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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 : Blind

Change 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 of Extrude1 as shown

in the picture.

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 madesketch as underlay to simplify the design process

of the engine.

Go to: Tools > Sketch Tools > Sketch Picture

Select Chopper Underlay.Jpeg

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

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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


Create an extrude


Direction 1 : Blind

Change 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


Direction 1 : Blind

Change into 40 mm

Click OK

Select the MIDPLANE ENGINE andcreate a new sketch

Draw the sketch as shown in

the picture.

Create an extrude


Direction 1 : Mid Plane

Change 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 asshown in the picture.

Click OK

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Create a new plane parallel at the Right 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


Create a revolve


Axis of revolution : Select the green

line as shown in

the picture.

Click OK

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Select the green surface of Revolve1 as shownin 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 originin the middle of

the circle.

Number of instances : 40

Angle : 360 deg

Radius : 60 mm

Arc Angle : 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

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Create another circular pattern sketch


Circular Pattern

Pattern Axis : Select the midpointof the circle.


Angle : 360 deg

Radius : 70 mm

Arc Angle : 270 deg


Entities to Pattern : Select therectangle

Click OK

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Create an extruded cut


Direction 1 : Blind

Change 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


Select the MIDPLANE ENGINE.


Ensure that the offset direction is correct.


Click OK

Select the green surface of Dome1 as shown


Draw the sketch as shown in the picture

on the next page.

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Circular Pattern

Pattern Axis : Select the midpointof the big circle.


Angle : 360 deg

Radius : 55 mm

Arc Angle : 270 deg



Small circle

Click OK


Go to: Insert > Cut > Extrude

Direction 1 : Offset From Surface

Change into 3 mm

Select the pink surface as shown in the picture.

Select the Reverse offset option.

Click OK

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Select the other green surface of Dome1 as shown




Circular Pattern

Pattern Axis : Select the midpoint

of the big circle.


Angle : 360 deg

Radius : 65 mm

Arc Angle : 270 deg



Small circle

Click OK

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Change into 3 mm

Select the pink surface as shown

in the picture.


Click OK

Create a chamfer

Go to: Insert > Features > Chamfer

Select the green surfaces as shown in the picture.

Select the Angledistance option.

Change into: 3 mm

Angle : 45 deg

Click OK

Create fillets on the edges



Click OK

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Select the MIDPLANE ENGINE

and create a new sketch

Draw the sketch as shownin the picture.

Create an extrude


Direction 1 : Midplane

Change into 150 mm

Click OK

Select the MIDPLANE ENGINE again


Draw the sketch as shown

in the picture.

Create an extrude



Change into 110 mm

Select the Selected bodies option.

Select the two cyan bodies

as shown in the picture.

Click OK

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Draw the sketch as

shown in the picture.

Create an extrude



Change 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


Direction 1 : Blind

Change into 240 mm

Click OK

Create four chamfers


Select the four green edges as shown in the picture.

Select for the Distancedistance 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


Create a new sketch

Go to Tools > Sketch Tools > Convert Entities

Create an extrude


Direction 1 : Blind

Change into 125 mm

Click OK

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Create four chamfers



Select for the Distancedistance option.

Change into: 90 mm

Change into: 15 mm

Click OK

Create sixteen fillets on the edges



Click OK

Create a new plane parallel at the green

surface


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.


Click OK

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Draw the two squares as shown in the picture.



Direction 1 : Blind

Change 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



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 : 14

Features to pattern : Extrude13, Fillet4

Click OK

Create fillets on the edges of Extrude13



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



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

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Create fillets on the green edges



Click OK




Click OK

Create four fillets on the green edges



Click OK

Select the green surface of Chamfer3 and

create a new sketch


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Create an extrude


Direction 1 : Blind

Change 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 Mirroroption

Features to Mirror : Extrude15, Fillet9, Dome2

Click OK

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Connect the construction line with the green

edge of Chamfer3.

