2021
	SKILL-LYNC         MODELING OF AMERICAN  CHOPPER IN SOLIDWOEKS

 

By

ABHIJNA K

 

 

 

CHAPTER

     NO                  TITLE                                     PAGE NO

    LIST OF FIGURE                                                   i

1. INTRODUCTION

• Objectives                                                      6

2. METHODOLOGY                                              7
3. FEATURES AND PROPERTIES

• Extrude boss                                                  8
• Fillet                                                              9
• Revolved boss feature                                     9
• Extrude cut                                                   10
• Shell                                                             11
• Sweep boss / sweep cut                                 12
• Loft boss / loft cut                                         14
• Linear pattern                                               15
• Mirror                                                           16
• Projected curve                                             17
• Reference geometry                                       18
• Combine                                                       19
• Dome                                                            21
• Split                                                              21
• mate                                                             22

4. MODELLING

• Transmission Belt                                           23 
• Kickstand                                                      24
• Front Fender                                                  25                                             
• Rear Fender                                                   26                                                                             
• Chain                                                            27
• Oil tank                                                         28
• pedal                                                            29
• Front Wheel                                                  30
• Rear Wheel                                                   31
• Front Fork                                                     32
• Chassis                                                         33
• Engine                                                          34
• Gas Tank                                                       36                                                   

5. AMERICAN CHOPPER ASSEMBLY                      38
6. RENDERING                                                   40
7. CONCLUSION                                                 51

 

 

 

LIST OF FIGURES

  FIGURE

       NO                  TITLE                                  PAGE NO

• Extrude boss                                                    8
• Fillet                                                                9
• Revolved boss feat e                                        10
• Extrude cut                                                     11
• Shell                                                               12

3.6.1  Sweep boss                                                    13

• Sweep cut                                                       13

3.7.1  Loft boss                                                        14

3.7.2  Loft cut                                                          15

• Linear pattern                                                  16
• Mirror                                                              17
• Projected curve                                                18
• Reference geometry                                         19
• Combine                                                          20
• Dome                                                              21
• Split                                                                22
• mate                                                               22
• Transmission Belt                                             23
• Kickstand                                                        24
• Front Fender                                                    25
• Rear Fender                                                     26
• Chain                                                              27
• Oil tank                                                           28
• Pedal                                                               29
• Front Wheel                                                     30
• Rear Wheel                                                      31
• Front Fork                                                        33
• Chassis                                                            34
• Engine                                                             35
• Gas Tank                                                          37

          5.1Assembly mate features                              38

          5.2Chopper assembly                                       39

           6.1SOLIDWORK Visualize                                 40

           6.2Rendering image 1                                      41

           6.3Rendering image 2                                      42

           6.4Rendering image 3                                      43

           6.5Rendering image 4                                      44

           6.6Rendering image 5                                      45

           6.7Rendering image 6                                      46

           6.8Rendering image 7                                      47

           6.9Rendering image 8                                      48

           6.10Rendering image 9                                    49

           6.11Rendering image 10                                   50

 

                                            

 

 

                                                                                                CHAPTER 1

INTRODUCTION

 

         SOLIDWORKS have different software that are used by mechanical, electrical, civil etc engineering branches. Here we use SPLIDWORKS CAD modeling software which use for 3D and surface designing, plastic and mold designing, photo realistic rendering, FEA analysis etc.

          In this project we do solid and surface modeling for designing of parts and then these parts where assemble together in solid work software

 

• OBJECTIVES

• Learn the basic features and tools of the SOLIDWORKS Model the different parts of American chopper
• Assemble the part models of American chopper
• Using PHOTOVIEW 360 perform a photo realistic rendering of an American chopper

 

 

 

 

CHAPTER 2

METHODOLOGY

CHAPTER 3

FEATURES AND PROPERTIES

 

• Extrude boss:

            In this blog we will be covering the Extruded Boss/Base feature, this is one of the most common and universal features used within the 3D modeling world. This is a handy feature for creating 3D solid models within SOLIDWORKS.

              Using the modeled 2D sketch created, you are ready to turn the 2D sketch element into a 3D solid feature.

 

 

Figure 3.1: extrude boss

 

 

 

• Fillet:

              Fillet 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.

 

 

Figure 3.2: fillet

 

 

 

 

 

 

• Revolved boss feature

              Revolved boss feature 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 revolve feature can be a solid, a thin feature, or a surface.

