FINAL INDEPENDENT PROJECT

MODELING OF VOLVO FH16-750 TRACTOR TRUCK IN SOLIDWORKS

OBJECTIVE

• To model 33 different components using solidworks with various tools, features and methods.
• To assembel the parts using mates and constrains to create the Truck.
• To add lighting and camera view for rendering.
• The final render with different views and scenes is done with PhotoView 360.

INTRODUCTION

SolidWorks is a solid modeling computer-aided design and computer-aided engineering computer program published by Dassault Systèmes, that runs primarily on Microsoft Windows. We can create both 3D modeling and 2D skeches in this software. Most of the parts created for the truck are solid bodies. Only the cabin part of the truck uses surface modeling. The primary goal of this project is to understand the function and usage of the tools and features for creating the parts. Most importantly we should understand when and where a particular tool or feature is to be used so that the total time spend on sketching and modeling a part would be minimal. The assembly of the truck will be performed using various mates and constrains and the final render will be performed in PhotoView 360 with the proper lighting, appearance and camera view for a realistic representation of the Volvo Truck.

DESIGN METHODOLOGY

In this design of the truck we are using Bottom-Up & Top-Down approach, which is to create the individual parts and assembel them using mates and constrains to create the whole model. The ladder frame will act as the fixed component.

TOOLS & FEATURES USED

• Offset

This tool helps us to displace a line or curve linearly in its perpendicular axis with defined length and direction. Here we can select the lines individually or by turning on "select chain" and clicking any one line, then the lines and curves which has tangential relation will also get selected.

• Extrude

This a feature that converts a 2D closed sketch to a solid body and the parameters needed are direction and length. Here the direction is selected as blind towards us with 88mm.

• Fillet

Fillet feature will create a curved edge to give the part appearance and reduce damage to edges. There is a radius parameter which is 1mm and the selction is done by selecting the inside and outside face. Because the edges are tangential to each other, so the whole edges will get selected which makes the process easy.

• Spline

A spline is a free hand drawn curve. We can chage its radius and if we enable tangent driving by clicking on the spline we can see a handle at each spline vertex. The handle has end arrow which gives the spline at that end a weight which is a parameter in millimeters and there is a up and down arrow at the midpoint of the handle which controls the angular rotation at that end of the spline. Here in this two point spline the spline will be straignt line but by clicking on the spline we made the bottom spline handle horizontal and the upper spline handle an angle of 55 degrees with respect to the vertical construction line.

• Make Pierce

This is a constrain that helps us to make the spline on a perpendicular plane to the plane of the elipse to be in contact with the center of the elipse.

• Loft

This tool is used where there are two similar or different sketches on two different planes to be converted in to a solid body with a defined path between the two sketch centers. As we can see in the figure there are two sketch profiles and a centerline parameter. The green dots controls the twist of the loft and will help us to snap to the correct locations.

• Cut Extrude

This feature performs the function of removing or substracting solid material from a solid body. The parameters include direction of cut which can be changed to a blind direction, through all, upto next, upto surface, upto body, offset from surface, upto vertex, midplane and through all both. We can also change from which plane the extruction should be done even if the sketch is on the other plane.

• Split

Split is a feature used to cut and remove a solid body from its parent solid body. This can be done by just drawing a line. In the split feature box we need to select the body to be remove and click on "consume cut bodies". The cut part can also be saved externally.

• Revolve

The revolve feature is similar to boss extrude, the only difference is that the extruction is circular. So the parameters include the axis of revolution and the directions are on the basis of angle of rotation.

• Shell

Shell feature lets us to convert a solid body to a shell body, which means that there will only be an outer thick wall. The parameter entered is the thickness of the shell wall. In this fender the shell is created on the inner face to create a ridge around the outer edge of the fender.

• Mirror

The mirror feature is used to create an exact mirror of the selected bodies by taking a reference mirror plane/face. Here the mirror bodies are just the chain plates and the mirror plane is selected as the midplain. To make the selection of the chain plates easy, in the solid body dropdown the chain plates are grouped together in a single file.

