SKILL LYNC

PROJECT REPORT

MODELLING OF AMERICAN CHOPPER IN SOLIDWORKS

BY

SUVADEEP GHOSH

INTRODUCTION

In this project, different cosmetic components for a chopper are designed and assembled as a whole system depicting the external view of an American Chopper model in SolidWorks. The assembly is rendered using Photoview 360 and SolidWorks Visualize to resemble a photo-realistic model of a chopper.

MODELLING & ASSEMBLING FEATURES

The various modelling features used for modelling the American Chopper are discussed as follows:

· EXTRUDE:

It is a basic tool in Solidworks which converts a 2D sketch in to a 3D model with respect to its geometry in normal direction. First we have to draw a fully closed 2D sketch and then extrude it by defining its starting point, ending point, contours and direction of extrusion.

· REVOLVE:

The revolve feature is used to revolve a 2D sketch along an axis or centerline and makes it a 3D model. A 2D sketch is drawn and revolved by selecting a line as a reference for axis of rotation and defining the angle of rotation.

· SWEEP:

A sweep tool is used to sweep a closed 2D sketch along an open or closed path. This tool is generally used for making tubes and bars. A closed loop and a path to sweep are required.

· FILLET:

A fillet is a tool used to round an edge, vertex or face on both inside and outside of a 2D or 3D model. The fillet type, location and radius of the fillet are defined.

· CHAMFER:

A chamfer is used to remove a sharp edge by creating a sloped edge, vertex or face. Distance and angle of the chamfer are defined.

· MIRROR:

Mirror tool in solidworks is used to copy a 2D or 3D object about a reference line or plane. We can have either only the mirrored object or both the original and mirrored objects.

· SHELL:

The shell tool hollows out a part, leaves open the faces you select, and creates thin-walled features on the remaining faces. If you do not select any face on the model, you can shell a solid part, creating a closed, hollow model. You can also shell a model using multiple thicknesses. The thickness of the shell is defined.

· LINEAR & CIRCULAR PATTERN:

The Linear Pattern Command is used to drive features, faces, or bodies in a linear direction. The Circular Pattern Command is an excellent tool used to replicate features, faces, or bodies in a rotational manner about an axis.

· PROJECTED CURVES:

A projected curve is a 3D curve that represents the intersection of two extruded surfaces of two sketches on intersecting planes.

· MATES:

Mate operation is the basic tool for assembling the parts. There are various mate operations such as coincident, parallel, perpendicular, tangent, concentric, lock, etc. We can mate two faces by defining distance or angle between them.

DESIGNING APRROACH

MODELLING

· TRANSMISSION BELT:

Belts are used to transmit power efficiently or to track relative movement. It was modelled by using basic tools like extrude and fillets. Final appearance was given to the belt.

· KICKSTAND:

A kickstand allows the bike to be stay upright without leaning against another object or the aid of a person. A kickstand is usually a piece of metal that flips down from the frame and makes contact with the ground. The body of kickstand was created by using loft tool and dome was applied at the ends. Then split tool was used to create flat bottom end. Extrude and fillets were used to model the remaining part.

· FRONT & REAR FENDERS:

A Fender is the part of a car, truck or motorcycle that surrounds the wheel well. The primary function of a Fender is to prevent dirt and debris from being thrown into the air by the tire. It was very easy to model these fenders. Both fenders are modelled by using features like revolve, split and other features with different dimensions.

Front Fender

Rear Fender

• CHAIN:

Chain is used to transmit mechanical power from engine to rear wheel. Roller chain is the commonly used type. Though the chain is a complicated model, it was easily modelled by using mirror, curves and curve driven pattern. The links were modelled as blocks and later imported. The curve driven pattern was done multiple times to get the accurate result.

· OIL TANK:

Whether it is a car or a bike, a vehicle's engine is dependent on the oil tank for continuous lubrication supply. Oil tank was modelled by using dynamic mirror entity and combine features. Shell feature was used to make it hollow.

· PEDAL:

A pedal is a strong rigid body and used to rest the foot while riding bikes. Splines, fillets, dome and linear pattern were some of the features used to model the pedal.

· FRONT WHEEL:

Front wheel has a larger diameter to take and manage impact better than the rear. The front tire experiences the greatest forces during braking. First, the rim was created using revolve feature and spider webbed spokes were created by using arcs and offsets. Then rotor and caliper were modelled. Finally the tire was modelled using revolve and treads were applied.

· REAR WHEEL:

The rear tire is primarily used for acceleration and propelling the motorcycle forward. It is wider than the front wheel to improve stability of the bike. The steps followed for front wheel were used here. But this wheel has a rear sprocket as additional component. It has varying dimensions.

· FRONT FORK:

A front fork connects a motorcycle's front wheel and axle to its frame. Most forks incorporate the front suspension and front brake, and allow the front wheel to rotate about the steering axis so that the bike may be steered. This was modelled by using features like extrude and mirror. Projected curves were used to model the handles and cables.

· CHASSIS:

Chassis is the main body of the chopper. It is the skeletal frame of the bike and holds other components like front fork, pedals, kickstand, oil tank, gas tank and engine. It provides strength and support to the bike. Its modelling was started by using a picture as a reference for sketching. It involved features like splines, projected curves and split. It took more time to model.

· ENGINE:

Engine provides the power necessary to drive the vehicle. A picture is imported for reference before modelling. First, bottom part of the engine, consisting of crank shaft, motor and transmission pulleys, was modelled. Then upper part of the engine with cooling fins are drawn. Then rear sprocket and air filter were modelled. Finally the exhaust system and spark plug were modelled using splines, projected curves and sweep features.

· GAS TANK:

The gas tank covers the oil tank and engine and also acts as a shield that prevents the heat from engine. The seat and opening for fuel tank are located on the top of gas tank. This also involved using a reference picture for sketching. One half of the tank was created and the mirrored. Then seat was modelled on the top of it and fillets were applied. The tank was shelled to make it hollow.

ASSEMBLY OF THE CHOPPER

All the parts modelled were imported to assemble them. In assembly, mate feature was often used to locate and relate the parts with one another. Chassis was inserted initially and fixed. The other components were inserted and related to the chassis. Some parts were modified during assembly to avoid interference

Isometric View

Front View

Side View

Top View

Camera View

RENDERING OF THE CHOPPER

In rendering, the chopper was made to set up in such a way to look natural and unique. Decals were added to the body parts. Views and light directions were changed. Using solidworks visualize, the appearances, background scenes and camera views were changed and finally rendered.

Route 66 Render

Driveway Render

Bridge render

Tarmac Render

Warehouse Render