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Engine Open a new part with model units set to millimeters. Select the three planes in the feature tree and make them visible by clicking on the glasses.
Select the Front Plane and create a sketch by clicking on the 2D Sketch icon Draw the sketch as shown in the picture.
Create an extrude Go to: Insert > Boss/Base > Extrude Direction 1 Change
: Blind into 200 mm
Click OK
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Engine Open a new part with model units set to millimeters. Select the three planes in the feature tree and make them visible by clicking on the glasses.
Select the Front Plane and create a sketch by clicking on the 2D Sketch icon Draw the sketch as shown in the picture.
Create an extrude Go to: Insert > Boss/Base > Extrude Direction 1 Change
: Blind into 200 mm
Click OK
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Create a new plane parallel at the Front Plane Go to: Insert > Reference Geometry > Plane Select the Front Plane. Select the midpoint in the picture.
of Extrude1 as shown
Click OK
Change the name of the new Plane1 Double click on Plane1 in the feature tree. Change the name into: MIDPLANE ENGINE
Select the MIDPLANE ENGINE and create a new sketch
Insert a sketch underlay. For this part of the chopper we use a hand made sketch as underlay to simplify the design process of the engine. Go to: Tools > Sketch Tools > Sketch Picture Select “Chopper Underlay.Jpeg” Underlay.Jpe g” Click: open
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Change the dimensions of
and
as shown in the picture.
Change the position of the underlay to ensure that the bottom of Extrude1 is equal with the engine on the underlay.
Click OK | Page
Change the name of Sketch2 Double click on Sketch2 in the feature tree. Change the name into: ENGINE UNDERLAY Hide the underlay if this is appropriate Click on “Chopper Underlay” in the feature tree and hide this by clicking on the glasses. Use the underlay whenever you want.
Select the green surface of Extrude1 as shown in the picture and create a new sketch
Draw the sketch as shown in the picture.
Create an extrude Go to: Insert > Boss/Base > Extrude Direction 1 Change
: Blind into 50 mm
Click OK
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Select the front surface of Extrude2 and draw the sketch as shown in the picture
Create an extrude Go to: Insert > Boss/Base > Extrude Direction 1 Change
: Blind into 40 mm
Click OK
Select the MIDPLANE ENGINE and create a new sketch Draw the sketch as shown in the picture.
Create an extrude Go to: Insert > Boss/Base > Extrude Direction 1 Change
: Mid Plane into 150 mm
Click OK
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Create eleven fillets Select the green edges as shown in the picture. Go to: Insert > Features > Fillet/Round
> 50 mm
Click OK
Select the Front Plane and create a new sketch Draw the sketch as shown in the picture and detail.
Detail Create a revolve Go to: Insert > Boss/Base > Revolve Axis of revolution
: Select the green line as shown in the picture.
Click OK
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Create a new plane parallel at the Right Plane Go to: Insert > Reference Geometry > Plane Select the Right Plane. Change the Offset Distance
into 350 mm.
Ensure that the offset is directed to the middle of the engine. If not, select “Reverse direction” Click OK
Select the new Plane2 and create a new sketch Draw the sketch as shown in the picture.
Create a revolve Go to: Insert > Boss/Base > Revolve Axis of revolution
: Select the green line as shown in the picture.
Click OK | Page
Select the green surface of Revolve1 as shown in the picture and create a new sketch
Draw the sketch as shown in the picture and detail.
Detail
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Create a circular pattern sketch Go to: Tools > Sketch Tools > Circular Pattern Pattern Axis
: Select the origin in the middle of the circle.
Number of instances Angle
: 360 deg
Radius
: 60 mm
Arc Angle
: 40
: 270 deg
Select the “Equal spacing” option Entities to Pattern
: Select the rectangle of Sketch8
Click OK
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Create a new sketch as shown in the picture and detail.
Detail | Page
Create another circular pattern sketch Go to: Tools > Sketch Tools > Circular Pattern Pattern Axis
: Select the midpoint of the circle.
Number of instances Angle
: 360 deg
Radius
: 70 mm
Arc Angle
: 44
: 270 deg
Select the “Equal spacing” option Entities to Pattern
: Select the rectangle
Click OK
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Create an extruded cut Go to: Insert > Boss/Base > Extrude Direction 1 Change
: Blind into 88 mm
Click OK
Create a dome Go to: Insert > Feature > Dome Select the green surfaces of Revolve1 and Revolve2. Change the Distance
into 10 mm
Click OK
Create a new plane parallel at the MIDPLANE ENGINE Go to: Insert > Reference Geometry > Plane Select the MIDPLANE ENGINE. Change the Offset Distance
into 250 mm.
