Jafri_Chopper Report

Objective:

The Objective of this project is to re-create the American Classic with the use of technology at our disposal.
We would be creating all the individual parts like wheels, chassis, tank etc with the use of SOLIDWORKS.
Post creation of parts they would be assembled with the use of Assembly feature within SOLIDWORKS.
Finally we would be using PHOTVIEW360 to apply proper aesthetics like Lights, Camera, Background environment, Backdrop lights, Shadows etc. in accordance to real world scenarios.

Requirement:

We need Solidworks version 2015 and above for the creation and assembly of individual parts for the Chopper.

We would require PhotoView360 or Solidworks Visualize interface for the rendering process.

Method Followed:

1. Parts Creation:

SOLIDWORKS interface offers us a variety of features in order to create the desired model. Below mentioned is a short description of the tools used to create parts for the American Chopper under the tab SKETCH.

1. Line/Centre Line: As the name suggest we are able to create Lines using this tool both for creation of the model and creating references.
2. Circle: We can create a circle with the use of a centre point/ radius or we can use the perimeter.
3. Rectangle: We can create a rectangle with the use of different options corner rectangle, centre point rectangle, 3point corner rectangle, point centre rectangle and a parallelogram.
4. Slots: We have different types of slots but in our model, there is straight slot, centre point straight slot, 3point arc slot and centre point arc slot. We only make use of straight slot.
5. Arc: We use this tool quite often in our model creation. There is 3point arc, centre point arc and tangent arc.
6. Spline: This is an important tool in our arsenal towards the model creation. We have made use of only spline however there also is equation driven spline and Style spline.
7. Fillet: This is a tool heling us to smooth out edges/corners. We make use of fillet and Chamfer.
8. Trim Entities: This tool helps us in the removal of any excess material. There is also an option to extend part to the next sketch.
9. Convert Entities: The tool helps us to bring a sketch made on different plane into the current sketch. There is also an option to use intersection curve which is used for spherical/rolled models.
10. Offset entities: The tool helps us to create the same sketch but at an offset from the diagram.
11. Mirror: The tool helps us to copy the sketch along an axis.
12. Linear/ Circular Pattern: The tool helps us to copy the diagram in a linear or circular fashion.
13. Smart Dimension: We can define dimension of our diagram with the use of this tool.
14. Add Relation: The tool helps us decide whether our sketch has been defined completely. A fully defined sketch is always best.
15. Sketch Picture: We can bring in a picture for reference from Tool Sketch tools Sketch Picture.
16. Block: This tool helps us define a sketch as a block and hence forth allow us to insert the same in different sketches.

The Other feature used is the Features/Surface Tab. This where we define the thickness of the design to generate the model.

1. Extrude Boss: We can provide instant thickness to any contour sketched by us.
2. Revolve Boss: We can provide thickness to our sketch by rotating it about an axis.
3. Swept Boss: We can provide thickness to our sketch by sweeping contour along a path. There is an option to use guide curves to achieve better results.
4. Lofted Boss: We can provide thickness to our sketch by joining two contours along a path and define guide curves for creating our model.
5. Boundary Boss: We can provide thickness to our sketch by defining the boundary of contour to be joined.
6. Extruded Cut: Removes the material of the contour.
7. Revolved cut: Removes the material by revolving the sketch about the axis.
8. Swept Cut: Removes material by sweeping across the path.
9. Lofted Cut: Removes the material along the two sketches along a path.
10. Fillet/Chamfer: We can round the edges of our model with the use of this feature. We have the option to create a new edge.
11. Pattern: We can remove or add material for our model by selecting the feature, body in a linear fashion or in circular fashion.
12. Shell: We can provide thickness to the model created in order for it to be hollow.
13. Split: The construction of a line can removes the material with the use of split by selecting the surface to remove. We can also use it to remove the coincident/ merged point of two or more surfaces and remove the unwanted part.
14. Combine: We can merge together two or more single parts into one with the use of this feature.
15. Dome: This feature allows us to create a lift a surface into a dome fashion.
16. Reference: This helps us to create Plane and Axis with the use of reference points/plane/surface/vertex.
17. Curves: We use this feature to create 3d curves by the use of two or more reference sketches. We can combine two or more curves with the use of composite curve. We can split a face into parts with the use of split line.
18. Knit Surface: This is only in surface to join two or more surface together into one.

The initial step to create required parts with defined material for the creation of an American Chopper as listed below:

• Transmission Belt:
  
  Image: Isometric view of the Transmission Belt

A transmission belt helps us to transmit the power generated by our engine to our wheels that are not axially aligned. These are simple, inexpensive, minimal lubrication, maintenance is low. The clutch is used by releasing the tension in the belt. Different speeds can be achieved by manipulating stepped or tapered pulley.

