MODELING OF AMERICAN CHOPPER IN SOLIDWORKS

Objectives-

The main objectives of this project are:

• To create individual parts of chopper using solidworks
• To assemble all the individual parts into chopper
• to know the application of decals,lights and camera etc

To create photorealistic model and render it using photoview 360 and solidwork visualize

Introduction-

Solidworks is one of the prominent modelling software avaliable today this software is mainly used to model 3D parts using 2D sketch.It also has the option to specify the material and look of the model which we created.It has other ADD-in features like photoview360 which helps in rendering of the final model to make it look photo realistic. In this project we learnt about detailed design of Americal chopper parts and assemblig them and rendering the final after assembly.

Details of SOLIDWORKS Features Used -

Sketch

The sketch is used to create the 2D representation of model. In solid work there are different entities are available like as follows:

• Line
• Circle
• Arc
• Spline
• Rectangle
• Polygon
• Fillet
• Ellipse

(Some sketch entities like line, circle, spline, arc, rectangle, etc. contain more options)

• Offset

The offset command create parallel line, curve, and concentric circles through a point or at a specified distance.

• Trim and extend entity

The trim command is used to remove the selected extra line/parts of an object. And the extend command is used to extend the selected boundaries or edges.

• Covert entity

It is used to project the last sketch in to the current sketch plane.

• Mirror

Mirror is used to create remaining half of a sketch/ copy of selected sketch about a specified line.

• Linear sketch pattern

It is used to create multiple instance of feature that can uniformly specified along one or two linear paths.

• Smart dimension

It allows you to dimension the part which is created.

• Dynamic mirror

Select the dynamic mirror feature to mirror pre-existing sketch. First select line, centerline, and linear model edge about which to mirror, and then create a sketch to mirror.

Path - Tool> Sketch Tools>Dynamic Mirror

Extruded boss/base:-

It is used to convert 2D sketch into 3D model in one or both directions from sketch plane. Here you have to specify direction up to surface, vertex, value, body from sketch plane.

Extrude cut

It helps to remove material from the created 3D model by using 2D sketch. It is opposite of extrude boss/bass feature. Here also you have to specify direction up to surface, vertex, value, body from sketch plane.

Revolved boss/base:

It is used to revolve a 2D sketch (one or more profile) along a axis, line or centerline.

Revolved cut:

This feature is just opposite of revolve boss/base. The revolved cut allows to cut a profile around an axis, plane, and line to create complex geometry.

Swept Boss/Base

A swept feature is used to create a solid body by moving a closed entity/ profile along specified sketch/path. In order to complete a feature, two sketches are necessary. One will be the closed profile and second will be the path.

Swept Cut

A swept cut feature allows to cut a 3D model by sweeping a closed sketch profile along a specified path sketch. The path sketch will control the direction of cut. Profile sketch should be connected to the path sketch.

Lofted boss/base

The loft feature creates a solid body by making transition between multiple profile and guide curve. It helps to generate complex geometry in one feature.

Lofted cut

The loft cut is allows to remove material between two sketch profiles. Make sure that selections are must under the profile selection box and not the guide curve selection box

Fillet

It is used to create a rounded shapes at internally or externally faces of the part. There are different types of fillet:

• Constant Size fillet
• Multiple radius fillet
• Round corner fillet
• Setback fillet
• Variable size fillet
• Face fillet
• Full round fillet
• Asymmetric fillet

Chamfer

This feature is creates a cut on selected edge, face or a vertex. Types of chamfer:-

• Angle –Distance- Enter the values of distance and angle in the chamfer parameter box.
• Distance- Distance- Enter the values for both distances in the chamfer parameter box or on the side of selected edges.
• A vertex- Enter values for the three distances on each side of selected vertex.

Patterns

• Linear pattern – To create multiple instances of one or more feature to that can space uniformly along specified path, plane.
• Circular pattern – To create multiple instances of one or more feature to that can space uniformly along an axis, line.
• Curve Driven Pattern – To Curve creates multiple instance of one or more feature to that can space uniformly along 3D curve (open or closed curve).

Shell

It is used to define the thickness of wall, hollows out a part, leaves open the selected faces. Shell may be with uniform or multiple thickness faces.

Dome

Dome features is used to one or more dome on the same model in one feature.

• Face to dome - Used to apply dome to faces whose centroid lies outside the face.
• Elliptical Dome -Used to apply dome for cylindrical/ conical model.

Path- Insert>Feature>Dome

Split

Split feature is used to create multiple body or surfaces from one part/ surface. In the trim tool box we need to select sketch and click on cut part. In this feature we can create multiple body or consume cut bodies.

Path- Insert>Feature>Split

Combine

There are three different options are available to use combine feature.

• Add-To merge multiple bodies together into one.
• Subtract-To remove multiple bodies from main body.
• Common- To add two bodies together and keep the area that is common to them.

Path- Insert>Feature>Combine

Feature description for surface Modelling:

Surface modelling is used to build out a represent of solid objects exterior and it’s a contours. Following feature are used in design of seat, gas tank of chopper.