• Combine

In the model of the oil tank, there are several methods to create it. By using combine feature it is a three step procedure. First a skech is boss extruded from the top plain and a second sketch is also extruded in the right plain. Both the bosses are midplane extrudes. Then use the combine feature and select the two boss extrudes and check the "common" in operation type. The end result will the visual of the common solid that intresects with both the boss extrudes.

• Chamfer

The chamfer feature creates a angular cut at the edge of a solid body. Here the solid body is a cylinder and the type of chamfer is a "distance distance" type with two different distance parameters which will create a sharp point.

• Lineat Pattern

Linear pattern is a usefull feature which reduce time of modeling a particular feature which repeats itself in a linear direction. Here a ring like structure is linearly patterned and the parameters needed for this process is the number of instance and the spacing in between two instances. Also an edge is selected to identify the direction. We have selected the features, fillet and boss extrude to pattern, in the case of patterning a whole body we can check the body tab and add the solid body to pattern.

• Cut Revolve

This feature is similar to the cut extrude tool. Instead of linear extruction here the extruction is curcular with respect to the center point or axis of rotation. Here the extruction is 360 degrees.

• Circular Pattern

The circular pattern creates pattern of a body or a feature in circular manner. The parameters can include a circular face or edge, a point or an axis. Here there are 3 instances to create a 3 spoked wheel.

• Project Curve

The project cure feature will create a common cure which is reference with the two skeches in two different planes.

• Sweep

This feature will create a solid body with two parameters, a closed sketch and a curve. So a projected curve can be used to create a 3D sweeping extrude.

• Plane

A new plane can be created by using a reference plane and a line or an axis or even an another plane.

• Sketch Picture

The function of this tool is to help us to create a sketch or a model with the help of a reference image also called as blueprint. We can change its size and give some transparancy so that the skeching will be easy to perform in both sides of the sketch picture plane.

• Surface Sweep

With the parametres sketch profile and sketch path we can create a surface extrude.

• Surface Trim

With a sketch, we can trim away selected sections of a surface.

• Surface Loft

Like solid body loft, we can create surface with boundaries. Two adjacent profiles are selected and a guide curve acts as a boundary sketch.

• Boundary Surface

The side of the gas tank is a challenging part to make into a surface. We divided the surface into two sections. The right most end has a sketch and a mid sketch and left side also have a closing sketch. In the boundary surface tool box, there is a direction 1 box in it the top and bottom curves were entered. In the direction 2 box the sketches that made the sketch into two sections were entere. These all parametere enabled the boundary surface work and output the desired surface.

• Surface Knit

Knit surface convets the individual surfaces which have gaps in between them to a single connected surface.

• Split Line

The seat sketch is to be projected from a plane to the curved surface of the tank, so the tool split line is used and the parameters are the sketch and the surface the sketch is to be projected.

• Surface Extrude

The surface extrude a shelled varient of a boss extrude. Here we can use weather the top end should be caped or not and weather the bottom face should be present or deleted. We also can knit with in the tool box.

• Sketch Pattern

In such a case where we cannot use either linear pattern or cirrcular pattern, then we can use sketch driven patterns. Here for patterning a screw in the other three corners, we create new sketch in the plane we we want to pattern the screw. We make three points which are defined by dimensions. The feature takes this sketch as the location for the features of the screw to be patterened.

• Dome

The dome feature will convert a flat face into a dome with a length parameter.

• Helix/Spiral

It creates helix like 3D sketch with parameters include, constant or variable pitch, pitch, revolution, start angle and clockwise or counterclockwise.

• Extrude Thin

With the help of a line sketch we can create a solid body. In the boss extrude there is a thin feature option, in which we can add the thickness value along with the extrusion value.