 

Figure 3.3: revolved boss feature

 

• Extrude cut:

             Using the Extruded Boss/Base model created in the Extruded Boss/Base blog, we will modify the 3D block to include a circle feature by removing material. The Extruded Cut feature can be found on the features tab in the Command Manager interface

             The Cut-Extrude feature is a very useful tool. In the manufacturing world, it can be a common practice to start with stock material and proceed to use the Cut-Extrude tool to remove material as you would during the machining phase.

 

 

 

 

 

Figure 3.4: extrude cut

 

• 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. If the Shell tool has problems shelling a model, the Error Diagnostics section appears in the Property Manager to help you diagnose the problem.

Figure 3.5: shell

 

 

• Sweep boss/ sweep cut

              Sweep is the one feature in SOLIDWORKS that helps sweep a closed profile along a closed or open path. In this session, we are going to use a simple 3D object as an exercise to demonstrate the use of the SWEEP command in SOLIDWORKS.

             The most common usage is in creating cuts around cylindrical bodies. This option would also be useful for end mill simulation. When you select Solid Sweep, the path must be tangent within itself  and begin at a point on or within the tool body profile.

 

Figure 3.6.1: sweep boss

Figure 3.6.2: sweep cut

 

• Loft boss/ loft cut

              The loft feature is an important tool for modeling in SOLIDWORKS. The loft feature creates a shape by making transitions between multiple profiles and guide curves. This tool is very valuable for modeling complex surfaces. You can do some really cool stuff when you use this feature properly.

                Loft creates a feature by making transitions between profiles. A loft can be a base, boss, cut, or surface. You create a loft using two or more profiles. Only the first, last, or first and last profiles can be points. All sketch entities, including guide curves and profiles, can be contained in a single 3D sketch.

 

 

3.7.1: Loft boss

 

 

 

 

3.7.2: loft cut

 

 

 

 

• Linear pattern:

             The SOLIDWORKS Linear Pattern tool is a great way to make a grid of holes or multiple bodies very quickly. This tool is very easy to use and saves you a lot of time. Use linear patterns to create multiple instances of one or more features that you can space uniformly along one or two linear paths.

            

Figure 3.8: linear pattern

 

• Mirror:

              Mirroring is another way that SOLIDWORKS can create a copy of an existing object. In most cases, you will have to create your own plane to have the mirror done the way you need.

               Various commands are available for mirroring and creating opposite-hand versions of items such as sketch entities, features, parts, and assembly components. The command you need depends on the type of item for which you want to create a mirror or an opposite-hand version.

Figure 3.9: mirror

 

• Projected curve:

              SOLIDWORKS has a tool called Projected Curve that can take any sketch and transfer it over to another sketch or face. You can then use that sketch for creating features to even to split a body.

              The Project Curve feature is more like the Split Line than the Wrap feature. It can do everything the Split Line feature with one exception, it gives up the ability to split faces in favor of being able to use open contour sketches that are within the boundary of a face.

Figure 3.10: projected curve

 

• Reference geometry:

              Reference geometry defines the shape or form of a surface or a solid. Reference geometry includes items such as planes, axes, coordinate systems, and points.

              You can use reference geometry in the creation of several kinds of features. For example:

• Planes are used in lofts and sweeps.
• An axis is used in a circular pattern.

 

 

 

 

Figure 3.11: reference geometry

 

• Combine:

               In a multi body part, you can combine multiple solid bodies to create a single-bodied part or another multi body part. You can add or subtract bodies, or keep material that is common to the selected bodies.

• Combining Bodies - Add:
  In a multi body part, you can combine multiple bodies to create a single body.
• Combining Bodies - Subtract:
  In a multi body part, you can subtract one or more bodies from another body.

 

• Combining Bodies - Common:
  In a multi body part, you can create a body defined by the intersection of multiple bodies.
• Combine Property Manager:
  In the Combine Property Manager, you specify which bodies in a multi body part to add, subtract, or overlap.

Figure 3.12: combine

• Dome:

              SOLIDWORKS provides a tool called ad ‘Dome’ that you can create domes on 3D parts and shapes. The use of dome command is very easy.

             The Parameters in the dome Property Manager includes Faces to dome. Select one or more planar or non-planar faces. You can apply domes to faces in which centroid lies outside the face. This allows you to apply domes to irregularly shaped contours

 

Figure 3.13: dome

 

 

• 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.

Figure 3.14: split

 

• Mate:

              Mates create geometric relationships between assembly components. As you add mates, you define the allowable directions of linear or rotational motion of the components. You can move a component within its degrees of freedom, visualizing the assembly's behavior.

