FINAL INDEPENDENT PROJECT
SURFACING AND SOLID MODELLING OF W MOTORS LYKAN HYPERSPORT CAR
Objective :
The main objective of this project to create a virtual model of the W motors Lykan HyperSport car using SolidWorks 2019. In this project, the individual parts of the automobile such as main body, seat, dashboard, door, steering wheel, and sub-assemblies such as wheels, steering mechanism assembly, rear wheels and differential assembly are designed using either surfacing or solid modelling. All the individual components and sub-assemblies are assembled using different mates. Finally, realistic views are created using photoview360.
Introduction :
Lykan HyperSport -
A car is a wheeled motor vehicle used for transportation. Cars came into global use during the 20th century, and developed economies depend on them. W Motors is an Emirati sports car company founded in Lebanon in 2012, being the first developer of high performance luxury sports cars in the Middle East. The Lykan HyperSport is a Lebanese limited production sports car manufactured by W Motors. The bodywork, chassis and engine were all produced in Germany and assembled in Italy. The production of the car was limited to a total of seven units.
The Lykan consists of boxer typer engine which is rear mounted and has twin turbocharger with independent intercooler. This vehicle has rear-wheel drive. The vehicle engine has fully catalyzed, stainless steel exhaust system with active bypass valves.
Specifications :
Length : 4495 mm
Width : 1995 mm
Height : 1180 mm
Wheelbase : 2625 mm
Front track : 1506 mm
Rear track : 1585 mm
Tires size : 255/35 R19 (front) ; 335/30 R20 (rear)
Wheel rims size : 8.5J x 19 (front) ; 12.5J x 20 (rear)
SolidWorks -
The designing software allows the engineers to create the virtual models before a product is produced, and it also allows for much better visual representation of the product before manufacturing. It also helps engineers with various analysis to know whether product is ready for manufacturing or not. SolidWorks is a 3D CAD design software, analysis software and product data management software developed by Dassault systems. This software enables the designers and research engineers to model the products better, faster and more cost-effective.
Features of SolidWorks used in this project :-
Sketch tools -
- Sketch picture
- Line
- Circle
- Arc
- Spline
- Rectangle
- Fillet
- Offset entities
- Convert entities
- Trim and Extend entities
- Mirror entities
- Smart dimensioning
Solid modelling tools -
- Boss extrude
- Cut extrude
- Revolve boss
- Sweep boss
- Combine and Split
- Dome
- Fillet and Chamfer
- Linear pattern
- Shell
- Mirror
- Reference planes
- Projection curve and Split line
Surfacing tools -
- Extruded surface
- Revolve surface
- Swept surface
- Lofted surface
- Surface fill
- Offset surface
- Ruled surface
- Fillet
- Delete face
- Extend surface
- Trim surface
- Knit surface
Methodology :
Blueprint set up :
The blueprint is first edited using photoshop and cropped to each view, and image size is changes as per the standard dimensions. The blueprints image of the car are set as reference in accordance with original vehicle dimensions to help create curves and boundaries of the vehicle surface.
Parts modelled :
1. Main body assembly
The main body assembly consists of the main body of the car, doors, seats and dashboard. All these parts are assembled using various mates such as coincidence, concentric, width, etc. The main houses the all the components of the car including the chassis and frame.
Main body :
The main body of the car is created using the surfacing tools. Different curves are generated using the projecting the sketches which are drawn in reference to the blueprint. Most commonly surface loft, filled surface and trim surface tools are used.
The main features used to create the main body of the hypersport are curve projection, surface loft, filled surface, extrude surface, sweep surface, trim surface, ruled surface, knit surface, etc.
Seats and Doors :
Since it has only two doors, two doors are modelled using surfacing tools, and they are attached to the main body using hinge joint. The Lykan HyperSport is a two-seater sports car and a seat is modelled using solid modelling features.
By taking reference surfaces from the main body, these features are created. Both are generated using solid modelling tools. Two doors are created using a mirror feature and a seat is solid modelled.
The features used are boss extrude, cut extrude, fillet, lofted boss and mirror.
Dashboard :
The dashboard or instrument panel is a control set within the central console of a vehicle. It is located directly ahead of the driver, it displays instrumentation and controls for the vehicle's operation. The Lykan HyperSport's IP consists of fully digital displays. It also consists of
The dashboard is designed by taking reference surface from the main body. The surfacing and solid modelling tools are used.
Wheel :
The Lykan HyperSport is equipped with forged aluminum wheels with diameters of 19 inches at the front and 20 inches at the rear.
The wheel assembly consists of tire, rim, brake caliper, brake disk, hub and stub axle as shown in the figure. The whole wheel assembly is created in part modelling by using individual bodies.
The main feature used are revolved boss, revolved cut, sweep cut, boss extrude, cut extrude, fillet and chamfer.
2. Steering assembly
The steering system converts the rotational motion of the steering wheel into the linear motion that turns the wheels and guides the path.
Steering assembly consist of wheel assembly, track arms, tie rod, rack and pinion, steering rod and steering wheel. The main mates used to assemble this are concentric , width, parallel and rack and pinion mate.
Differential assembly
The differential is a system of gears that allows different drive wheels on the same axle to rotate at different speeds. The differential allows the wheels to rotate at different speeds on turns. The gears in this assembly are imported from SolidWorks tool box and axles are attached. Universal couplings are used to join the wheel to the axles.
3. Rear axle assembly
The rear axle assembly propel the vehicle by converting rotational force into linear motion. The drive shaft sends rotational power from the engine and transmission to the rear axle assembly differential.
The assembly consist of wheel assembly, axles, universal joints and differential assembly.
Assembly
There are two types of approaches in assembly of a model. Top down and bottom up approach. In modelling of the sunseeker predator yacht, bottom up approach is implemented. The individual parts are first designed, and then they are assembled together.
For assembling the yacht, all individual models are imported into the assembly workspace, and they are placed relative to the other parts. Mates are used to create the geometric relationship between the individual parts. The various types of mates used are concentric, coincident, distance, width mate, rack and pinion mate, limit angle and limit distance, etc.
Rendering
The photo realistic renders are created in SolidWorks using the add-in called PhotoView 360. The rendering of the image include setting up the environment, arranging the lights, setting up the scenes and creating the final view of the designed part. SolidWorks visualize is also an add-in which is used to create the high quality rendered images with minimum amount of time.
Conclusion
The project gave me a good understanding of how to convert a 2D blueprint into a nice 3D model. The surfacing and solid modelling are completely done in SolidWorks 2019. I got a good understanding of the surfacing modelling and learned about how to create the complex curves using project curves tools. In assembly, I learned about using the advanced and mechanical mates. Applying different background scenes, lights and setting up cameras in PhotoView 360 to create a good rendered views.
Link to files - https://drive.google.com/drive/folders/1zaZpXnephCIglUKUNv9dg7xwCNpRNMZf?usp=sharing
THANK YOU