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Photo Realistic Rendering

American Chopper Moto Design and Assembly Objective: The objective of this project is to understand and demonstrate the design philosophy of a retro American chopper motorcycle model using…

pradeep meesala
updated on 07 Oct 2021

American Chopper Moto Design and Assembly

Objective:

The objective of this project is to understand and demonstrate the design philosophy of a retro American chopper motorcycle model using a new-age design tool - Solidworks. In the design, assembly, and the rendering phases, usage of sketch tools and making sure that it is fully defined, the importance of mates in assembly, usage of rendering tools in Photoview 360 as well as Solidworks Visualize is completely dealt with understanding.

Introduction:

American Chopper motorcycles

American Chopper motorcycles are bikes with, high rake angles and trail, low seat heights, low ground clearance, long wheelbase, and long front suspension travel. The rider sits with the upper torso upright or leaning slightly rearward. The footpegs are in such a position that the rider has to extend his/her legs forward. Handlebars tend to be high and wide. The emphasis is on comfort while compromising cornering ability because of low ground clearance and the greater likelihood of scraping footpegs, floorboards, or other parts if turns are taken at the speeds other motorcycles can more readily accomplish.

Parts to be modeled :

• Transmission Belt

• Kick Stand

• Front Fender

• Rear Fender

• Oil tank

• Chain

• Pedal

• Front Wheel

• Rear Wheel

• Front Fork

• Chassis

• Gas tank

Transmission Belt :

• The transmission belt is a loop of flexible material used to connect to the spinning Shaft Mechanically. The belt may be used as a motion transmitter or to control the motion relatively. The belt transmission is generally used in low-powered 2 wheelers.

Commands Used :

• Sketch

• Extrude

• Fillet

Sketch - A sketch is a 2D representation of a component from different views. It provides us with a reference on which we can perform 3D operations. Basic geometries are used to create a sketch in a 2d plane.

Extrude - Extrude command is used to create a solid or surface extrusion using the contoured profile or a 2d sketch.

Fillet - A fillet is provided at the sharp edges and corners to reduce the stress concentrations, it is rounded in geometry and provides an aesthetically pleasing feature.

Kick Stand :

A kickstand is a Device in a motorcycle that helps the bike to be held stable without the support of a 3rd body. It is generally located in the middle of the back of a motorcycle. It is connected with a hinged joint on a motorbike and can be retracted when not in use.

Commands used:

• loft

• Dome

Extrude

• Split.

• Fillet

Loft - Loft command is used to connect 2 cross-sections with different dimensions with the help of a guide curve. The resulting solid has a smooth cross-section and the material is added normally to the direction of the guide curve.

Dome-Dome command is used to create a circular or elliptical dome on the given surface. it provides a bump on the surface.

Split - This tool is used to split 2 entities with the help of a sketch or a surface.

Front and Rear Fender :

• A fender is a sheet metal part that is used to frame the front and rear wheel well. The main objective of a fender is to stop the mud and gravel from spraying in the air.

Commands used :

• Sketch

• resolve split

•split

• fillet

Revolve - A revolve command is used to create a revolved feature such as a shaft. An axis is needed to perform the command, also, the angle of rotation must be provided.

The split -The split tool is used to cut a single body into 2 or more bodies with the help of a sketch or surface. We can keep or discard the selected bodies.

Oil tank:

the oil tank is used to store lubricating oil in a dry-sump engine setup.

EXTRUDE BOSS/BASS:

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.

COMBINE:

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

FILLET:

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.

SHELL

It is used to create the thickness of the profile.

Chain:

. The transmission chain is used to deliver power from the engine to the rear wheel of the vehicle. it is the most commonly used setup in 2 wheelers, the tooth in the socket meshes with the holes in the chain. when the gear turns it pulls the chain resulting in power transmission.

Commands used -

• Block feature

• extrude

. fillet

• linear pattern

• Sketch

Block Feature - it is used to create a Template for the sketch of a part so that it can be used again in the future. -

Linear pattern - the linear pattern is used to create multiple entities of the same part in a particular direction, the number of patterns and the direction can be specified in the options dialogue box.

PEDAL:

EXTRUDE BOSS/BASS

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.

FILTER

CHAMFER

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

REVOLVED BOSS/EXTRUDED

Create a sketch with a centerline, a plane, or an axis for revolving.

Schedule a

DOME

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

LINEAR PATTERN

The feature is used to create a different number of patterns required to create the linear pattern.

WHEEL RIMS:

• The rim is the "outside edge of the wheel holding the tire." This is the outside circular shape

of the wheel on which the inner edge of the tire is placed on automobiles such as cars.

• A regular wheel rim for automotive steel is made of rectangular sheet metal. To create a cylindrical sleeve the metal plate is bent, and then the

• In this model, we have created a spider web pattern in both the front and rear rims

Commands used :

• revolve

• Revolve cut

• extrude

• circular pattern

• fillet

• Chamfer

Revolve cut - Revolve cut removes the excess material with the reference of sketch and axis of rotation. The profile can remove the material with revolution up to 360 degrees of rotation.

Circular pattern - this feature creates multiple entities of a single part on a circular path. the minimum no of entities and degree of rotation must be provided in the input window.

Front Fork :

• A front fork or a motorcycle fork connects Front-wheel and its axile to the motorcycle frame.

• A triple clamp mechanism is generally used to connect the front suspension with the handlebars for steering. Brake disk and calipers are also mounted on it.

Commands used:

• Revolve

. Extrude

• Extrude cut

• mirror

• Swept

Extrude cut - The extrude cut feature is used to remove the unwanted material as per the modified sketch. Based on the design of Sketch the material is removed.

Mirror - The mirror command is used to create a replica of the body feature in a specific direction up to a user-defined number of instances. Swept - The sweep command is used to create a solid feature by sweeping a closed profile along an open or closed path.

Engine:

• The engine is the main power generating unit in an automobile. Generally, 4 stroke petrol engine is used in the modern-day bike. In this Project, we have modeled a Double Cylinder engine for our chopper assembly

Commands used :

Extrude

fillet

• Circular pattern

• projected curve

• Mirror

• Dome

• Split

• Sweep

Projected curve - this command creates a 3d curve with the help of the intersection of 2 two dimensional sketches.

Gas Tank

• The gas tank is a sheet metal part that holds the fuel for the engine unit. It is an airtight unit designed such no fuel vapor can escape the boundary. For our Chopper, we have designed the fuel tank in a surface Environment