• 3D Sketch

A 3D sketch is independent of planes. We can sketch any shapes or curves in the 3D space. We define the position of the sketch with help of constraining the points. We can convert a 3D edge using this feature.

• Thicken

It gives thickness to the selected surface.

DESCRIPTION OF PARTS

1. Cabin

It is the enclosed section where the driver sits and drives the truck with the in built controlls and protects him/her from external elements.

Feature Tree

2. Connecting Rod

It connects with the piston and the crankshaft. It converts the linear motion of a piston to rotational motion with the help of crankshaft.

Feature Tree

3. Crank Shaft

It is that shaft which transfers the linear motion of the piston to a rotational motion with the help of connecting rod. It act as the output shaft for power supply.

Feature Tree

4. Cross Pin

It is the connecting pin which is in the shape of a cross for the universal joint. It allows the axial rotation of the two shafts with 90 degree difference.

Feature Tree

5. Engine

It is the heart of the truck. It converts chemical energy into mechanical energy.

Feature Tree

6. Belt

It transfers rotational motion from one pulley to an another.

This component was made in the engine sub assembly with the help of Belt/Chain tool in the assembly features drop down box. After selecting the two pulleys outer surface check on "create belt part".

Feature Tree

7. Engine Hub

It engages with the belt to receive the rotational motion from crankshaft for the working of the over head valves.

Feature Tree

8. Fifth Wheel

It is the component which connects any trailer or container to the truck using hooks and other mechanisms in the fifth wheel. It is positioned a the rear of the truck in between both rear tyres.

Feature Tree

9.Front Axle

It is the structure which holds the front wheels and give stuctural stability at the front of the truck.

Feature Tree

10. Front Wheel Hub Right

This is the component which rotates in its axis and houses the bracking system and the extensions for the steering mechanism. The front right wheel is bolted on to his component.

Feature Tree

11. Front Wheel Hub Left

The front left wheel is bolted on to his component.

Feature Tree

12. Gas Tank Left

It is rectangular container which carries the fuel placed on the left of the truck.

Feature Tree

13. Gas Tank Right

It is rectangular container which carries the fuel placed on the right of the truck.

Feature Tree

14. Ladder Frame

It is the most important structure of the truck. We can say its the back bone of the tuck. It is shaped as a ladder because it has two long section connected with several perpendicular smaller sections.

Feature Tree

15. Middle Differential Axle

It is the shaft which has the differential gear for receiving the rotatinal torque from the transmission shaft and to connect the wheels through wheel hub. It is called the middle shaft because it gives power to the middel wheels of the truck.

Feature Tree

16. Middle Differential Case

It holds the middle differential axle and the suspension system. It is the component which connects to the ladder frame.

Feature Tree

17. Middle Transmission Shaft

This shaft transfers power from engine to the middle wheel differential using universal joint.

Feature Tree

18. Middle Universal Shaft

It is a short universal shaft which joins the middle transmission shaft and the cross pin.

Feature Tree

19. Mudguard

It protects other componenets from mud and other particles which is stuck on the tyres.

Feature Tree

20. Piston

It is a cylindrical part inside the engine which is free to move up and down. The combustion of the air-fuel mxture will propell the piston downward to receive mechanical energy from chemical energy.

Feature Tree

21. Rack

It is a rectangular block with gear teech on one side to covert the rotational motion from a pinion to a linear motion.

Feature Tree

22. Rear Differential Axle

It is the shaft which has the differential gear for receiving the rotatinal torque from the transmission shaft and to connect the wheels through wheel hub. It is called the rear shaft because it gives power to the rear wheels of the truck.

Feature Tree

23. Rear Differential Case

It holds the rear differential axle and the suspension system. It is the component which connects to the ladder frame.

Feature Tree

24. Rear Transmission Shaft

This shaft transfers power from engine to the rear wheel differential using universal joint.

Feature Tree

25. Steering Link

It is a shaft which links the rack and steering rod.

Feature Tree

26. Steering Mechanism Cross Pin

It is the cross pin used for the steering universal shaft.

