Assembly of American chopper

AIM:

1. To design all the parts of the American chopper using solid works part workbench.

2. To assemble all the parts designed using an assembly workbench following a bottom-up or top-down approach.

3. To create a photorealistic photo rendering using solid works visualize and photo view 360.

OBJECTIVE:

To get familiar with part workbench commands.

INTRODUCTION:

a)Part modeling:

Part modeling is the process of creating a virtual prototype of something by modeling each part separately, which can then all be assembled to create the model of the final product. Think of all of the different parts of a car engine for example.

b)Assembly:

You can build complex assemblies consisting of many components, which can be parts or other assemblies, called subassemblies. For most operations, the behavior of components is the same for both types. Adding a component to an assembly creates a link between the assembly and the component. When SOLIDWORKS opens the assembly, it finds the component file to show it in the assembly. Changes in the component are automatically reflected in the assembly.

The document name extension for assemblies is .sldasm.

Top-down approach:

Top-down assembly modeling is an assembly-centric modeling method where the assembly design is started at the highest level possible, and individual parts and subassemblies are defined within the context of the overall assembly. With this approach, an assembly layout is typically created first, and this assembly layout is used to define individual part geometry and position.

This approach is often used at companies where the product being designed is large enough that it requires many people to complete the design. A senior-level designer might create the initial assembly layout, then divide the assembly layout into logical subassemblies and parts for the remainder of the organization to complete.

Bottom-up approach:

Bottom-up assembly modeling is a part-centric modeling method where the assembly design is started with a principal structural or functional element, and individual parts are designed in relative isolation from the overall assembly. Parts and subassemblies are defined as the process moves up towards the top-level assembly. With this approach, as the design of a key component is completed, its geometry may or may not be used to aid the design of related mating components.

This approach is often used at companies where the product being designed is small enough that one or only a few people are needed to complete the design.

Design Methodology:

Components of American Chopper:

1. Chassis

2. Engine

3. Pedal

4. Transmission Belt

5. Kick Stand

6. Oil Tank

7. Rear Wheel

8. Front Wheel

9. Gas Tank

10. Rear Fender

11. Front Fender

12. Front Fork

13. Chain

1. Chassis

Chassis is the main support structure of the vehicle which is also known as 'Frame'. It bears all the stresses on the vehicle in both static and dynamic conditions. In a vehicle, it is analogous to the skeleton in living organisms.

Fig 1.1 Isometric view of Chassis

Commands used in creating chassis are:

a)Sketch:

When you open a new part document, first you create a sketch. The sketch is the basis for a 3D model. You can create a sketch on any of the default planes (Front Plane, Top Plane, and Right Plane), or a created plane.

b)Projection curve:

You can project a sketched curve onto a model face to create a 3D curve. You can also create a 3D curve that represents the intersection of two extruded surfaces generated by creating sketches on two intersecting planes.

Sweep creates a base, boss, cut, or surface by moving a profile (section) along a path. A sweep can be simple or complex.

To generate the sweep swept geometry, the software creates a series of intermediate sections made by replicating a profile at various positions along the path. The intermediate sections are then blended. Additional parameters can be included in the sweep feature such as guide curves, profile orientation options, and twist to create a wide variety of shapes.

d)Split:

Use the Split feature to create multiple parts from an existing part. You can create separate part files, and form an assembly from the new parts.

You can split one or more solid or surface bodies. To split a surface, the Trimming Surface must extend past the boundaries of the surface to split.

Fig 1.2 Rendered Image of Chassis

During modeling the chassis in solid works I was introduced to the option called projection curve where the curve can be created in a 3d environment and also combined curve which combines the two curves into one single entity.

2. Engine:

A V-twin engine, also called a V2 engine, is a two-cylinder piston engine where the cylinders share a common crankshaft and are arranged in a V-configuration.

Fig 1.3 Isometric View Of Engine

Commands used in creating engine:

a)Boss extrude:

The Boss-Extrude/Base feature will project a 3D model with the selected sketch or face.

b)Circular pattern:

Use circular patterns to create multiple instances of one or more features that you can space uniformly around an axis.

c)Projection and Combine curves:

From a sketch projected to a model face or surface, or from sketched lines on intersecting planes and a single curve can be created using two different curves.

d)Revolve:

Revolves add or remove material by revolving one or more profiles around a centerline. You can create revolved boss/bases, revolved cuts, or revolved surfaces. The revolving feature can be a solid, a thin feature, or a surface.

Fig 1.4 Rendered Image Of Engine

By modeling evolving engine of the American chopper, I gained some insights into projection and composite curves. Projected curves were used to create the complex exhaust pipes.

3. Pedal:

The pedal is used is to rest the feet while driving a two-wheeler. It is an extended piece from the chassis which is used to rest the feet to maintain balance and comfort while riding the vehicle.

Fig 1.5 Isometric View Of Pedal

Commands used in creating pedal:

a)Linear pattern:

Linear patterns are used to create multiple instances of one or more features that you can space uniformly along one or two linear paths.

b)Dome:

It is used to create multiple domes on a single body.

Fig 1.6 Rendered image Of Pedal

4. Transmission Belt:

A transmission belt is a loop of flexible material which transmits the power from the engine to the wheels.