Figure 3.15: mate

 

 

CHAPTER 4

MODELLING

 

THE CHOPPER CONSISTS OF FOLLOWING PARTS:

 

4.1. Transmission belt:

           Belts are mechanical elements used for power transmission without phase shift. They are loops of flexible materials used to mechanically connect several rotating shafts. Belts can be used as a transmission element, to efficiently transmit power or movement.

The steps used to model the transmission belt:

Step1:

           Create a 2D sketch based on the vertical cross section of the Transmission belt and make sure they are in relation to each other and dimensioned correctly.

Step2:

           Create an Extrude by selecting the sketch loop and then specifying the dimension of the Extrude. Use fillet tool to give the transmission Belt a smooth finish.

Step3:

           Select appearance tab specify the material for the Transmission Belt Rubber matte.

Step4:

           Save the part. 

Figure 4.1: transmission belt

4.2. Kick stand:

             Kick stand is a device for supporting a bicycle or motorcycle. when not in use, pivoted to the rear axle in such a way that it can be kicked down from a horizontal to a vertical position on.

The steps used to model the kick stand:

Step1:

           Create a 2D sketch based on the cross section of the thick portion of the kickstand, then use line function to draw the guide way for the loft and then finally add a plane normal to the direction of our line. After creating a plane create a 2D sketch based on the cross section of the thin portion of the kickstand and create a loft across the guide curve .All the sketch are in relation and dimensioned correctly and the sketch is fully defined.

Step2:

           Use the dome tool to create a curved shape at both the end sections, and then extrude cut to create a cut near the thick portion of the kickstand so that it can be attached to the pivot. After that split feature used to create pivot point to attach to the frame we will create cylindrical section near cut out of the kickstand.

Step3:

           Fillet the edges for a smooth finish and in the appearances select chrome plate.

Step4:

           Save the part as a kickstand.

Figure 4.2: Kick stand

4.3. Front fender:

              Front fender is the part of the vehicle that covers the front wheel. Its primary purpose is to stop the dirt, water or sludge from being thrown around the wheel.

The steps used to model the front fender:

Step1:

            Create a 2D sketch based on cross section of the front Fender and then use the revolve tools by specifying the angle of revolving in both the dimensions.

Step2:

            Sketch the design of the cut out portions at both the end section of the front fender.

Step3:

            Fillet the edge of the front fender .using appearances under painted car sienna color Looking very stylist.

Step4:

            Save the part as Front Fender.

Figure 4.3: Front fender

 

 

 

 

4.4. Rear fender:

              Rear fender is the part of the vehicle that covers the rear wheel. Its primary purpose is to stop the dirt, water or sludge from being thrown around the wheel.

The steps used to model the rear fender:

Step1:

            Create a 2D sketch based on cross section of the Rear Fender and then use the revolve tools by specifying the angle of revolving in both the dimensions.

Step2:

            Sketch the design of the cut out portions at both the end section of the Rear fender.

Step3:

            Fillet the edge of the Rear fender .using appearances under painted car siena  color .looking very stylist .

Step4:

            Save the part as Rear Fender.

Figure 4.4: Rear fender

 

 

 

 

4.5. Chain:

              Chains are used as the part of the drive train to transmit the motor power to the back wheel. Chains are superior to gears, which are in the crank cases, by the ease in adjusting the shaft center distance and the number of teeth of the sprocket.

The steps used to model the chain:

Step1:

            Create a 2d sketch using of line and arc tools making the outer edges of the chain link.

Step 2:

            Create the front and back link of a chain and saved as a block diagram to use continuously with the relation of concentric to joint of the path. Determine how much block diagram needed to compact the curve by using our mouse middle button scrolling until the entire loop compacted.

Step3:

           After that mirror the face’s to the pins with respect to the mid plane. A fine finished chrome plate metal is used as the appearance of the linked part.

Step4:

            Save the part.

Figure 4.5: Chain

 

4.6. Oil tank:

              Oil tank is a part of the chopper. Oil tank is used to store the oil required to run the engine. Oil tank is hollow one. The thickness of the oil tank is given as 3mm in our chopper.

The steps used to model the oil tank:

Step1:

            Create a 2D Sketch based on the Top plane and extruded. Again create a sketch on the mid plane and extruded.

Step2:

            After that Extruded the Sketch Combine Feature used and combine both the extrude together. And another feature is used that is shell feature   is used to make the part hollow and edges are fillet.

