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DESIGN OF AMERICAN CHOPPER INTRODUCTION : This…
Amit Kumar
updated on 02 Feb 2021
DESIGN OF AMERICAN CHOPPER
INTRODUCTION :
This report is about Designing of American Chopper in Solidworks and modelong of all its majpor components. It is also includes Final Assembly of each Components. Photo realistic Rendering for each parts with the whole assembly via PhotoView 360 and SolidWorks Visualize.
OBJECTIVE :
The Objective this Project is get to know the process of Solid Part modeling and Surface modeling by designing each parts of American Chopper using SolidWorks. There is also the motive of gainig proper knowledge of Solid works Interface and make use of tools, tool bars, command manger and make custom shrotcut in an efficient way.
. Designing of each componetns using 2D Sketch and dimensions. Then convert each into 3D Solid Models.
. Assembly of Solid Models with proper relations and use of Mate.
. Able to know the professional way to use Decals , Light, Appearance, Environment, backplates.
. Acquire proper knowledge in Solidworks Visualize and Photoview 360 rendering tools to make realistic rander of the model chopper.\
METHODOLOGY :
COPONENTS OF AMERICAN CHOPPER :
There are 13 componets of American Chopper designed seperetly and used for assembly.
Those are as follows :
1. Transmission Belt
2. Kick Stand
3. Front Fender
4. Rear Fender
5. Chain
6. Oil Tank
7. Pedal
8. Front wheel
9. Rear wheel
10. Front fork
11. Chasis
12. Engine
13. Gas tank
DESCRIPTION OF COMPONENTS DESIGN
1. TRANSMISSION BELT
.Component Description : Transmission Belt is used to transmit power from one end to another end of pulley.
. Features: 1.Boss Extrude - Used to expand the object in 3Dm according to sketch plane.
2.Fillet - Fillet is a featuer used for making round edges to avoid sharp edges.
. Constrains used: 1.Tangent
2.Midpoint
. Tools used: Line tool - used to draw straight and tangent arcs.
. Methodology: Using Line and arc constrains making a sketch with given dimensins offest entities after get defined sketch make extrude using Boss extrude. After making Extrude of belt model make 1mm Fillet at edges of Transmission Belt.
. Images(Front view, Side view, Isometric View, Camera Setup View) :
2. KICK STAND
Component Description : KIck Stand is a supporting Mechanisim which is used to prevent the chopper lean on ground and makes upright with out interfere with aperson or object.
. Features: 1.Extrude Boss base - Used to Expand the object in 3D according to sketch plane.
2.Fillet - Fillet is fesature used for making round edges to avoid sharp edges.
3.Lofted BossBase - Lofted bossbase is a feature used to achive complex shapes which basically extruded loft surfaces by means of two lofted profiles along with guided curves direct the path of lofting.
4.Split - Split tool is used to split single solid part into two parts.
. Constrains used: 1.coincident
2.midpoint
. Tools used: 1.Ellipse - Used to make elliptical sketchses as per dimension.
2.Spline - Spline tool use to spline curves and complex geometry shapes.
3.Center point - It is used to make Rectangle based on center point Rectangle.
. Methodology: Create a Ellipse acccording to vertical and horizontal dimensions after thatb mqake a spline in perpendicular plane. With reference of spline and its end point creating another plane for draqw another loft profile after sketching by using using loft bossbase feature creste saaloft profile spline as guide curve to make perfect loft needed after that make a dome in the side of stand which going to lean in ground and finally make a flat surface to lean in ground by using split tool.
. Images(Front view, Side view, Isometric View, Camera Setup View) :
3. FRONT FENDER
Component Description : Fender is frame like structure which is laying over a wheel is used to prevnt the mud, liquids, slippery things will be lfloen into air while rotating at hogh speed also it prevnts the small stones will be flown over a rider beacause of acceleration cover a tyre.
. Features: 1.Revolve bossbase - Revolve feature is used to make cylidrical or circular 3d Extrude a;lonf with a gven reference axis as per drawn sketch.
2.Split- Split tool is used to split single solid part into two solid parts.
3.Fillet - Fillet is fesature used for making round edges to avoid sharp edges.
4.Dome - Dome is feature used to make dome shaped extrude including elliptical dome.