Feature Tree

27. Steering Rod

It is component which joins both the front wheels and the linear motion of this rod will enable the wheel to rotate in a particular direction.

Feature Tree

28. Steering Universal Shaft

It is a shaft for the steering mechanism which is integrated with the pinion gear and it connects the steering wheel and the to the pinion using a universal joint.

Feature Tree

29. Steering Wheel

It is the front wheel direction control input device for the driver.

Feature Tree

30. Universal Geared Shaft

This is the shaft which meshes with the large gear on the differential axle and transfers the rotational motion in a 90 degree with the help of spiral bevel gears. The other end has a universal joining features.

Feature Tree

31. Universal Shaft

This shaft has a universal joining end for transfering rotational motion to an another shaft at an angle.

Feature Tree

32. Wheel

It is the part which enables forward and backward movement for the truck. This part uses the torque produced by the engine and transfers into the ground for movement.

Feature Tree

33. Wiper

It slides on the front wind screen to and fro for removing the rain water to enable perfect visbility of the road in front.

Feature Tree

ASSEMBLY OF THE CHOPPER

The ladder frame is the part which is fixed in place and helps as a reference for mating other components. The only mirrored part is the mudguard.

Mates Used

• Coincident: This mates makes the selected entities on the same plane.
• Distance: We can set a distance parameter between two entities.
• Concentric: The selected circular edge or a vertex will have a common center after applying this mate.
• Limit Angle: It gives a component a rotational constrain by giving maximum and minimum angle.
• Width: It mates a component at a midpoint of another component by selecting two wnd faces.
• Angle: It gives an angular constrain between two entities.
• Parallel: It makes two entities parallely constrained.
• Tangent: A tangential relation is given to a circular edge and a line or a face.
• Rack Pinion: This mate enables a rack and pinion to mate and convert the rotational motion of the pinion to the linear motion for the rack. In the selection box for rack, the base edge of the rack is selected and for the pinion the circle is selected which is at the mid of addendum and dedendum circle.

Sub-Assemblies

• Engine Sub-Assembly

The piston, crankshaft, connecting rod, engine hub and the belt which is modeled with in the assembly is used for the engine sub-assembly.

• Middle Axle Sub-Assembly

In this sub assembly there are middle differential axle, middle differential case, two universal geared shaft and four wheels.

• Rear Axle Sub-Assembly

There are rear differential axle, rear differential case, universal geared shaft and four wheels.

Assembly Model Rendered Views

• Front View

• Side View (Left Side)

• Isometric View

• Camera View

• Top View

Rendered Parts

• Belt

• Cabin

• Connecting Rod

• Crankshaft

• Cross Pin

• Engine

• Engine Hub

• Fifth Wheel

• Front Axle

• Front Wheel Hub Left

• Front Wheel Hub Right

• Gas Tank Left

• Gas Tank Right

• Ladder Frame

• Middle Differential Axle

• Middle Differential Case

• Middle Transmission Shaft

• Middle Universal Shaft

• Mudguard

• Piston

• Rack

• Rear Differential Axle

• Rear Differential Case

• Rear Transmission Shaft

• Steering Link

• Steering Mechanism Cross Pin

• Steering Rod

• Steering Wheel

• Steering Universal Shaft

• Universal Geared Shaft

• Universal Shaft

• Wheel

• Wiper

Rendered Sub-Assembly

• Engine Sub-Assembly

• Middle Axle Sub-Assembly

• Rear Axle Sub-Assembly

Rendered Images of Assembly with Scenes

CONCLUSION

After finishing this project, i understood the various tools and features and when and where to use them for sketching and modeling a component efficiently. Learned some tips and tricks. Performed adding decals, lighting and camera view to the Yacht and understood tools on how to make the model more realistic for a final render after adding scenes. Acquired more knowledge on surface modeling. After completing this independent project,i acquired more knowledge about top down approach in designing and advance mates.