MODELING, ASSEMBLING, AND RENDERING OF AN AMERICAN CHOPPER

Aim:

• To create different parts of an American chopper in Solidworks using various types of sketches and features tools.

• To assemble the different modelled parts to create the chopper.

• To create photorealistic rendered images of the chopper using Solidworks Visualize.

Introduction:

The chopper was modelled using part modelling. Once after all the parts were modelled separately they were assembled to create the chopper. It consists of the following parts

• Chain

• Chassis

• Engine

• Front fender

• Front fork

• Front-wheel

• Fuel tank

• Kick-stand

• Oil tank

• Pedal

• Pedal LHS

• Rear fender

• Rear-wheel

• Transmission belt

Part Modelling:

The 3D part is the basic building block of any large-scale design. Features are the individual shapes that, when combined, make up the part. One can also add some types of features to assemblies. Part documents can contain multiple solid bodies that we can manipulate the same way as single solid bodies.

Design Methodology:

Commands Used In Solidworks:

Sketch Tools:

Features:

• EXTRUDE BOSS: This feature is to convert 2D into solid modeling only when the 2D sketch is completely closed. It also allows to extrude the surface in both directions and also offset it to require distance.

• EXTRUDE CUT: It is used to remove materials from a solid model in desired patterns and also it can be extruded in both directions.

• REVOLVED BOSS/ EXTRUDED: Create a sketch with a centre line, a plane, or an axis for revolve.

• FILLETS: This is to create a curved surface on the profile edges on the solid model by selecting the required lines or the face. This fillet also has a feature to select multiple lines which reduces time consumption.

• CHAMFER: It is similar to the fillet feature but in chamfer, it cuts the solid model intersection area into recurred length and angle.

• SPLIT TOOL: This tool is very handy when two or more solid bodies intersect in between or intersect each other than split tool allows to delete unwanted solid body formation and gives a clean look.

• DYNAMIC MIRROR: To make the solid body identical to each other this feature is used.

• COMBINE: Combine feature is used to combine two or more bodies when intersecting to each other and make it a single body.

• DOME: This tool provides a smooth curve on the face of the profile.

• SHELL: It is used to create the thickness of the profile.

• CIRCULAR/LINEAR PATTERN: Feature is used to create a different number of patterns required to create the circular pattern.

• COMPOSITIVE CURVE: When the two curve profile is broken this composite curve helps to join and make it a complete smooth single curve.

• LOFTED SURFACE: Surface generated by existing edges creating a smooth tangent between the selected curves.

• SURFACE KNIT: Which create one single solid surface body from multiple solid surface body.

Parts:

1.Chain:

Motorcycle chains are part of the drive train to transmit the motor power to the back wheel. Properly lubricated chains can reach an efficiency of 98% or greater in the transmission. Unlubricated chains will significantly decrease performance and increase chain and sprocket wear.

Commands used: Following were the commands used to model the part,

2.Transmission Belt:

A belt is a loop of flexible material used to link two or more rotating shafts mechanically, most often parallel. Belts may be used as a source of motion, to transmit power efficiently or to track relative movement. Belts are looped over pulleys and may have a twist between the pulleys, and the shafts need not be parallel.

Commands used: Following were the commands used to model the part,

• 2D sketch

• Fillet

• Smart Dimensions

• Appearance

• Extruded boss/base

• Curve driven pattern

• Mirror feature

• Body-Delete/keep

3.FENDERS

A fender is the part of a vehicle that protects and frames its wheels and keeps mud from splashing it. Most modern vehicles have fenders on their front and back wheels.

Commands used: Following were the commands used to model the part,

• 2D sketch

• Fillet

• Smart Dimensions

• Appearance

• Split

• Revolve

4.Kick-Stand

It is a metal rod attached to a bicycle or motorcycle, lying horizontally when not in use, that may be kicked into a vertical position to

support the vehicle when it is stationary.

Commands used: Following were the commands used to model the part,

• 2D sketch

• Fillet

• Smart Dimensions

• Appearance

• Split

• Lofted boss/base

• Extruded boss/base

• EXtruded cut

• Dome

5.PEDAL

It is a foot lever or treadle by which a part is activated in a mechanism.