Ensure that the offset direction is correct. If not, select “Reverse direction” Click OK
Select the green surface of Dome1 as shown in the picture and create a new sketch
Draw the sketch as shown in the picture on the next page.
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Create a circular pattern sketch Go to: Tools > Sketch Tools > Circular Pattern Pattern Axis
: Select the midpoint of the big circle.
Number of instances Angle
: 360 deg
Radius
: 55 mm
Arc Angle
: 12
: 270 deg
Select the “Equal spacing” option Entities to Pattern
: Select the Small circle
Click OK Create an extruded cut Go to: Insert > Cut > Extrude Direction 1 Change
: Offset From Surface into 3 mm
Select the pink surface
as shown in the picture.
Select the “Reverse offset” option. Click OK | Page
Select the other green surface of Dome1 as shown in the picture and create a new sketch
Create a circular pattern sketch Go to: Tools > Sketch Tools > Circular Pattern Pattern Axis
: Select the midpoint of the big circle.
Number of instances Angle
: 360 deg
Radius
: 65 mm
Arc Angle
: 14
: 270 deg
Select the “Equal spacing” option Entities to Pattern
: Select the Small circle
Click OK
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Create an extruded cut Go to: Insert > Cut > Extrude Direction 1 Change
: Offset From Surface into 3 mm
Select the pink surface in the picture.
as shown
Select the “Reverse offset” option. Click OK
Create a chamfer Go to: Insert > Features > Chamfer Select the green surfaces as shown in the picture. Select the “Angle – distance” option. Change Angle
into: 3 mm : 45 deg
Click OK
Create fillets on the edges Select the green surfaces as shown in the picture. Go to: Insert > Features > Fillet/Round
> 1 mm
Click OK
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Select the MIDPLANE ENGINE and create a new sketch Draw the sketch as shown in the picture.
Create an extrude Go to: Insert > Boss/Base > Extrude Direction 1 Change
: Midplane into 150 mm
Click OK
Select the MIDPLANE ENGINE again and create a new sketch Draw the sketch as shown in the picture.
Create an extrude Go to: Insert > Boss/Base > Extrude Direction 1 Change
: Midplane into 110 mm
Select the “Selected bodies” option. Select the two cyan bodies as shown in the picture. Click OK
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Select the MIDPLANE ENGINE and create a new sketch Draw the sketch as shown in the picture.
Create an extrude Go to: Insert > Boss/Base > Extrude Direction 1 Change
: Midplane into 100 mm
Click OK
Select the green surface of Extrude10 and create a new sketch Draw the square as shown in the picture.
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Create an extrude Go to: Insert > Boss/Base > Extrude Direction 1 Change
: Blind into 240 mm
Click OK
Create four chamfers Go to: Insert > Features > Chamfer Select the four green edges as shown in the picture. Select for the “Distance – distance” option. Change
into: 30 mm
Change
into: 240 mm
Click OK
Convert the four edges of the green surface Select the green top surface of Extrude11 as shown in the picture. Create a new sketch Go to Tools > Sketch Tools > Convert Entities
Create an extrude Go to: Insert > Boss/Base > Extrude Direction 1 Change
: Blind into 125 mm
Click OK | Page
Create four chamfers Go to: Insert > Features > Chamfer Select the four green edges as shown in the picture. Select for the “Distance – distance” option. Change
into: 90 mm
Change
into: 15 mm
Click OK
Create sixteen fillets on the edges Select the green edges as shown in the picture. Go to: Insert > Features > Fillet/Round
> 15 mm
Click OK
Create a new plane parallel at the green surface Go to: Insert > Reference Geometry > Plane Select the green top surface of Extrude12 as shown in the picture. Change the Offset Distance
into 315mm.
Ensure that the offset is directed downwards. If not, select “Reverse direction” Click OK
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Select the new Plane4 and create a new sketch Draw the two squares as shown in the picture.