Step3:

            In the appearance tap use same as sienna color in the body. Fillet edges are painted as White paint.

Step4:

            Save the part.

Figure 4.6: Oil tank

 

4.7. Pedal:

            Pedal is the external part attached to the chassis. Pedal is used to place the leg on top of that. To give comfort to the rider pedal is used.

The steps used to model the pedal:

Step1:

            Create a 2D sketch based on Front plane the base of the pedal ,and then extruded boss is created with dimensional  circular hole for the foot rest. And pins extruded again.

Step2:

            Now create a sketch on the top plane and revolved. And now applied Dome Feature and filleted the edges.

Step3:

            After that the front and rear extruded cylindrical part chamfered. Circular pattern is extruded on each of the front facing extrudes which are then arranged using linear pattern and filleted edges.

Step4:

           Save the part.

Figure 4.7: Pedal

4.8. Front wheel:

            A wheel is a circular block made of the steel/alloy materials. On the top of the wheel the tire is covered. The tire is made of rubber and has thin wire within it.

The steps used to model the front wheel:

Step1:

           Create a 2D sketch on front plane. Then use revolved feature for making tires. After that using the Extrude Boss Feature for making or create the rims calipers, rotor, sprocket.

Step2:

           Now we using the Extrude Cut feature for remove the additional materials from the extruded rims for the spider webbed design. After that we use cut Revolve to cut out the side sections.

Step3:

           Then use circular pattern in the sprocket, Rotor, Rim, Tire Grip Design.

Step 4:

           Apparances uses to specify the materials of various part.

Step5:

           Save the part.

Figure 4.8: front wheel

4.9. Rear wheel:

             A wheel is a circular block made of the steel/alloy materials. On the top of the wheel the tyre is covered. The tyre is made of rubber and has thin wire within it.

The steps used to model the rear wheel:

Step1:

            Create a 2D sketch on front plane . Then using revolved feature for making tires . After that using the Extrude Boss Feature for making or create the Rims Calipers, Rotor, Sprocket etc.

Step2:

            Now we using the Extrude Cut feature for remove the additional materials from the extruded rims. After that we using Cut revolve to cut the side section from the extruded rims for the spider Webbed Design.

Step3:

            After that we  using circular pattern in the sprocket, Rotor, Rims Tire Grip Design.

Step4:

            Appearances  uses to specify the materials of various part

Step5:

            Save the part.

Figure 4.9: Rear wheel

4.10. Front fork:

             It is more common in motorcycle and chopper design for front forks to be perfectly straight rather than employing any angle in the actual fork to create the desired rake. The modern motorcycle designer usually introduces rake to the forks through angling the triple tree to the desired angle. Choppers are designed with both fork rake and fork extension to create the unique, low and long look associated with these custom motorcycles.

The steps used to model the front fork:

Step1:

            To Creat a 2D sketch On a Front plane. And by using Revolved Boss feature to create fork tube. Again create a sketch and create handle grip by Revolve boss Feature. In this Revolve Boss Feature We create Head light.

Step2:

            We using Extrude Boss to create the Triple clamps, Breaks etc.

Step3:

            In this Extrude Cut Feature we create circular cutouts for the triple clamps. And use another feature that is dome to create the dome shape of the headlight.

Step4:

            To create the two portions of the triple clamps by using linear pattern feature. we create the complex shape of the Bike Handle bars and the Break Wires, Projected curve was used to create the path for the sweep command and then the sweep too we used from the feature tab to complete the Bike Handles. The same procedure was used to design the break wires.

Step5:

            Appearance to specify the materials of various part.

Step6:

            Save the part.

Figure 4.10: Front fork

 

4.11. Chassis:

A chassis or frame of the chopper forms its skeleton. All the components of a chopper like the suspention, wheel, fuel tank etc, are attached to the base structure which lends its strength and ability to handle well.

The steps used to model the chassis:

Step1:

           Before Creating Sketch Rename the Plane For Better Understanding . Now Create a 2D   Sketches on the Mid plane Chassis. The Sketch Based On the Reference blue Print Of the American Chopper.

Step2:

           Extrude feature was used to create plate sections of the chassis. And then used Sweep feature to design the chassis cylindrical structures of the chassis.

Step3:

           Projected curve features are used to create the sweep paths of the complex geometry. Then using Extruded cut Feature to cut the Extra portions of the Extruded bodies.

 

Step4:

           After that we using Revolve cut functions to create the cylindrical geometries and to cut out unwanted portions from the revolved parts. Some other features used  included Mirror, Dome, Fillet, Chamfer.