PROCEDURE:

1. Sketch on Front Plane by selecting it, draw a horizontal line from Origin and a 3 Point arc. Apply relations like Tangent with line,etc. & give dimensions to make it fully defined.
2. Make an Offset of 3.5mm of the sketch inward direction.
3. Extrude the created sketch by giving appropriate dimensions.
4. Apply fillets to all sides of Extrude sketch for Smooth finish.
5. Give Appearance to the part.

• Kick Stand:
  
  Image: Isometric view of the Kick Stand

This part keeps the bike from tipping over when there is no person sitting on it. The kickstand helps the bike to achieve equilibrium by being in contact with the ground and bike.

PROCEDURE:

1. Sketch on the Front Plane, by drawing an ellipse which is horizontal to origin and give dimensions and relations to make it fully defined. Then Sketch on the Right Plane, by drawing a spline from origin, activate handle and dimension it.
2. Create a new Plane at the end of Spline, sketch on it by drawing an ellipse and make Pierce relation between Spline and Ellipse mid point.
3. Now Loft the Part using both sketches. Active loft on spline and check coincidence for desired output.
4. Apply Elliptical Dome to the end of spline and remove the unnecessary Portion using Extruded cut.
5. Apply Fillet & Appearance to the Part.

• Front Fender:
  
  Image: Isometric view of the Front Fender

A fender typically is a cover for the tire since that comes in contact with the ground. The idea is to prevent any mud, rocks, liquids, slug gets thrown into the air when the rires are rotating.

• Rear Fender:
  
  Image: Isometric view of the Rear Fender

A fender typically is a cover for the tire since that comes in contact with the ground. The idea is to prevent any mud, rocks, liquids, slug gets thrown into the air when the tires are rotating.

PROCEDURE:

1. Sketch on Front Plane, by drawing a 3 Point arc above the origin apply vertical relation with origin. Apply Offset inwards, to extrude make it closed sketch using extended entities & trim entities.
2. Revolve the Sketch across the horizontal construction line at origin by giving proper directional angles.
3. Remove the Unwanted area using the Split tool and apply fillet.
4. Give Desired Appearance to make it realistic.

• Oil Tank:
  
  Image: Isometric view of the Oil Tank

As the name suggests this is a contaciner for holing oil. The purspose of the oil tank varies as per our engine design. Most times the use is to ensure the engine has enough oil and there is smooth operation. There can also be coolants for the engine.

PROCEDURE:

1. Sketch on Top plane by drawing line, 3 point arc and give relation, dimension them for fully defining, extrude it.
2. Sketch on the Front plane by drawing a spline, line dimension them to make it fully defined and extrude it by midplane, through all and combine two separated bodies.
3. Apply Fillet and give appearance.

• Chain:
  
  Image: Isometric view of the Chain

The idea of chain is to transmit the power generated by the engine to the Rear wheels. The one is question is a Roller chain used on bikes, this consists of outer plate, inner plate, pin, bushing and a roller. This complete set up can ensure efficiency of upto 98%.

PROCEDURE:

1. Sketch on Front Plane, by drawing two circles of different diameter, separated by a distance & connect them using 3 point arc on both sides,trim the unwanted portion.
2. Create a throwaway sketch which is used to create inside and outside chain links. Make a block of these and save it.
3. Insert Blocks on the larger end of the drawn circle and make a coincident relation. Extrude the sketch by selecting holes in inserted blocks as contours to create Pins. Extrude again to create Plates by selecting the remaining part in blocks & apply fillet. Repeat the Process.
4. Use a Curve driven pattern to get required number of Pins & Plates over the curve.
5. Repeat the process over other curves to get desired output.

• Give appropriate Appearance to the part.

• Pedal:
  
  Image: Isometric view of the Pedal

Pedal on our bikes serve multi purpose. Manuplating the position of the pedals help us to swirch gears to increase or decrease speeds during transmission. The other ides is also to provide a resting place for the rider.

PROCEDURE:

1. Draw a sketch on the front plane, line & spline from origin and give dimension to make it fully defined. Extrude it and apply fillet. Select the front surface of the extruded part and sketch on it by drawing two circles. Use a dome circular feature.
2. Apply Linear Pattern across the boss extrude. Use distance - distance chamfer to it.
3. Give Appearance to the part.