Create an extruded cut Go to: Insert > Cut > Extrude Direction 1 Change
: Blind into 8 mm
Ensure that the offset is directed upwards. If not, click “Reverse direction” Click OK
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Create fillets on the edges Select the four green edges as shown in the picture. Go to: Insert > Features > Fillet/Round
> 10 mm
Click OK
Create a linear pattern Go to: Insert > Pattern/Mirror > Linear Pattern Select an edge that lies parallel at the direction of the pattern. This could be the green line as shown in the picture. Change
into: 16 mm
Number of Instances Features to pattern
: 14 : Extrude13, Fillet4
Click OK
Create fillets on the edges of Extrude13 Select the green surfaces as shown in the picture. Go to: Insert > Features > Fillet/Round
> 2 mm
Click OK
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Select the MIDPLANE ENGINE and create a new sketch Draw the arc as shown in the picture.
Create a thin extruded cut Go to: Insert > Cut > Extrude Direction 1
: Midplane
Change
into Trough All
Change
into Trough All
Select the “Thin feature” option. Direction
: One-Direction
Change
into 0,5 mm
Ensure that the extrusion is directed upwards. If not, click “Reverse direction”
Click OK Bodies to Keep: Select All bodies Click OK The body is now divided into two parts | Page
Create fillets on the green edges Select the green edges as shown in the picture. Go to: Insert > Features > Fillet/Round
> 10 mm
Click OK
Create fillets on the green edges Select the green edges as shown in the picture. Go to: Insert > Features > Fillet/Round
> 5 mm
Click OK
Create four fillets on the green edges Select the four green edges as shown in the picture. Go to: Insert > Features > Fillet/Round
> 8 mm
Click OK
Select the green surface of Chamfer3 and create a new sketch Draw the sketch as shown in the picture.
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Create an extrude
Go to: Insert > Boss/Base > Extrude Direction 1 Change
: Blind into 2 mm
Click OK
Create four fillets on the green edges Select the four green edges as shown in the picture. Go to: Insert > Features > Fillet/Round > 10 mm Click OK
Create a dome Go to: Insert > Feature > Dome Select the green surface of Extrude15. Change the Distance
into 2,5 mm
Turn of the “Continuous dome” option. Click OK
Create a mirror Go to: Insert > Pattern/Mirror > Mirror Mirror Face/Plane
: MIDPLANE ENGINE
Select the “Features to Mirror” option Features to Mirror
: Extrude15, Fillet9, Dome2
Click OK | Page
Select the MIDPLANE ENGINE and create a new sketch Draw the sketch as shown in the picture and detail. Connect the construction line edge of Chamfer3.
with the green
Detail
Create an extrude Go to: Insert > Boss/Base > Extrude Direction 1 Change
: Mid Plane into 20 mm
Click OK
Create six fillets on the green edges Select the green edges as shown in the picture. Go to: Insert > Features > Fillet/Round
> 10 mm
Click OK
Create another six fillets on the green edges Select the green edges as shown in the picture. Go to: Insert > Features > Fillet/Round
> 2,5 mm
Click OK
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Create a mirror Go to: Insert > Pattern/Mirror > Mirror Mirror Face/Plane
: Right Plane
Select the “Bodies to Mirror” option Bodies to Mirror
: Select the green body
Click OK
Create a fillet on the green edge Select the green edge as shown in the picture. Go to: Insert > Features > Fillet/Round
> 25 mm
Click OK
Create two fillets on the green edges Select the green edges as shown in the picture. Go to: Insert > Features > Fillet/Round
> 4 mm
Click OK
Select the green surface as shown in the picture and create a new sketch
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Draw the sketch as shown in the picture.
Mirror
the rectangle around the green construction line.
Mirror
the two rectangles around the green construction line.
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Create an extrude Go to: Insert > Boss/Base > Extrude Direction 1 Change
: Blind into 50 mm
Click OK
Select the green surface as shown in the picture and create a new sketch Draw the four rectangles in the same way as the previous rectangles.
Create an extrude Go to: Insert > Boss/Base > Extrude Direction 1 Change
: Blind into 12 mm
Click OK | Page
Create fillets on the green edges and surfaces Select the green edges and surfaces as shown in the picture. Go to: Insert > Features > Fillet/Round
> 5 mm
Click OK
Create fillets on the green edges Select the green edge as shown in the picture. SolidWorks automatically selects the other edges of this body. Those are marked in yellow.
Go to: Insert > Features > Fillet/Round
> 2 mm
Click OK
Select the green surface as shown in the picture and create a new sketch Draw the circle.
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Create an extrude Go to: Insert > Boss/Base > Extrude Direction 1 Change
: Blind into 85 mm
Click OK Create a new sketch on the front surface of the new Extrude19 Draw the sketch as shown in the picture.