Swept Surface

The surface is created by sweep profile and sweep path.

Lofted Surface

The surfaces are generated by multiple 3D curves / existing edges. There should be a tangency between the selected curve/edges.

Boundary Surface

The boundary surface creates surfaces that can be tangent or curvature continuous in both direction. In most of cases, we get high quality result as compare to lofted surface.

Filled Surface

The feature create a surface to fill the gap in a model.

Surface Trim

It is used to cut away material from a surface.

Extend Surface

This feature extend the surface by selecting as edge, multiple edges or a face.

Surface Knit

The surface knit feature combine multiple faces and surfaces into one. Surface edges must be adjacent and not overlapping.

Appearance

An appearance is define the visual properties of model which include color and texture. We can apply appearance to the individually to the complete model / one or more face /edges .It does not affect on physical property which are defined by material.

Description of American chopper parts and used features in detailed:-

1.Transmission Belt:-

It is made up of flexible material and used to transmit power efficiently from a motor to drive shaft/ pulley or to track relative movement. Sometimes it’s called as drive belts, gear belts or automotive belts.

Features used to create Transmission belt:

• Rename the Planes:-

Front Plane – Front Plane of Transmission Belt

Top Plane- Top Plane of Transmission Belt

Right Plane-Right Plane of Transmission Belt

• Sketch
• Offset
• Extrude Boss/Base
• Fillet
• Appearance :- Matte Rubber
• Save the part- Transmission Belt

Note- All used features are explained above.

Fig.1 Transmission Belt

2.Kickstand:-

A kickstand is a supporting structure provide to a bike which flips down from the frame and makes contact with ground when stationary. It is also known as side stand.

Features used to create kickstand-

• Rename the Planes:-

Front Plane – Front Plane of Kickstand

Top Plane- Top Plane of Kickstand

Right Plane-Mid Plane of Kickstand

• Sketch
• New Plane
• Loft Boss/base
• Dome
• Extrude Cut
• Extrude Boss/Base
• Split
• Fillet
• Appearance:- Chrome
• Save the part- Kickstand

Fig.2 Kickstand

3.Front fender:-

The Front fender is an automobile part mounted on the fork above the wheel. Its purpose is to protect rider and bicycle from mud, sand, or liquids.

Features used to create front fender-

• Sketch
• Revolve
• Sketch with dynamic entity
• Split
• Fillet
• Appearance -Siena
• Save the part model- Front fender

Fig.3 Front Fender

4.Rear fender:-

Application of rear fender is same as front fender. The rear fender is mounted on rear part of chassis and above the rear wheel.

Features used to create rear fender

• Sketch
• Revolve
• Sketch with dynamic entity
• Split
• Fillet
• Shell
• Appearance- Siena
• Save the part- Rear Fender

Fig. 4 Rear Fender

5.Oil Tank:-

The oil tank is used to store the lubricating oil which is required to run the engine. Oil is generally used to avoid wear and tear due to extreme heat. It is hollow from inside.

Features used to create oil tank -

• Rename the plane-

Front plane- Mid plane of Oil Tank

• Sketch
• Extrude Boss/Base
• Combine
• Fillet
• Shell
• Appearance- Siena
• Save the part- Oil Tank

Fig. 5 Oil Tank

6.CHAIN:-

Chains are used as the part of the drive train to transmit the motor power to the back wheel.

Feature used to create chain-

• Rename the planes-

Front Plane- Mid Plane of Chain

Top Plane- Center Plane of Chain

Right Plane- Front Plane of Chain

• Sketch
• Sketch Block
• Extrude Boss/Bass
• Fillet
• Curve Driven Pattern
• Solid Body Folder
• Mirror
• Appearance- Carbon Steel
• Save the Part- Chain

Fig. 6 Chain

7.Pedal:-

The pedal is the part of a chopper and it is used to rest the leg on top of that.

Features used to create pedal-

• Sketch
• Extrude Boss/Base
• Revolve
• Dome
• Chamfer- Distance –Distance
• Fillet
• Linear pattern
• Appearance- Chrome steel
• Save the part -Pedal

Fig.7 Pedal

8.Front wheel:-

The front wheel is a rolling part of chopper situated in front side. The part guide the vehicle as per movement of front fork. Wheel contains – Caliper, Rim, Rotor and tire. At the outer side of wheel, rubber material is attached called as tire.

Features used to create front wheel-

• Sketch
• Revolve Boss/bass
• Extrude Boss/base
• Extrude cut
• Intersection entity.
• Revolved Cut
• Circular pattern
• Combine
• Fillet
• Chamfer
• Appearance-

Rim- Chromium Plate

Rotor- Carbon steel

Caliper- Siena

Tire- Matte Rubber

• Save the part- Front Wheel

Fig.8 Front Wheel

9.Rear Wheel:-

The rear wheel is a rolling part of chopper situated in rear side. The part revolves on an axle. The wheel contains – Caliper, Rim, Rotor, Disc, Sprocket and tire. Chain is connected between engine and sprocket of rear wheel.

