American Chopper Modelling

Design of American Chopper using Solidworks

Introduction

This report contains a detailed explanation of design an American Chopper using Solidworks from part modeling to final rendering of the assembly.

Objective:

The objective of this project is to learn the tools and its operations in solid works.

*Design the model of different components.

*Assemble all parts of the chopper in the assembly.

*Finally render the American chopper.

Parts Modeled for Chopper:

The following Parts of the American Chopper are Modeled and assembled in SolidWorks.

• Transmission Belt
• Kickstand
• Front fender
• Rear fender
• Chain
• Oil Tank
• Pedal
• Front Wheel
• Rear Wheel
• Front Fork
• Chassis
• Engine
• Gas Tank

FEATURES DESCRIPTION:

SKETCH:

• Sketch is a two-dimensional representation of the model with respect to the plane / view from the outside of the model. There are distinct sketch possibilities available
  in solid works to create a sketch. These are referred to in solid works as Entities. The following are the parts available in Line, Arc, Spline, Circles, Rectangular solid works.

OFFSET:

• A specified distance includes one or more sketch entities, selected model edges, or model faces. For example, you may offset sketch entities such as
  splines or arcs, model edge sets, loops, and so on. Finite lines, circles, and splines may be offset.

EXTRUDE BOSS/BASS:

• Extrude is a form of function available for transforming a 2D sketch into a 3D model in solid works.

LOFTED BOSS/BASS:

• The loft function creates a single feature to produce complex geometry. It provides this by interpolating surfaces between a model's different cross-sections. Sketches, faces, or edges
  may be these cross-sections. These cross-sections are called 'Loft Profiles' in the loft interface.

FILLET:

• A rounded internal or external face on the component is created by Fillet / Round. All the edges of a face, selected sets of faces, selected edges, or edge loops can be filled.

CHAMFER:

• A cut on something's edge or corner that makes it slope slightly instead of being perfectly accurate.

SPLIT:

• The Split tool is used to project an object onto other surfaces or curved / planar faces (sketch, solid, surface, face, plane, or surface spline). You're also capable of splitting faces into

  different bodies with one order.

DOME:

• Choose one or two planar or non-planar faces. For faces whose centroid lies outside the face, you can apply domes. This helps you to add domes to contours which are irregularly shape.

EXTRUDE CUT:

• Another great feature, Extrude cut, helps remove materials from the 3D model.It is just the opposite of the boss / base extrude feature, since while extruding, it cuts a sketch profile.
  You can cut in both directions and use them exclusively to create holes, channels, slots, etc.

REVOLVE:

• Create a sketch containing one or more profiles and a centerline, line, or edge that can be used as the axis around which the feature revolves. Tap on one of

  the following revolving tools.

DYNAMIC MIRROR:

• The important tool in solid works is the Dynamic Mirror. When you sketch the entities, the pre-selected sketch entity mirrors them.

COMBINE:

• Combine is the type of feature available for manually merging the two bodies in solid works.

TRIM ENTITIES:

• Based on the entities you choose to trim or expand, pick the trim form. With 2D sketches and 2D sketches on 3D planes, all trim forms are available. Any of the following trim

  options can be used: Power trim.

SHELL:

• For determining the thickness of thin and thick shell components, the Shell Definition Property Manager is used.

LINEAR PATTERN:

• To create a different number of instances needed to create the pattern linearly, the linear parent bodies / features are used.

CIRCULAR PATTERN:

• To generate a different number of instances needed to create the pattern circularly, the circular parent bodies / functions are used.

SURFACE MODELING:

• Surface modelling allows you the opportunity to produce a visual depiction of the exterior of an object and its contours. It is, in other words, a surface. Parts such as the seat and
  the classic 350 fuel tank are surface-modeled.

APPEARANCES:

• An appearance, including colors and textures, determines the visual properties of a model. Physical properties, which are determined by materials, are not affected by appearances.

  A default appearance that emulates the look of the material is given to any material.

DESCRIPTION OF THE PARTS AND FEATURES USED:

1. Transmission Belt:

* The transmission belt is used to transfer power from the output shaft of the engine to the input shaft of the gear box. Polyster material with the layers or kevlar and sandwich with

metallic wires is usually made. It's a combination of different components that gives it strength to transfer the full horse power produced from the motor to the gear box.

* The transmission belt profile is produced according to the dimensions of the front plane, with a thickness of 3.5 mm provided to the belt. The belt is extruded after

FEATURES USED:

• Boss Extrude
• Fillet

2. Kick stand:

Kick stand is a supportive framework provided to a bicycle or motorcycle to help it stand while stationary in a vertical position.

FEATURES USED:

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

The body of the kick stand is built using the loft. To build the rounded end of the kick stan, the elliptical dome feature is used.At the top end of the stand, a slot with an extruded boss is

formed by connecting it to the chassis. The sharp edges of the stand are finally supplied with fillets. The appearance of the Chrome plate will be added to the kick stand.

3.FRONT FENDER:

• Sketch
• Offset Entities
• Trim entities
• Revolve
• Dynamic mirror
• Split
• Appearances

5.CHAIN

Chain is the connection used to transmit power from the engine to the rear wheel. It passes over toothed member known as sprockets.