Create an extrude Go to: Insert > Boss/Base > Extrude Direction 1 Change
: Blind into 15 mm
Click OK Create two chamfers Go to: Insert > Features > Chamfer Select the two green edges as shown in the picture. Select the “Angle – distance” option. Change Angle
into 4 mm : 45 deg
Click OK | Page
Create a new sketch on the green front surface of the new Extrude20 Draw the sketch as shown in the picture and detail.
Detail
Create an extruded cut Go to: Insert > Cut > Extrude Direction 1
: Up To Next
Click OK
Create two fillets on the green edges Select the two green edges as shown in the picture. Go to: Insert > Features > Fillet/Round
> 2,2 mm
Click OK
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Create a circular pattern Go to: Insert > Pattern/Mirror > Circular Pattern Pattern Axis
: Select the green surface as shown in the picture.
Total Angle
: 360 deg
Number of instances
: 21
Select the “Equal Spacing” option. Features to Pattern
: Extrude21, Fillet16
Select the “Geometry Pattern” option. Select the “Propagate Visual Properties” option. Click OK Create a chamfer Go to: Insert > Features > Chamfer Select the green edge as shown in the picture. Select the “Distance – distance” option. Change
into: 24 mm
Change
into: 75 mm
Click OK Create another chamfer Go to: Insert > Features > Chamfer Select the green edge as shown in the picture. Select the “Angle – distance” option. Change Angle
into 5 mm : 45 deg
Click OK | Page
Create a new plane parallel at the green surface Go to: Insert > Reference Geometry > Plane Select the green surface as shown in the picture and detail. Change the Offset Distance
into 10 mm.
Ensure that the offset is directed to the middle of the body. Select the “Reverse direction” option.
Click OK
Detail
Create a new sketch on the new Plane5 Draw the sketch as shown in the picture. Connect the top of the vertical construction line with the green edge of Mirror2. Close the sketch.
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Create a new sketch on the MIDPLANE ENGINE Draw the arc as shown in the picture and detail. Start the center point of the arc at the origin.
Close the sketch.
Detail
Create a sweep Go to: Insert > Boss/Base > Sweep Profile Path
: Select the green Sketch25 : Select the pink Sketch26
Click OK
Create a new sketch on the MIDPLANE ENGINE Draw the circle as shown in the picture. Connect the bottom of the vertical construction line at the origin.
Close the sketch.
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Create a new plane parallel at the Top Plane Go to: Insert > Reference Geometry > Plane Select the Top Plane. Change the Offset Distance
into 350 mm.
Ensure that the offset is directed to above. If not, select “Reverse direction” Click OK
Create a sketch on the new Plane6 Draw the two lines as shown in the left picture. Select the two lines and create a sketch fillet
as shown in the right picture.
Close the sketch.
Create a sweep Go to: Insert > Boss/Base > Sweep Profile Path
: Select the green Sketch27 : Select the pink Sketch28
Click OK | Page
Create a new sketch on Plane6 Draw the sketch as shown in the picture.
Create a revolve Go to: Insert > Boss/Base > Revolve Axis of revolution
: Select the green line as shown in the picture.
Click OK
Create fillets on the green edges Select the green edges as shown in the picture. Go to: Insert > Features > Fillet/Round
> 5 mm
Click OK | Page
Create a new sketch on the Top Plane Draw the sketch as shown in the picture.
Create an extruded cut Go to: Insert > Cut > Extrude Direction 1 Change
: Offset From Surface into 1 mm
Select the pink surface in the picture.
as shown
Select the “Reverse offset” option. Select the “Translate surface” option. Click OK
Create a circular pattern Go to: Insert > Pattern/Mirror > Circular Pattern Pattern Axis
: Select the green surface as shown in the picture.
Total Angle
: 360 deg.
Number of instances
: 30
Select the “Equal Spacing” option. Features to Pattern
: Extrude22
Click OK | Page
Create a new sketch on the green surface of Chamfer3
Draw the sketch as shown in the picture. Close the sketch. Create a new plane perpendicular at the green surface Go to: Insert > Reference Geometry > Plane Select the green surface. Select the green horizontal construction line of Sketch31. Select an angle
of 90 degrees.
Click OK Select the new Plane7 and create a new sketch Draw the two lines as shown in the picture and first detail. Fix the horizontal line with the circle center of Skecth31. Add a Sketch Fillet
Close the sketch.
with a dimension of 27,5 mm.
Details | Page
Create a sweep Go to: Insert > Boss/Base > Sweep Profile Path
: Select the green circle of Sketch31 : Select the pink line of Sketch32
Click OK
Create a new sketch on the MIDPLANE ENGINE Draw the sketch as shown in the picture.