• Front Wheel:
  
  Image: Isometric View of Front Tire

The Wheels have been in existence since the Neolithic age. They have served us for millions of years in transportation. In the case of bikes specially choppers the front wheel is always larger in diameter and slimmer when compared to its companion. These models help us ensure us the turning motion is smoothly achieved. If we take a close look at our image we can notice the disc brake gripped by a caliper is also mounted on the front wheel.

• Rear Wheel:
  
  Image: Isometric View Rear Tire

The Rear Wheel in the case of a chopper bike is Large and wide. The reason is to provide max traction between the road and the bike to avoid any splipage. If we take a close look at our image we can notice the disc brake gripped by a caliper is also mounted on the rear wheel.

PROCEDURE :

1. Select Front Plane and sketch the outer part of wheel and dimension it to make fully defined.
2. Revolve the sketch across the temporary axis.
3. Sketch on Right plane, by drawing a vertical Construction line from the origin and one more line at an angle. Draw a spline and mirror all the three entities across vertical construction line, extrude them.
4. For Spider webbed design, Offset all the drawn three entities and remove the unwanted part using cut extrude.
5. Connect the spokes using 3 point arcs, offset them and make it closed sketch by using lines. Extrude the sketch.
6. Select the front plane and a draw a spline from origin to remove unwanted area using extrude cut.
7. Select Spokes and use a circular pattern. Combine them to make a single solid body.
8. For Rotor- sketch on the front plane, by drawing a circle and extruding it, removed the unwanted portion. Use a circular pattern to create holes over the rotor.
9. For Caliper - Draw circles and lines as per design of body. Remove the unwanted area by trimming & extrude it. Apply Chamfer.
10. For Sprocket - Draw a circle and extrude it. Apply chamfer to the outer part & create teeth by cut extrude to it. Remove the unwanted portion by using cut extrude & Apply fillet.
11. For Tyre - Use Rim as Convert Entities & revolve. Draw rectangles and apply dimensions, relations to make it fully defined. Extrude cut it & apply fillet.
12. Give Appearance to Rotor, Rim, Caliper, Sprocker & Tire.

• Front Fork:
  
  Image: Isomteric View of Front Fork

We have different types of forks for chopper bikes like Telescopic, inverted, springer and girder. In our case we have a Telescopic. Lower sleeve slides up into the upper sleeve within the tube there is a coil spring. The compression of spring provides a smooth ride.

PROCEDURE:

1. For Fork tube - Sketch on the Front plane, by drawing a cylindrical diagram using line and give dimensions, relations to make it fully defined, then revolve it.
2. For Triple Clamps - Select Top Plane and draw a concentric circle to the fork tube and draw another circle left and upward. Connect the circles and make it fully defined by giving dimensions, then extrude it.
3. For Bulb - Select Front Plane, draw a horizontal construction line, spline and revolve it. Move the bulb in z direction then fillet it.
4. For Handle & Brake wires - Select Top plane and draw the handle using spline, make it fully defined. Draw a circle at the end of the spline and sweep along the path.
5. Select the Bodies Mirror it and combine.
6. Give Appearance to the fork to make it realistic.

• Chassis:
  
  Image: Isometric View of the Chassis

Frame of a bike or in this case a chopper is a crucial part of design element. This frame provides a base to build/ join the model together. Where to attach the rear wheel and front wheel, where to mount the engine.

PROCEDURE:

1. Insert Blueprint of chopper in the front plane ,adjust the location, transparency & sketch on it. Draw two concentric circles with an offset of 4mm.
2. Draw a horizontal & vertical line from origin. Then a spline connects the circle center and tangent to the horizontal line and gets a projected sketch.
3. Sketch on Top Plane, draw a horizontal line parallel to the line and draw on the front plane connected with the spline to make it fully defined.
4. Next Sketch on Right plane, draw a spline from top to bottom with relation to origin and make it fully defined.
5. Remove the unwanted area using cut extrude, Mirror the bodies and combine.
6. Apply fillet, Chamfer and give appearance to it.

• Engine:
  
  Image: Isometric View of the engine

This is the heart of any bike is its engine. This decides how fast would a bike go and how well can it perform. In most chopper’s V-twins are used in iconic fashion as meant to. This where the fuel is mixed and compressed to generate the to and fro motion for the pistion in the case of diesel engine. In the case of petrol engines the compreseed fuel air mixture is ingnited with sprak plugs to provide to and from motion of the pistons. The Pistons in turn are coneected in a V orientation to ensure when one is compressing the other is expanding. This linear motion is converted over to the rotors which with the help of bevel/ sun gears/ spur gear depending on the design trasnmoit the power onto the chain and wheels. Thus achieveing motion.