Features used to create rear wheel-

• Sketch
• Revolve Boss/Base
• Extrude Boss/base
• Extrude cut
• Intersection entity
• Revolved Cut
• Circular pattern
• Combine
• Fillet
• Chamfer
• Appearance-

Rim- Chromium Plate

Rotor- Carbon steel

Caliper- Siena

Sprocket- Chromium Plate

Tire- Matte Rubber

• Save the part- Rear Wheel

Fig. 9 Rear Wheel

10.Front fork:-

A chopper fork connects a front wheel and axle to its chassis. It guide the complete vehicle. Fork contains – Handles, brake, axle, lights, etc.

Feature used to create front fork -

• Sketch
• Revolve
• Extrude boss/base
• Fillet
• Linear pattern
• Extrude Cut
• Fillet
• Dome
• Body- move / copy
• Composite curve
• Sweep Boss/Base
• New Plane
• Projected Curve
• Mirror
• Combine
• Appearance-

Fork- Chromium plate

Brake Wire and Accelerator - Rubber

Lights- Area Light

• Save the part- Front Fork

Fig. 10 Front Fork

11.Chassis:-

The Chassis is also called as frame. The components like front fork, gear box, engine, gas tank, wheels, etc are attached to it. It mostly consist of hollow tube.

Features used to create chassis-

• Blueprint of American Chopper (Underlay Sketch)
• Sketch
• Offset
• Convert Entity
• Composite Curve
• Projected Curve
• Sweep Boss/Base
• Mirror
• Extrude Boss/Base
• Fillet
• Extrude Cut
• Dome
• Combine
• Chamfer
• Split
• Revolved Boss/Base
• Appearance- Siena
• Save the part- Chassis

Blueprint / Underlay Sketch

Path- Sketch>Tool>Sketch Tools>Sketch Picture

Fig. 11 Chassis

12.Engine:-

The engine is main part of the vehicle, where power is generated by burning of fuel and later transmit the rotational motion to the wheel through chain and sprocket.

Features Used to create engine

• Blueprint (Underlay Sketch)
• Sketch
• Extrude Boss/Base
• Revolved Boss/Base
• Circular Pattern
• Convert Entity
• Extrude Cut
• Dome
• Fillet
• Chamfer
• Mirror
• Composite Curve
• Projected Curve
• Sweep Boss/Base
• Split
• Appearance- Carbon Steel
• Save the Part- Engine

Fig.12 Engine

13.Gas Tank:-

The gas tank or fuel tank is used to store the fuel and it is required to run the engine.

Feature used to create gas tank

• Blueprint sketch
• Sketch
• Projected Curve
• Convert Entity
• Sweep Surface
• Loft Surface
• Boundary Surface
• Surface Trim
• Swept Cut
• Mirror
• Knit Surface
• Split Surface
• Extrude Surface
• Fillet
• Appearance-

Seat- Leather

Gas Tank- Siena

• Save the part- Gas Tank

Fig. 13 Gas Tank

Assembly of American chopper

• All part modelling windows should be opened.
• Initially, chassis part is inserted in to the main assembly environment by using insert part option and press ok to fix the chassis.
• Similarly other parts also inserted into the main assembly environment and give them possible mates to fully define. Following is the part insertion sequence:-

1. Chassis
2. Engine
3. Pedal
4. Kickstand
5. Transmission Belt
6. Oil Tank
7. Rear Wheel
8. Rear Fender
9. Chain
10. Gas Tank
11. Front Fork
12. Front Wheel
13. Front Fender

Features used to create assembly-

• Insert Components
• Mates
• Mirror
• Save the assembly- American Chopper

Insert components

We can insert component in the assembly which is need to be mated with fix component.

Mates

Mates creates geometric relations with the components which are inserted into the assembly. While making assembly we used various type of mates like –

1. Standard Mates- concentric, parallel, coincident, tangent, distance, angle, etc.
2. Advanced Mates- Limit, Width, etc.

Fig.14 Isometric, Front, Top, Left Side and Camera View of American Chopper Assembly

Decals used for American Chopper

• We can apply decals to a part faces, rather than to an assembly because we cannot select specific faces.
• Path- Click PhotoView 360 > Edit Decal,

Fig. 15 Decals on Gas Tank, Rear Fender, Oil Tank resp.

Rendering for American Chopper

Rendering is process of creating realistic images of the model with environment.

In rendering various aspects such as camera, light, environment, background scene, appearance, etc. are taken in consideration before final rendering. To check the all thing preview rendering option is used.

There are two ways of rendering in SOLIDWORKS.

1. Photoview 360
2. Solidworks Visualize

In photorealistic model, some of the mates and conditions are changed to render realistic model. So we have to change as per different view before rendering.

Fig. 16 Rendered images of American Chopper

Fig. 17 Rendered images in Camera, Front, Left, Top, and Isometric View resp.

Conclusion:-

• The parts are sketched and modelled in the SOLDWORKS.
• The modelled parts are assembled with possible mates in to the main assembly of American chopper.
• The decals are applied to faces of parts.
• The realistic images was rendered with use of both ways “Photoview 360 and Solidworks Visualize.