DESIGN OF AMERICAN CHOPPER

DESIGN OF AMERICAN CHOPPER

Objective

• To learn the basic features and tools of Solidworks.
• To learn the modelling and surface modelling of the parts of American Chopper and assemble them in Solidworks.
• To create the photo realistic rendering of American Chopper in PhotoView 360.

Introduction

• Solidworks have different software that are used by mechanical, electrical, civil etc. engineering branches. Here we use Solidworks CAD modelling software which use for 3d and surface designing, plastic and mold designing, photo realistic rendering, FEA analysis etc.
• In this project we do solid and surface modelling for designing of parts and then these parts where assemble together in Solidworks software.

Parts modelled in Solidworks are:-

Transmission belt

It is used transmit power from engine shaft to another shaft.

Some tools used for the designing of the transmission belt are:-

• Boss-extrude
• Fillet

Kick stand

It is used support the chopper when not in use. It is pivoted to the chassis.

Features used to design kick stand are:-

• Loft
• Dome
• Boss-extrude
• Cut-extrude
• Fillet
• Split

Front fender

It is used to protect to tyre and wheel from debris.

Features used to design front fender are:-

• Revolve
• Split
• Fillet

Rear fender

It is used to protect to tyre and wheel from debris. In this project we have designed rear fender and used a sticker for decal.

Features used to design front fender are:-

• Revolve
• Split
• Fillet
• Shell

Oil tank

Oil tank is used to store oil for lubrication of parts. In this project we use a sticker for decal.

Features used to design oil tank are:-

• Boss-extrude
• Combine
• Fillet
• Shell

Chain

It is used transmit power from engine to rear wheel.

Features used to design chain are:-

• Boss-extrude
• Circular pattern
• Fillet
• Mirror

Pedal

Pedals are attached to chassis and use by the rider to rest his feet while riding.

Features used to design pedals are:-

• Boss-extrude
• Dome
• Fillet
• Chamfer
• Revolve
• Linear pattern

Front wheel

Front wheel has disc brake attached to it to which a brake calliper attached. The front wheel is attached to the front fork.

Features used to design front wheel are:-

• Boss-extrude
• Cut-extrude
• Fillet
• Chamfer
• Revolve
• Circular pattern
• Combine

Rear wheel

Rear wheel has disc brake and chain sprocket attached to it. The disc brake has brake calliper attached to it. The rear wheel is attached to the chassis. The engine transmit power to the rear wheel by transmission belt and chain.

Features used to design rear wheel are:-

• Boss-extrude
• Cut-extrude
• Fillet
• Chamfer
• Revolve
• Circular pattern
• Combine
• Cut-revolve

Front fork

Front wheel is attached to the front fork. The front fork acts as suspension for the front wheel. The front fork has handles and headlights attached to it.

Features used to design rear wheel are:-

• Boss-extrude
• Cut-extrude
• Fillet
• Chamfer
• Revolve
• Circular pattern
• Dome
• Cut-revolve
• Linear-pattern
• Sweep
• Combine
• Mirror

Chassis

Chassis is supporting frame used to mount the parts of the chopper. The blueprint of the chopper is imported and is use to model chassis.

Features used to design chassis are:-

• Boss-extrude
• Cut-extrude
• Fillet
• Chamfer
• Revolve
• Dome
• Split
• Sweep
• Combine
• Mirror
• Projected curve

Engine

Engine generates power using combustion of fuel for transmission of the chopper. The blueprint of the chopper is imported and is use to model engine.

Features used to design engine are:-

• Boss-extrude
• Cut-extrude
• Fillet
• Chamfer
• Revolve
• Dome
• Split
• Sweep
• Combine
• Mirror
• Projected curve
• Circular pattern
• Composite curve

Gas tank

Gas tank is used to store the fuel for power generation. The blueprint of the chopper is imported and is use to model gas tank. In this project, we use surface modelling for the part design and then it is knitted together and also stickers are used for decal.

Features used to design gas tank are:-

• Projected curve
• Cut-sweep
• Fillet
• Chamfer
• Split line
• Surface Sweep
• Surface trim
• Surface loft
• Boundary surface
• Surface knit
• Shell
• Mirror

Assembly of American Chopper

All the parts modelled which are mentioned are above are assembled in Solidworks assembly. In this project, we use coincident, concentric, tangent, distance, angle, limit angle, width and parallel mates are used.

Rendering of the American Chopper

Rendering feature is used for giving realistic effect to the model. It is an important feature used to know how the model once manufactured will look in the actual environment. Rendering is also used to dramatize the look of product for advertisement. In this project we used PhotoView 360.

Conclusion

All the parts of the American Chopper were modelled and assembled in Solidworks and the assembly was rendered in PhotoView 360 successfully.