5.Extrude cut - Extrude feature used to cut the 3D object in the linear path according to sketch.
. Constrains used: 1.Refernce axis for revolve
. Tools used: 1.3Point Arc - 3point arc usd to draw a arc with make center point as refernce point draw an arc.
2.Spline - Spline tool use to make spline curvees and complex geometry shapes.
3.Dynamic mirror - Dynamic mirror used to mirror the entire feature of the plane selected for mirroring.
4.Extent entities - it is used to extend the end point lines to make closed sketch.
5.Trim entities - Trim is used to trim/delete the additional lines in the geometry.
. Methodology: Creating 3point arc as per dimension with offest and using extend entities to make complete the sketch by amking areference axis by means mid plane which by means of axis using revolve fearture by two direction at specfic angle.
. Images(Front view, Side view, Isometric View, Camera Setup View) :
4. REAR FENDER
Component Description : Fender is frame like structure which is lying over a wheel is used to prvent the mud, liquids, slippery things will be flown into air while rotating at high speed also it prevents the small stones will be flown over a rider beacause of accleretion cover a tyre.
. Features: 1.Revovle Boss base - Revolve feature is used to make cylindrical or circular 3D exrude along wtih a given reference axis as per drawn sketch.
2.SPlit - Split rtool is used to split single solid part into two solid parts.
3.Fillet - Fillet is fesature used for making round edges to avoid sharp edges.
4.Shell - Shell feature is uded to make to hollow space in solid part by selecting outer wall of the solid parr is to make renmove the inner parts also uded to reduce the specific thickness.
. Constrains used: 1.Horizontal
2.Vertical.
. Tools used: 1.3Point Arc - 3point arc used to draw arc with make center point as reference point draw an arc.
2.Spline - Spline tool use to make spline curvees and complex geometry shapes.
3.Extent entities - it is used to extend the end point lines to make closed sketch.
4.Trim entities - Trim is used to trim/delete the additional lines in the geometry.
. Methodology: Creating a 3 point arc at midplane of rear fender at offest a nline at given distance at end of the arc line draw and extend using extend entities, as reference at two direction and angle neede to achieve fenderr after that make split at end of the fender to get aurvature bybusing 3 pointarc at last by selecting face of fender to make full fillet at edges at last to make shell command to reduce the thickness of the fender at given dimension.
. Images(Front view, Side view, Isometric View, Camera Setup View) :
5. CHAIN
Component Description : Chain is used to transmit poer from from engine to sprocket at rear wheel for acceleration of vehicle.
. Features: 1.Extrude Boss base - Used to Expand the object in 3D according to sketch plane.
2.Fillet - Fillet is fesature used for making round edges to avoid sharp edges.
3.Curve driven pattern - Curve driven pattern is used to make any pattern which followed by the curve is sketched before.
. Constrains used: 1.Concentric
2.Coincident
3.Tangent
. Tools used: 1.Circle - Circle is the tool used to draw a circular sketch.
2.3Point Arc - 3point arc used to draw arc with make center point as reference point draw an arc.
3.Blocks - Block are tool which make a particular sketch as blocks that we can get a sketch as block able to insert in geomentry and sketch any time.
4.Trim entities - Trim is used to trim/delete the additional lines in the geometry.
. Methodology: Started with a teo circles which located as construction line reference after that draw a 3 point curve which is tangent with two circles with specific radius thentrim additional lines after that create a chain pin block . By using the block to make coicident and cocentric relation which the chain block make path eith the curve which is drawn. After fixing block with curve make extrude the pin and chain plate at offest then make curve driven pattern by curve as refernce by following the same rhythm to create complete chain model.
. Images(Front view, Side view, Isometric View, Camera Setup View) :
6. OIL TANK
Component Description : Oil tank in an engine is used to maintain the internal temperature at cylindrical blocks beacause of ignition for which the oil stored in a tank is known as oil tank.
. Features: 1.Extrude Boss base - Used to Expand the object in 3D according to sketch plane.
2.Fillet - Fillet is fesature used for making round edges to avoid sharp edges.
3.Shell - Shell feature is uded to make to hollow space in solid part by selecting outer wall of the solid parr is to make renmove the inner parts also uded to reduce the specific thickness.