Step5:

           In Appearances Tab we use Siena colour .

Step 6:

           Save the part.

Figure 4.11: Chassis

 

4.12. Engine:

              Engine is a prime mover of the chopper. The engine converts a chemical energy into heat energy and then heat energy is converted into mechanical work. The mechanical work in the engine is rotational motion. This rotation is converted to the wheel with the help of chain and sprocket through the gear box and clutch.

The steps used to model the engine:

Step1:

            Initially, 2D sketch’s were drawn through the reference of blueprint  of

chopper image and the extruded feature is used to create each part of the engine like a sprocket, engine  cylinder, engine exhaust system.

Step2:

            Chamfer feature is used to create the tapering design of the two engine cylinder.

Step3:

           The sweep, projected curve feature is used to create the complex geometry path for the sweep, split, extrude cut, revolve feature were used to create the air Filter and the Exhaust manifold.

Step4:

           The linear pattern feature and circular pattern were used to design the cutout sections of the row of fins on the engine cylinder and the circular cutouts for the sprocket respectively. Some other feature were used like as mirror, dome, fillet.

Step5:

           Save the part.

Figure 4.12: Engine

 

4.13. Gas tank:

             Gas tank is used to store the gas, to supply the gas to the engine whenever it’s required.

The steps used to model the gas tank:

Step1:

           To create 2D sketches with Based on the Blueprint chopper image. Creating a 2D plane sketch its Surface sweep Feature was used for making the outer layer of the Gas tank.

Step2:

           The split line was used to remove the unwanted part by designing the shape to be cut.

Step3:

           Surface Knit feature were used and then combine the Surfaces of the gas tank.

Step4:

           And then using  a surface loft is created as the front face of the tank now with the help of boundary sweep feature the front face and the side face are joined. A sketch is drawn at the face of the gas tank to cut the u section all the sharp ends are then filleted a shell is created at the end to make it hollow. Other tools used like cut sweep.

Step5:

           In the Appearances Tab we were used sienna color .and for seat material we used Grey cotton.

Step6:

           Save the Part.

Figure 4.13: Gas tank

 

 

CHAPTER 5

AMERICAN CHOPPER ASSEMBLY

             You can build complex assemblies consisting of many components, which can be parts or subassemblies. Adding components to an assembly creates a link between the assembly and the component. When SOLIDWORKS opens the assembly, it shows the component file to show it in the assembly. And mate creates geometric relationship between assembly components. As you add mates, you define the allowable directions of linear or rotational motion of the component. You can move a component within its degree of freedom, visualizing the assembly’s behavior.

             The Different Assembly Parts are opened and then assembled in the assembly window by using different mate options like as coincident, concentric, angled, parallel, limit angel, tangent, width mate etc

 

Figure 5.1: Assembly mate features

Figure 5.2: Chopper assembly

 

 

CHAPTER 6

RENDERING

SOLIDWORK S VISUALISE

              SOLIWORKS Visualize has now made easier to create real view renderings since we can now import all custom saved cameras, views, and even the physical lighting straight into visualize from SOLIDWORKS 2020.

              At the end of Assembly we reach the final step of the bike to make sure to look the bike as realistic view. Initially make sure your assembled part in the correct position in which you want to be. In this case we want to the chopper to learn on the stand to make sure the chopper is slightly tilted towards the stand so that it gives a more realistic look. Using PHOTOVIEW 360 try different environments based on the project you are looking on. After selection of the environment make sure all the shadows light camera settings are set perfectly .Finally select the resolutions of your render, pixel and perform the final render. We can also use solid works visualize for more realistic renders. The parameters are same but the Solid works gives more options for rendering like HDR background selections, camera settings, and more options in the material selections. Finally save your Rendering.

Figure 6.1: SOLIDWORK Visualize

 

Figure 6.2: Rendering image 1

 

Figure 6.3: Rendering image 2

 

 

Figure 6.4: Rendering image 3

 

Figure 6.5: Rendering image 4

 

 

Figure 6.6: Rendering image 5

 

Figure 4.7: Rendering image 6

 

 

Figure 6.8: Rendering image 7

 

Figure 6.9: Rendering image 8

 

Figure 6.10: Rendering image 9

 

Figure 6.11: Rendering image 10

 

 

CHAPTER 7

CONCLUSSION

• All the parts of American chopper are modeled and assembled together successfully using SOLIDWORKS 2020
• The assembled chopper is rendered using PHOTOVIEW 360.