PROCEDURE:

1. Insert the picture according to X,Y,Z reference, Select the front Plane draw a diagram of base of engine by using line and 3 point arc, extrude it. The again extrude it on the large circle and small one.
2. Sketch on the front plane by line entities then extrude it and give fillet to the base of the engine.
3. Select a top plane, draw the pulley by line and then turn on a temporary axis to revolve it.
4. Sketch on Pulley by selecting on edge then draw rectangle and extrude towards outside to next surface then select sketch and make circular pattern.
5. Select the outer face of pulley and sketch on it, draw a circle inward then draw a small circle vertically to origin, use the circular pattern feature , select the center point respectively and coincident. Then use the cut extrude feature to remove the material.
6. Select the front plane to create the cylindrical part of the engine. Draw a line from origin again draw a line which will be collinear to line. Generate the new plane by selecting the line and end point of the line. Sketch in a new plane, draw a rectangle and extrude it upward. Use fillet as well. Create an angle rectangle to the new plane and use cut extrude.
7. Draw a curve, sketch 2D Diagram in two different plane by ensuring the end point should be same, use the feature like convert entities, Construction line, Spline after getting projected curve, draw two concentric circles, make use of Pierce relation to curve then sweep it.

• Gas Tank:
  
  Image: Isometric view of the Gas Tank

A container to store fuel is an essential part of any transportation. Here we have the opputunity to design the tank in a fashion that it provides the aesthetics and does the job of storage as well.

PROCEDURE:

1. Insert Blueprint in the front plane and give proper dimensions for locating and rename it.Sketch on front plane by drawing construction lines, Spline roughly as per sketch picture & give dimension to make it fully defined.
2. Create a plane at the end point of the spline and sketch on it, by drawing another spline & make a pierce relation with sketch 1, then sweep the surface.
3. Sketch on Top Plane by drawing a spline & lines. Trim the outside portion using a trim surface.
4. Create one more plane using the front plane & end point of surface 2 as reference. Sketch on it, by drawing a spline and a vertical construction line to dimension it.
5. Draw two sketches on Front Plane & Mid plane, using spline and line, then project curve and use lofted surface along projected curve.
6. Repeat the procedure for sketching the remaining surface, mirror it & apply knit surface.
7. For Seat - Select the outer edges and offset it and then extrude, apply fillet.
8. Remove the unwanted surface using a swept cut & apply shell to the body.
9. Give appearance to tank as well as driver seat.

Parts Assembly:

The Second step is to Assemble the parts with respect to each other. With the use of constrains while matting or bringing them together with the help of features like Coincidence, Concentric, Angle, Distance, Parallel, Width Defining, Tangency, Limit angle etc.

1. These constrains can be between two points of the model, two surfaces, two planes, two vertexes, two edges or this could be combination of a plane and surface, plane and edge etc. We can shuffle through any two options and constrain them together to assemble the model.
   

Image: Isometric View of an Assembled Chopper

1. Rendering Model:

The Final step towards completion would be Rendering of the Chopper. In this section we would be applying aesthetics (Lights, Shadow, Environment, Back drop light and camera views) to mimic the real world with the help of PHOTOVIEW 360.

1. Appearance:
   Here we can provide our model the appearance we desire by applying a material like glass, Metal, Paint, Rubber, Lights etc. This can be done by a simple drag and drop on the body or surface that we so wish to provide the material to.
2. Decals:
   Here we can apply crafty symbols/ designs onto the surfaces that we want. We use mapping for defining the location and illumination for brightness of the craft.
3. Scenes:
   Here we can add the environment in the back of our model. This utilizes the light in the environment as the light for our model. This could be in an Office room, Back yard, Factory, Living room, Beach, Mountains etc. We can define the amount of reflection from the environment onto the model and the brightness of the scenery.
4. Lights:
   We have option while adding lights like Directional Light, Spot Light, Point Light and Sunlight.
   We have used the Directional light we get the option to choose where longitudinally and latitudinally be located and then define the brightness created by them the light. We also have to define the shadow intensity and quality that it creates.
5. Camera:
   In this option we can create a camera of specified lenses power by defining options like filed of view angle, Length, height, Depth of field etc. while aiming at the target/Model.
   We can also position our camera for animation purpose on a specific body Ex: It would rotate around the model.
6. Options:
   One of the most important features that decides the resolution of the picture that will be rendered and quality of it.
   Here we can define the photons from the surface for reflection (Caustics) and level of brightness on the surface of those lights (Bloom).

Conclusion:

At the end of Project each and every component designed individually in part file and assembled them to complete Chopper Design. Additional Appearances/setup like Decals, Scenes, Camera, Lights given to make it more realistic & Finally Rendered after placing designed Chopper in decent background Scenes.