Commands used: Following were the commands used to model the part,

• 2D sketch

• Fillet

• Smart Dimensions

• Appearance

• Chamfer

• Revolved boss/base

• Extruded boss/base

• Linear Pattern

• Dome

6.OIL TANK

It is a container for holding or storing oil. Oil tank also comprises of a decal.

Commands used: Following were the commands used to model the part,

• 2D sketch

• Fillet

• Smart Dimensions

• Appearance and decals

• Extruded boss/base

• Combine

• Shell

7.WHEELS

It is a circular object that revolves on an axle and is fixed below a vehicle or other object to enable it to move easily over the ground.

FRONT WHEEL

It is at the front of the vehicle. It consists of following components,

Rim

Disc brake (Rotor)

Tyre

REAR-WHEEL

It is at the back of the vehicle. It has the following components in it,

Rim

Disc brake (Rotor)

Tyre

Sprocket

Caliper

Commands used: Following were the commands used to model the part,

• 2D sketch

• Offset entities

• Fillet

• Trim entities

• Smart Dimensions

• Appearance

• Chamfer

• Mirror Entities

• Combine

• Extruded cut

• Revolved cut

• Circular pattern

• Extruded boss/base

• Revolved boss/base.

• Caliper

Commands used: Following were the commands used to model the parts,

• 2D sketch

• Offset entities

• Fillet

• Trim entities

• Smart Dimensions

• Appearance

• Chamfer

• Mirror Entities

• Extruded cut

• Revolved cut

• Combine

• Circular pattern

• Extruded boss/base

• Revolved boss/base.

8.FRONT FORK

The front fork is a suspension component for either a bicycle fork or motorcycle fork. The forks can be most easily understood as simply large hydraulic shock absorbers with internal coil springs. They allow the front wheel to react to imperfections in the road while isolating the rest of the motorcycle from that motion.

Commands used: Following were the commands used to model the part,

• 2D sketch

• Fillet

• Trim entities

• Smart Dimensions

• Appearance

• Dome

• Mirror Entities

• Body-Move/Copy

• Combine

• Extruded cut

• Revolved cut

• Circular pattern

• Linear pattern

• Projected curve

• Reference Plane

• Extruded boss/base

• Swept boss/base

• Revolved boss/base.

9.FUEL TANK

A fuel tank is a safe container for flammable fluids. Though any storage tank for fuel may be so-called, the term is typically applied to part of an engine system in which the fuel is stored and propelled (fuel pump) or released (pressurized gas) into an engine. Fuel tanks range in size and complexity from the small plastic tank of a butane lighter to the multi-chambered cryogenic Space Shuttle external tank.

This fuel tank consists of three decals.

Commands used: Following were the commands used to model the part,

• 2D sketch

• Sketch picture

• Fillet

• Trim

• Smart Dimensions

• Appearance and decals

• Shell

• Mirror

• Split line

• Projected curve

• Reference Plane

• Surface trim

• Swept cut

• Lofted surface

• Boundary surface

• Swept surface

• Extruded surface

• Knit surface.

10.ENGINE

A motorcycle engine is an engine that powers a motorcycle. Motorcycle engines are typically two-stroke or four-stroke internal

combustion engines, but other engine types, such as Wankels and electric motors, have been used.

Commands used: Following were the commands used to model the part,

• 2D sketch

• Sketch picture

• Fillet

• Trim

• Smart Dimensions

• Appearance

• Chamfer

• Mirror

• Split

• Combine

• Dome

• Extruded cut

• Circular pattern

• Linear pattern

• Projected curve

• Composite curve

• Reference Plane

• Extruded boss/base

• Revolved boss/base

• Swept boss/base

11.CHASSIS

It is a vehicle frame, the underpart of a motor vehicle, on which the body is mounted; if the running gear such as wheels and transmission, and sometimes even the driver's seat, are included, then the assembly is described as a rolling chassis.

Commands used: Following were the commands used to model the part,

• 2D sketch

• Sketch picture

• Fillet

• Split

• Smart Dimensions

• Appearance

• Chamfer

• Mirror

• Combine

• Dome

• Extruded cut

• Projected curve

• Reference Plane

• Extruded boss/base

• Revolved boss/base

• Swept boss/base.

Assembly:

Photo Realistic Rendering:

Conclusion:

All the parts of the American chopper were modelled and the assembly was created using Solidworks and the photorealistic renders of the chopper were created using Solidworks Visualize.