Fig 1.7 Isometric view of Transmission Belt

Commands used in creating transmission belt:

a)Boss Extrude:

Extrude tool is used to extend a sketched profile in one or two directions as either a thin feature or a solid feature.

b)Fillet:

Fillet/Round creates a rounded internal or external face on the part. You can fillet all edges of a face, selected sets of faces, selected edges, or edge loops.

5. Kick Stand:

A kickstand is a device on a motorcycle that allows the bike to be kept 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.

Fig 1.8 Left View Of Kick Stand

Fig 1.9 Isometric View Of Kick Stand

By modeling kickstand, I got familiar with splines, ellipse. Also got familiarised with extruded boss and dome features.

Fig 1.10 Rendered Image of Kick Stand

6. Oil Tank:

Oil tanks are used to store engine oil which is used to lubricate the other parts.

Fig 1.11 Isometric View of Oil Tank

Commands used in creating oil tank:

a) Shell:

The Shell command is used to thicken the surface either it can be done on the interior or exterior surface.

Fig 1.12 Rendered Image Of Oil Tank

7. Rear Wheel:

A wheel is a circular block of a hard and durable material at whose center has been bored a circular hole
through which is placed a front axle bearing about which the wheel rotates when the moment is applied by gravity or
torque to the wheel.
Wheel consists of

Fig 1.13 Isometric View Of Rear Wheel

• Rim
• Brake Caliper

Rim:

The rim is the "outer edge of a wheel, holding the tire. It makes up the outer circular design of the wheel on
which the inside edge of the tire is mounted on vehicles such as automobiles.

Brake Caliper:

A disc brake is a type of brake that uses the calipers to squeeze pairs of pads against a disc or 'rotor"
to create friction. This action slows the rotation of a shaft, such as a vehicle axle, either to reduce its rotational speed
or to hold it stationary.

Fig 1.14 Rendered Image Of Rear Wheel

8. Front Wheel:

Fig 1.15 Isometric View Of Front Wheel

In this session, I modeled the various components of the American chopper's front wheel. After modeling the rim, rotor, brake caliper, and tire, I gave appropriate aesthetics to each component. I started by drawing a cross-section of the rim and hub. Then, using the 'Revolve Boss/Base tool,' I rotated the sketch along an axis. After sketching essential designs, a single spoke was built using the spline tool, and unwanted materials were deleted using the Extruded Cut tool. The spokes were mostly designed using the '3point arc' paradigm, which was influenced by the spider web model. The 'Circular Pattern' tool was used to generate the remaining two spokes at identical distances around the hub after completing a single spoke. The brake caliper and disc were then modeled. The holes and cuts on the rotor were modeled using both a linear and circular pattern. Finally, the tire was designed to fit the rim. The 'Convert entities' tool came in handy when sketching the tire. Then I drew a cross-section of the tire and rotated it around a makeshift axis. The next stage was to design the tread patterns on the tire. Using the '3 points center rectangle' tool, I began designing the tread pattern and provided the essential dimensions. Finally, the tread pattern was created on the tire's surface, and the tread patterns were applied uniformly using the 'Circular Pattern' tool. Finally, appropriate appearances were applied.

Fig 1.16 Rendered Image Of Front Wheel

9. Gas Tank:

By modeling gas tanks, I got familiar with projection and combining curves. Due to the complex geometry of gas tank surface workbench commands surface knit and surface loft are used.

Fig 1.17 Rendered Image Of Gas Tank

Commands used in creating gas tank:

a)Surface Knit:

Knit surfaces absorb the surface bodies you used to create them. Create a solid body when the knit surfaces form a closed volume or leave it as a surface body. Select Merge entities to merge faces with the same underlying geometry.

b)Surface loft:

The loft feature creates a shape by making transitions between multiple profiles and guide curves. This tool is very valuable for modeling complex surfaces

10. Rear Fender:

Fenders do have a purpose, which is to catch the water spraying off of a tire. So, another term for a bicycle fender would be a mudguard.

Fig 1.18 Isometric View Of Rear Fender

By modeling Rear Fender, I got familiar with three-point arc, splines, and shell features. In the end, Siena's appearance was applied.

Fig 1.19 Rendered Image Of Rear Fender

11. Front Fender:

The design procedure was the same as the rear fender but the front fender was not wide as compared to the rear fender.

Fig 1.19 Rendered Image Of Front Fender

12. Front Fork:

A motorcycle fork connects a motorcycle's front wheel and axle to its frame, typically via a yoke, also known as a triple clamp, which consists of an upper yoke joined to a lower yoke via a steering stem, a shaft that runs through the steering head, creating the steering axis. 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.

Fig 1.20 Isometric View Of Front Fork

Commands used in creating the front fork:

a)Body Move/Copy:

In multibody parts, you can move, rotate, and copy solid and surface bodies, or place them using mates.

b)Reference geometry:

Reference geometry is used to create a reference plane, axis, coordinate system based on one, two, or, three references.

Fig 1.21 Rendered Image Of Front Fender

13. Chain:

I learned how to make blocks and save them so that we can use them later for modeling repeating parts or components. I got to know that only one sketch can be used for repeated parts which save a lot of time.

Fig 1.22 Rendered Image Of Chain

Assembly of American Chopper:

First I inserted every component in the assembly workbench and then I applied specific mates to assemble all the parts correctly. And rendering was done in photo view 360.

Rendered Images:

Conclusion:

All the parts of the American chopper were created and assembled using solid works successfully. And rendering was carried out using photo view 360 and key shot.