulates the look of the material.
  
  
  
  

5. Oil Tank :-
   
   The Oil tank is one the 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
  
  Where as,
  
  
• Combine : Combine is the type of feature available in Solidworks to manually combine the two bodies.
• Shell : The Shell Definition PropertyManager is used to define the thickness of thin and thick shell elements.

6. Chain :-
   
   Chain is a type of transmission system that is used to transmit a 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 Chain

• Sketch
• Trim
• Fillet
• Blocks
• Extrude
• Patterns
• Appearances
  
  Where as,
• Blocks : You can make, save, edit, and insert blocks for drawing items and sketch entities that you use often, such as standard notes, title blocks, label positions, and so on. You can attach blocks to geometry or to drawing views, and you can insert them into sheet formats.

To make 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 Block Entities.
4. Click .
5. Repeat steps 2-4 for each of the remaining sketch entities.
6. With the sketch in edit mode, add the necessary relations.
7. Save the part.

• Patterns : The Curve Driven Pattern tool allows you to create patterns along a planar or 3D curve. You can base your pattern on an open curve, or on a closed curve, such as 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 place the leg on top of that. To give comfort to the rider pedal is used.
   
   
   

Features used to create Pedal

• Sketch
• Extrude
• Fillet
• Linear pattern
• Dome
• Chamfer
• Appearances
  
  Where as,
• Chamber : A cut on the edge or corner of something that makes it slope slightly rather than being perfectly square.
• Linear pattern : Linear pattern is also more like a 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 covered. The tyre is made of Rubber and it has thin wires within it.

Features used to create Front Wheel

• Sketch
• Revolve
• Trim
• Fillet Entities
• Boss/Base Extrude
• Revolve Cut
• Linear pattern
• Chamfer
• Fillet Features
• Cut Extrude
• Circular Pattern
• Appearances
  
  Where as,
• 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 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 enable it to move 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 will be less comparatively.

Features used to create 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 coil springs. They allow the front wheel to react to imperfections in the road while isolating the rest of the motorcycle from that motion.

Features used to create Front Fork

• Sketch
• Extrude
• Trim
• Revolve
• Split
• Plane
• Convert entities
• Move/copy Body
• Dome
• Mirror
• Combine
• Curve (Project Curve)
• Sweep
• Appearance
  
  Where as,
• 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 mirror faces with a mid-plane selected only the chosen faces within the revolve will be mirrored. 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. In the fork part the one part of the fork is created and the other part is mirrored. Then the parts are manually combined.
• Project Curve : Project curve is the kind of 3D curve which is projected on the basis of the two different 2D sketches.
• Sweep : With the Sweep feature we can create a shape by moving a 2D sketch Profile along a 2D or 3D sketch Path.
  
  

11. Chassis :-
    
    A 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 well
    
    
    

Features used to create 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 is 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 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 tanks are used to store the gas. To give the gas to the engine whenever it’s required.

Features used to create Gas Tank

• Sketch
• Trim
• Project cuve
• Convert entities
• Sweep Surface
• Loft Surface
• Fill surface
• Surface trim
• Surface knit
• Sweep cut
• Fillet
• Appearances
  
  Where as,
  
  
• 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. Also it reduces the gap between the two edges of the surface.

Assembly of Chopper :-

• Initially, 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 Chopper

• Mates
• Insert part
  
  Where as,
  
  
• 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 behavior.

Photo Realistic 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,
• Photoview 360
• 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.

Following are some of the Rendered Images.

Conclusion :

• The parts of the chopper are modeled using most of the Solid modelling Tools in Solidworks
• The parts are inserted into the assembly environment and the chopper is assembled. Getting used to with Assembly Module of Solidworks
• The realistic image was rendered with the use of the Photoview 360 & Solidworks visualize. [The rendering extensions along with Solifworks]