4.Combine - Combine tookl is used to make integration of teo solid parts which intersect each other as same solid parts.
. Constrains used: 1.Tangent
2.Coincident
. Tools used: 1.Arc - Arc used to draw an arc with make center point as reference point draw an arc.
2.Spline - Spline tool use to make spline curvees and complex geometry shapes.
3.Dynamic mirror - Dynamic mirror used to mirror the entire feature of the plane selected for mirroring.
4. Line tool - used to draw straight and tangent arcs.
. Methodology: In Oil tank start with top plane making line and make tangent arc coincident with construction line make a straight line coincident with skecthing point to get fully definrd sketch make a dynamic mirror after that make a extrude. Then make a line with midplane a oil tank and extrude after that make combine both shapes to obtain a oil tank . Make a fillet with all ends . finally make shell a command without selcting body to get hollow tank inside
. Images(Front view, Side view, Isometric View, Camera Setup View) :
7. PEDAL
Component Description : Pedal is used to make suoppport for rider to spread his foot on a pedal and make rider comfortable while travelling and prevent the foot contact with road.
. Features: 1.Extrude Boss base - Used to Expand the object in 3D according to sketch plane.
2.Fillet - Fillet is fesature used for making round edges to avoid sharp edges.
3.Revolve bosasbase - Revolve boos base feature is used to make cylindrical or circular 3D extrude along with a given reference axis as per drawn sketch.
4.Dome - Dome is feature used to make dome shaped extrude including elliptical dome.
5.Chamfer - Chamfer isused to make a edges sharp edge to make angled tapering.
6.Linear Pttern - Linear pattern is to make a solid feature pattern in path as linearn.
. Constrains used:1.Tangent
2.Coincident
. Tools used: 1.Fillet - Fillet is fesature used for making round edges to avoid sharp edges.
2. Line tool - used to draw straight and tangent arcs.
3.3Point Arc - 3point arc used to draw arc with make center point as reference point draw an arc.
4.Offest - Offest is used to make asame sketch which is selcted at point of given Dimension.
. Methodology: Making a fully defined sketch filled with lots relation and sketch ended with fully defined skecth as like to get a exact dimension of a pedal. Then extrude a fixing pim using a contour selection make pedal freame same as that after that make a Revolve of leg rest from the same sketch to get a rest finish making a fillet and chamfer at end of the rest and make a dome at the end. Finally a pattern in aleg support at a pedal is extrude by using linear pattern command.
. Images(Front view, Side view, Isometric View, Camera Setup View) :
8. FRONT WHEEL
Component Description : Wheel is used as locomotive component of every tvehicle. The wheel generally rotated based on the axis fixed with the vehicle. Its built with hard rim cover with nylin tyre.
. Features: 1.Extrude Boss base - Used to Expand the object in 3D according to sketch plane.
2.Fillet - Fillet is fesature used for making round edges to avoid sharp edges.
3.Revolve bosasbase - Revolve boos base feature is used to make cylindrical or circular 3D extrude along with a given reference axis as per drawn sketch.
4.Revolve Cut - Revolve cut is method to cut/reduce the extrude of cylidrical/round.
5.Chamfer - Chamfer isused to make a edges sharp edge to make angled tapering.
6.Linear Pttern - Linear pattern is to make a solid feature pattern in path as linearn.
7.Extrude cut - Extrude feature used to cut the 3D object in the linear path according to sketch.
8.Circular Pattern - Circular pattern is afeature used to make 3d feature into circular pattern according to number of instances.
. Constrains used: 1.Coincident
2.Midpoint
3.Horizontal
. Tools used: 1.Fillet - Fillet is fesature used for making round edges to avoid sharp edges.
2. Line tool - used to draw straight and tangent arcs.
3.3Point Arc - 3point arc used to draw arc with make center point as reference point draw an arc.
4.Spline - Spline tool use to make spline curvees and complex geometry shapes.
5. Trim - Trim Used to trim extra lines
6.Extened entities - Used to extend line to the next sketch with relation along to the sketch.
. Methodology: For front wheel it consist of tyre, rotor, caliper, wheel rim.