Detail

Create an extrude


Direction 1 : Mid Plane

Change into 20 mm

Click OK

Create six fillets on the green edges



Click OK

Create another six fillets on the green edges


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 Bodiesto Mirroroption

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.


Click OK

Create two fillets on the green edges



Click OK

Select the green surface as shown in the picture


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Mirror the rectangle around the green construction line.

Mirror the two rectangles around the green construction line.

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Create an extrude


Direction 1 : Blind

Change 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


Direction 1 : Blind

Change into 12 mm

Click OK

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and surfaces

Select the green edges and surfaces


Go to: Insert > Features >

Fillet/Round > 5 mm

Click OK


Select the green edge


SolidWorks automatically selects the

other edges of this body.

Those are marked in yellow.


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


Direction 1 : Blind

Change into 85 mm

Click OK

Create a new sketch on the front surface

of the new Extrude19


Create an extrude


Direction 1 : Blind

Change into 15 mm

Click OK

Create two chamfers


Select the two green edges as shown in

the picture.


Change into 4 mm

Angle : 45 deg

Click OK

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Create a new sketch on the green front surface

of the new Extrude20


and detail.

Detail



Direction 1 : Up To Next

Click OK

Create two fillets on the green edges

Select the two green edges as shown in the picture.


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


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


Select the green edge as shown in

the picture.

Select the Distancedistance option.

Change into: 24 mm

Change into: 75 mm

Click OK

Create another chamfer


Select the green edge as shown in

the picture.


Change into 5 mm

Angle : 45 deg

Click OK

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Create a new plane parallel at the green surface


Select the green surface as shown in the picture and detail.


Ensure that the offset is directed to the middle

of the body.

Select the Reverse directionoption.

Click OK Detail

Create a new sketch on the new

Plane5

Draw the sketch as shown inthe 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 : Select the green Sketch25

Path : Select the pink Sketch26

Click OK


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


Select the Top Plane.


Ensure that the offset is directed to above.


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


Profile : Select the green Sketch27

Path : Select the pink Sketch28

Click OK

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Create a new sketch on Plane6


Create a revolve


Axis of revolution : Select the green line as shown in the picture.

Click OK


Select the green edges as shown

in the picture.


Fillet/Round > 5 mm

Click OK

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Create a new sketch on the

Top Plane

Draw the sketch as shown

in the picture.




Change into 1 mm

Select the pink surface as shown

in the picture.


Select the Translate surface option.

Click OK

Create a circular pattern

Go to: Insert > Pattern/Mirror > Circular Pattern

Pattern Axis : Select the green surfaceas shown in the picture.

Total Angle : 360 deg.


Select the Equal Spacing option.

Features to Pattern : Extrude22

Click OK

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Create a new sketch on the green surface of Chamfer3


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


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 with a dimension of 27,5 mm.

Close the sketch. Details

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Create a sweep


Profile : Select the green circle of Sketch31

Path : Select the pink line of Sketch32

Click OK



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


Convert the two circles.

Close the sketch.

Create a sweep


Profile : Select the green circles of Sketch35

Path : Select the pink Curve1.

Click OK

Create a new sketch on the green surface of Mirror2


Close the sketch.

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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


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


Profile : Select the green circle of Sketch36

Path : 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


and detail below.

Detail

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Make Sketch38 and Sketch39 visible

Select Sketch38 and Sketch39 in the

toolbar > Right mouse click > Show

The sketches are visible now.



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.




Click OK

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Create a sweep



Path : Select the pink Curve2

Click OK


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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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.

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Click OK

Create a sweep



Path : Select the pink Curve3.

Click OK


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


Change 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


Change into: 8 mm

Select the Thin Feature option.

Direction: Midplane

Change into: 8 mm

Feature Scope: All bodies

Click OK


Select the eight green edges as shown in the picture.


Click OK

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and connect the dimensions with the

origin.



Direction 1 : Trough All

Click OK



the picture.


Click OK

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the picture.


Click OK

Hide all planes and sketches except:

- MIDPLANE ENGINE

Save the file with the following name: Engine

12. engine

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