Close the sketch.
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Make Sketch33 visible Select Sketch33 in the toolbar > Right mouse click > Show The sketch is visible now.
Create a new sketch on the Top Plane
Connect the left side of the sketch with a vertical construction line to the grey end point of Sketch33. Connect the right side of the sketch with the midpoint of Sweep3.
Create a projected curve Go to: Insert > Curve > Projected Selections
: Sketch33 and Sketch34
Click OK
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Select the green surface of Sweep3 and create a new sketch Convert the two circles.
Close the sketch.
Create a sweep Go to: Insert > Boss/Base > Sweep Profile Path
: Select the green circles of Sketch35 : Select the pink Curve1.
Click OK
Create a new sketch on the green surface of Mirror2
Draw the sketch as shown in the picture. Close the sketch. | Page
Create a new plane perpendicular at the green surface Go to: Insert > Reference Geometry > Plane Select the green surface. Select the green horizontal construction line of Sketch36. Select an angle
of 90 degrees.
Click OK
Select the new Plane8 and create a new sketch Draw the sketch on the same way as Sketch32. Fix the horizontal line with the circle center of Skecth36.
Detail
Close the sketch.
Create a sweep Go to: Insert > Boss/Base > Sweep Profile Path
: Select the green circle of Sketch36 : Select the pink line of Sketch37
Click OK
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Select the green surface of Sweep3 and create a new sketch Convert the two circles.
Close the sketch.
Create a new sketch on the MIDPLANE ENGINE Draw the sketch as shown in the picture and detail below.
Detail | Page
Make Sketch38 and Sketch39 visible Select Sketch38 and Sketch39 in the toolbar > Right mouse click > Show The sketches are visible now. Create a new sketch on the Top Plane Draw the sketch as shown in the picture and detail.
Connect the left side of the sketch with the center point of Sweep5.
Detail
Connect the right side of the sketch with a vertical construction line to the grey end point of Sketch39.
Create a projected curve Go to: Insert > Curve > Projected Selections
: Sketch39 and Sketch40
Click OK
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Create a sweep Go to: Insert > Boss/Base > Sweep Profile Path
: Select the green circles of Sketch38 : Select the pink Curve2
Click OK
Create a new sketch on the MIDPLANE ENGINE Draw the sketch as shown in the picture below.
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Create the green straight line as shown in the picture.
Close the sketch.
Make Sketch33 visible Click on the
before Sweep4 in the feature tree.
Click on the
before Curve1
Select Sketch33 > Right mouse click > Show
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Create a new sketch on the Top Plane Draw the sketch as shown in the picture and detail. Pull at the blue arrow to change the shape of the spline.
Detail Create the green straight line as shown in the picture. Fix the vertical construction line at the left point of Sketch33.
Close the sketch. | Page
Create a projected curve Go to: Insert > Curve > Projected Selections
: Sketch41 and Sketch42
Click OK
Create a sweep Go to: Insert > Boss/Base > Sweep Profile Path
: Select the green circles of Sketch43 : Select the pink Curve3.
Click OK
Create a new sketch on the MIDPLANE ENGINE Draw two green construction lines as shown in the detail.
Detail
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Draw the spline as shown in the picture. Pull at the blue arrow to change the shape of the spline.
Create a thin extrude Go to: Insert > Boss/Base > Extrude Direction 1 Change
: Midplane into: 8 mm
Select the Thin Feature option. Direction: Midplane Change
into: 8 mm
Feature Scope: All bodies Click OK
Create another sketch on the MIDPLANE ENGINE Draw two green construction lines as shown in the detail.
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Draw the spline as shown in the picture. Pull at the blue arrow to change the shape of the spline.
Create a thin extrude Go to: Insert > Boss/Base > Extrude Direction 1 Change
: Midplane into: 8 mm
Select the Thin Feature option. Direction: Midplane Change
into: 8 mm
Feature Scope: All bodies Click OK
Create fillets on the green edges Select the eight green edges as shown in the picture. Go to: Insert > Features > Fillet/Round
> 3,99 mm
Click OK
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Create a new sketch on the Top Plane Draw the sketch as shown in the picture and connect the dimensions with the origin.
Create an extruded cut Go to: Insert > Cut > Extrude Direction 1
: Trough All
Click OK
Create fillets on the green edges Select the two green edges as shown in the picture. Go to: Insert > Features > Fillet/Round