For Rim: The rim is made by extrude revolve in the front plane refrence by making sketch and reovlve to achive the rim after making a revolve bossbase. Then making a sketch to do make a spider like forks by using circular pattern and other sketch entities according to dimensions.
For Rotor: Rotor is extrude along with mid plane to offset at specific dimension and amke a circular patterned holes for grip to calipers.
For Caliper: Caliper is extrude along with midpplane extrude at both direction and make fillet and chamfer to achive caliper.
For Tyre: Tyre is done by making revolve with front plane as per dimension to achive in tyre making a circular pattern feature.
. Images(Front view, Side view, Isometric View, Camera Setup View) :
9. REAR WHEEL
Component Description : Wheel is used as locomotive component of every vehicle. The wheel generally rotated based on the axis fixed with the vehicle. Its built with hard rim cover with nylon tyre. Its also include sprocket, Caliper, Rotor, Tyre.
. Features: 1.Extrude Bossbase - Used to expand the object in 3D according to sketch plane.
2.Fillet - Fillet is fesature used for making round edges to avoid sharp edges.
3.Revolve bosasbase - Revolve boos base feature is used to make cylindrical or circular 3D extrude along with a given reference axis as per drawn sketch.
4.Revolve Cut - Revolve cut is method to cut/reduce the extrude of cylidrical/round.
5.Chamfer - Chamfer isused to make a edges sharp edge to make angled tapering.
6.Linear Pttern - Linear pattern is to make a solid feature pattern in path as linearn.
7.Extrude cut - Extrude feature used to cut the 3D object in the linear path according to sketch.
8.Circular Pattern - Circular pattern is a feature used to make 3d feature into circular pattern according to number of instances.
. Constrains used: 1.Coincident
2.Midpoint
3.Horizontal
. Tools used: 1.Fillet - Fillet is fesature used for making round edges to avoid sharp edges.
2.Line tool - used to draw straight and tangent arcs.
3.3Point Arc - 3point arc used to draw arc with make center point as reference point draw an arc.
4.Spline - Spline tool use to make spline curvees and complex geometry shapes.
5. Trim - Trim Used to trim extra lines.
6.Extened entities - Used to extend line to the next sketch with relation along to the sketch.
. Methodology: For Rear wheel it consistent of Tyre, Caliper, Wheel, Rim, Sprocket
For Rim: The rim is made by extrude revolve in the front plane reference by making sketch and revolve to achieve the rim after making a revolve bossbase. The making a sketch to do make a spider web like forks by using circular pattern and other entities according to dimensions.
For Rotor : Rotor id extrude along with mid plane extrude at both direction and make fillet and chamfer to achieve caliper.
For Caliper: Caliper is extrude along with mid plane extrude at both direction and make fillet and chamfer to achieve caliper
For Tyre: Tyre is done by making rvolve with front plane as per dimension to achieve pattern in tyre making a circular pattern feature.
For Sprocket: Sprocket is made by extrude from the midplane of wheel with offest from a distance which parellel to sprocket at engine block the sprocket is made by circular pattern to achieve the teeth at sprocket.
. Images(Front view, Side view, Isometric View, Camera Setup View) :
10. FRONT FORK
Component Description : Front frok is consists teo narrow tube consists of two shock absorbes along with axis of front wheel nad tope fixed with handle bar to control direction of vehicle with head light.
. Features: 1.Revolve bosasbase - Revolve boos base feature is used to make cylindrical or circular 3D extrude along with a given reference axis as per drawn sketch.
2.Dome - Dome is feature used to make dome shaped extrude including elliptical dome.
3.Extrude Bossbase - Used to expand the object in 3D according to sketch plane.
4.Split - Split rtool is used to split single solid part into two solid parts.
5.Combine - Combine tookl is used to make integration of teo solid parts which intersect each other as same solid parts.
6.Move/copy body - This feature is used to move/copy the 3D body to one plce to another face.
7.Mirror - Mirror is used to make a mirroring a feature or body by referance of the selected plane it makes reduce the working timing of the model.
8.Sweep - This feature is used to sweep any kind of fulloy defined sketch along with the path.
9.Fillet - Fillet is fesature used for making round edges to avoid sharp edges.