FEATURES USED:

• Sketch
• Trim
• Fillet
• Blocks
• Extrude
• Mirror
• Patterns
• Appearances

6.OIL TANK

• Sketch
• Boss Extrude
• Combine
• Fillet
• Shell
• Appearances

7.PEDAL

The external part mounted to the frame is the pedal. To rest the leg on top of that, the pedal is used. The pedal is used for the convenience of the rider

FEATURES USED:

• Sketch
• Extrude
• Fillet
• Linear pattern
• Dome
• Chamfer
• Appearances

8.FRONT WHEEL

A wheel is a circular block of a hard and durable material with a circular hole through an axle bearing around which the wheel rotates, where the middle has been drilled.

FEATURES USED:

• Extruded Boss
• Cut Extrude
• Revolved Cut
• Circular Pattern
• Combine
• Fillet
• Chamfer

Initially, by sketching on the front plane, the rim is formed and the rotated extruded using an imaginary axis at the origin. On the front line, a spider web pattern of the rim is formed and

is extruded using the functionality of mid plane extrusion. And this spider web is patterned circularly to the numbers necessary and the rim is finished. To form a single solid body, the

spider web spokes and the rim are merged.

9.REAR WHEEL

A wheel is a circular block of a hard and durable material with a circular hole through an axle bearing around which the wheel rotates, where the middle has been drilled.

FEATURES USED:

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

10.FRONT FORK

For the front suspension, most bikes today use telescopic forks. The forks with internal coil springs can more readily be understood as essentially large hydraulic shock absorbers.

They cause the front wheel to adapt to road imperfections while isolating the remainder of the motorcycle from the motion. To provide comfort to the rider, it removes the bums.

FEATURES USED:

• Extruded Boss
• Revolved Boss
• Fillet
• Extruded Cut
• Dome
• Revolved Cut
• Swept Boss
• Project Curve
• Mirror
• Combine

Project Curve:

The project curve is the type of 3D curve that is projected on the basis of two separate 2D sketches.

Sweep:

We can create a form with the Sweep function by moving a 2D sketch profile along a 2D or 3D sketch path.

11.CHASSIS

Its skeleton shapes the chassis or assembly. All of a motorcycle's parts, such as the suspension, wheels, fuel tank, seats, handlebars, etc., are related to this simple structure

that gives a motorcycle its power and capacity to handle well.

FEATURES USED:

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

12.ENGINE

An engine or motor is a system that is designed to transform mechanical energy into one type of energy. Heat engines burn a gasoline, such as the internal combustion

engine, to produce heat that is then used to do work.

FEATURES USED:

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

13.GAS TANK

A safe reservoir for flammable fluids is a gas tank (or petrol tank). The term is usually applied to part of an engine structure in which the fuel is contained and pushed (fuel pump) or

released (pressurised gas) into an engine, but any holding tank for fuel may be called so.

FEATURES USED:

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

LOFTED SURFACE:

• Loft surfaces are surfaces developed by several 3D curves or existing edges that create a smooth tangency between the curves chosen.

SWEPT SURFACES:

• Sweep Surfaces are surfaces created along a path from a segment curve.

FILLED SURFACE:

• A surface patch with any number of sides is built by the Filled Surface function, inside a boundary defined by existing model edges, sketches, or curves, including composite curves.

SURFACE TRIM:

• It is mainly used to cut material away from a board, and offers two modes: Normal and Shared.

EXTEND SURFACE:

• To expand the surface that is already made, Extend Surface is used. On the expanded board, there are various choices available. We can expand the surface to the same surface, or
  we can extend the tangent of the surface to the surface.

SURFACE KNIT:

• The two free edges / open edges of the surfaces are knit together by Surface Knit. It also eliminates the distance between the two surface edges.

Assembly of the American Chopper

1. In Solid Works, all the designed parts are taken into the assembly section and the whole assembly of the American Chopper is produced using distinct mating

characteristics such as concentric, coincident, parallel, etc. The decals are added to the chopper after assembly.

2. I used multiple possibilities for limitations, such as Coinsident, Concentric, Tangents, and Distance, when making Assembly.

3. In addition, by considering the geometry simulation features (plane surfaces and vertices), I added the above-mentioned limitations

FEATURES USED:

• Mates
• Insert part

Mates:

Mates build geometric relations between components of the assembly. We define the permissible paths of linear or rotational motion of the components as we add matches.

Inside their levels of independence, we may transfer a part, visualising the actions of the assembly.

RENDERIND

• Rendering is the method of making with the reality accurate representations of the Photorealistic model.
• In SolidWorks, rendering has been accomplished in two respects. The two manners are as follows,

1. 360 Photoview
2. Visualize Solidworks

• Any of the mate conditions and locations are
  altered in the photorealistic model to make realistic ones.
  
  
  Then, from various perspectives, the photorealistic
  model is turned into functional pictures.

Conclusion :

• The components of the chopper are sketched and modelled in SolidWorks.
• The components are placed into the setting of the assembly and assembled by applying the mates' chopper.
• Using 'Photoview 360 & SolidWorks Visualize', the realistic image was rendered.