. Constrains used: 1.Midpiont
2.Coincident
3.Horizontal
. Tools used: Projected Curve - Projected Curve is a special tool to make work easier projected used to combine a curves from differnt plane in to single plane sketch my means of integration.
2.Convert Entities - This is tool is used to make sketch according to plane which under sketch makes a trace of single line.
3.Line tool - used to draw straight and tangent arcs.
4.3Point Arc - 3point arc used to draw arc with make center point as reference point draw an arc.
5.Spline - Spline tool use to make spline curvees and complex geometry shapes.
. Methodology: Starting with the long barrel which where suspension located make a revolve feature as per sketch at front plane. From top plnae extrude the center part of fork where head light and speedo meter located offest from some dostance. After extrude making right plane make a revolve of head light using move/copy feature move a head light towards z direction to make head light center. Make fillet at the end of the head light to get soft round edges. Make a mirror as plan as right side of solid part which mounted upside of fork make a mirror feature to get complete fork, making revolve of handle bar then make a composite curve to get break wire connected with fork at last make a new for front used to assembly.
. Images(Front view, Side view, Isometric View, Camera Setup View) :
11. CHASSIS
Component Description : Chassis is skeleton of bike which is main frame that is used to hold everything like Engine, Gas, Tank, Pedal.. each and every parts.
. Features: 1.Mirror - Mirror is used to make a mirroring a feature or body by reference of the selected plane it makes reduce the working timing of the model.
2.Sweep - This feature is used to sweep any kind of fully defined sketch along with the path.
3.Revolve bosasbase - Revolve boos base feature is used to make cylindrical or circular 3D extrude along with a given reference axis as per drawn sketch.
4.Dome - Dome is feature used to make dome shaped extrude including elliptical dome.
5.Extrude Bossbase - Used to expand the object in 3D according to sketch plane.
6.Split - Split rtool is used to split single solid part into two solid parts.
7.Combine - Combine tookl is used to make integration of teo solid parts which intersect each other as same solid parts.
8.Chamfer - Chamfer isused to make a edges sharp edge to make angled tapering.
9.Fillet - Fillet is fesature used for making round edges to avoid sharp edges.
. Constrains used: 1.Midpoint
2.Coincentric
3.Coincident
. Tools used: 1. Projected Curve is a special tool to make work easier projected used to combine a curves from differnt plane in to single plane sketch my means of integration.
2.Convert Entities - This is tool is used to make sketch according to plane which under sketch makes a trace of single line.
3.Line tool - used to draw straight and tangent arcs.
4.Spline - Spline tool use to make spline curvees and complex geometry shapes.
5.Circle - Used to make circles according to given radiusdiameter.
. Methodology: Need of reference blue print for make chassis by importing chopper blue print using image sketch feature after importing image by using splines to make projected curve of botttom part of chassis make sweep along with curve.
. Images(Front view, Side view, Isometric View, Camera Setup View) :
12. ENGINE
Component Description : Mirror is the power house of vehicle it transmit the power to rear wheel through chain and sprocket.
. Features: 1.Mirror - Mirror is used tomake a mirroring a feature or body by reference of the selected plane it makes reduce the working timing of the model.
2.Sweep - This feature is used to sweep any kind of fully defined sketch along with the path.
3.Revolve bosasbase - Revolve boos base feature is used to make cylindrical or circular 3D extrude along with a given reference axis as per drawn sketch.
4.Dome - Dome is feature used to make dome shaped extrude including elliptical dome.
5.Extrude Bossbase - Used to expand the object in 3D according to sketch plane.
6.Split - Split rtool is used to split single solid part into two solid parts.
7.Combine - Combine tookl is used to make integration of teo solid parts which intersect each other as same solid parts.
8.Chamfer - Chamfer isused to make a edges sharp edge to make angled tapering.
9.Fillet - Fillet is fesature used for making round edges to avoid sharp edges.
10.Extrude cut - Extrude feature used to cut the 3D object in the linear path according to sketch.
11.Circular Pattern - Circular pattern is a feature used to make 3d feature into circular pattern according to number of instances.
12..Linear Pttern - Linear pattern is to make a solid feature pattern in path as linearn.
. Constrains used: 1.Coincident
2.Coincentric
3.Horizontal
4.Vertical
. Tools used: 1.Fillet - Fillet is fesature used for making round edges to avoid sharp edges.
2.Line tool - used to draw straight and tangent arcs.
3.3Point Arc - 3point arc used to draw arc with make center point as reference point draw an arc.
4.Offest - Offes is used to make a same sketch which is selected at point of given Dimension.
5.Projected cueve - Projected curve is aspecial tool to make work easier projected used to combine a curves from different plane in to single plasne sketch my means of integration.
6.Convert Entities - This tool is used to make sketch according to the plane which under sketch makes a trace of single line.
7.Trim - Trim used to trimdelete the additional lines in the geometry.
8.Composite curve - Composite curve Compositer curve is used to composite two curves into single curve.
. Methodology: Engine part modeling neeedf a reference image same as chassis after that using engine. Blue print make line and tangency of pulley used to drive, after that making an extrude from the reference to make a engine block using cut extrude cut the fins in engine and make mirror after that make an air intake using revolve and projected curve finally making composite curve to sweep the exhaust and make a spark plug cable at end of the engine block
. Images(Front view, Side view, Isometric View, Camera Setup View) :
13. GAS TANK
Component Description : Gas tank is used to store the fuel which is need for making power engine in combustion process.
. Features: 1.Swept suface - Its used to make a surface along with a path curve is driven.
2.Boundry Surface - Boundry surface which make surface in between two finshed surface.
3.Loft surface - Loft surface is used to make loft between two profiles along with guide.
4.Knit surface - Knit surfsce is used to make kintzipped two surface.
5.Sweep cut -Sweep cut is same as sweep featuure but its directly proportional to sweep which make cut along wtih the swep path.
6.Combine - Combine tool is used to make integration of two solid parts which intersect each other as same solid parts.
7.Shell - Shell feature is uded to make to hollow space in solid part by selecting outer wall of the solid parr is to make renmove the inner parts also uded to reduce the specific thickness.
8.Fillet - Fillet is fesature used for making round edges to avoid sharp edges.
. Constrains used: 1.Tangent
2.Coincident
. Tools used: 1.Line tool - used to draw straight and tangent arcs.
2.3Point Arc - 3point arc used to draw arc with make center point as reference point draw an arc.
3.Projected cueve - Projected curve is aspecial tool to make work easier projected used to combine a curves from different plane in to single plasne sketch my means of integration.
5.Convert Entities - This tool is used to make sketch according to the plane which under sketch makes a trace of single line.
6.Mirror - Mirror is used to make a mirroring a feature or body by referance of the selected plane it makes reduce the working timing of the model.
. Methodology: In gas tank which is make an surface extrude along with blue print by making sweep surface extrude making a tangential nspline curve along with seep path to make a outer tank wall. After that to amke projected curve to extrude loft surface using guided curve and make complete ga tank finally a shell for gas tank because of hollow object to make fully modeled design model
. Images(Front view, Side view, Isometric View, Camera Setup View) :
ASSEMBLY OF CHOPPER
Assembly of chopper which is make a assembly of components which is designed before. For an assembly import all component solid works.
. Cosntrained used: Constrains play a major role for assembly which is used to assemble each parts
1.Coincentric
2.Coincident
3.Tangent with planes
4.Parallel
5.Perpendicular
Etc..
. Mates: Mates is a feature used to make mate with each other components properly used to make accirate assembly a components.
There is a type of Components:
1.Advanced mate
2.Mechanical Matte
. Images(Front view, Side view, Isometric View, Camera Setup View) :
RENDERING
Rendering is process of making real time products.
Rendering consists of following features-:
1.Environment settings
2.Light settings
3.Colours and Material editing
4.Scene Composition
Setup of solid works photo view 360 with above mentioned Aspects with proper environment.
Solid works visualize is advanced individual rendering setup to make a real time rendering experiance.
RENDERING IMAGES
CONCLUSION
From this we able to know how Solidwork Software works during designing of American Chopper. There are many advantages to the solidworks software like reducing time taken to produce the drawing needed in the work environment.
In end of this you also able to know through American Chopper project how to use a new features and tools and learn about assembly according to planes of models including advanced mates. Finally leaning about Light, environment, setup, Colour, Decals, Back Plates. Using Photo view 360 and Solid Works Visualize.
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