Photo Realistic Rendering

                                                                                     Design and Rendering of American Chopper using Solidworks software

Introduction

This project consists of design and then rendering of American Chopper from scratch to a fully developed model with the help of using Solidworks software.

Objective

The main aim of this project is to learn and understand the use of various tools and methods present in Solidworks in order to successfully make the American Chopper.

Below were the steps taken to build the American Chopper:

1. Design each component with accurate dimensions and features.

2. Assembling the components using insert components and mates to make a final assembly.

3. Render and make photorealistic view in Solidworks Visualize and PhotoView 360.

 

Parts present in American Chopper

1. Transmission Belt

2. Kick Stand

3. Front Fender

4. Rear Fender

5. Chain

6. Oil Tank

7. Pedal

8. Front Wheel

9. Rear Wheel

10. Front Fork

11. Chassis

12. Engine

13. Gas Tank

Part Modelling

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, most often parallel. Belts can be used as a transmission element, to efficiently transmit power or movement.

 

Features used to build above component:

1. Boss Extrude
2. Fillet

• Boss Extrude:

An Extruded Boss/Base feature will allow you to take a 2D sketch and add thickness to it in the third dimension.

• 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.

The various views of the component are presented below:

Procedure used to make the component:

• In order to build the component various 2D sketches were used like lines, arc’s and then they were combined together using constraints like tangency between lines and arcs and then proper dimensions were given to each sketch in order make the component fully defined.

• After this boss extrude and fillet was applied to make the 2D sketch to make it 3D component and then proper appearance was given to the part.
The various views of the component are presented below:

2. Kick Stand

It is a metal part attached to a motorcycle that is used to support it when it is not moving and no one is riding it

Features used to make the component:

1. Loft
2. Dome
3. Cut Extrude
4. Boss Extrude
5. Fillet
6. Split

• Loft:

Loft is a feature used to make transition between two profiles in order to add material to it.

• Dome:

It is a rounded structure used to make the ends of the stand smooth.

• Cut Extrude:

This feature is used to remove the material from the component.

• Split:

Split feature is used to first split the part and then remove whichever portion is not required in the component.

The various views of the component are presented below:

Procedure used to make the component:

• First the sketch was made using sketch tools like lines, ellipse, spline etc and then proper constraints were used between them.

• Proper dimensions were given in order to make the component fully defined.

• Sketch feature of Loft was used to add material to the sketch, then dome was used to give rounded structure to the ends of the kickstand.

• Cut extrude was used to remove material from one side of the stand in order to fix the stand to the chassis of Chopper.

• Split feature was then used to remove the material in the bottom of the stand so that it can be made flat so that it is perfectly stands on the ground.

 

3. Front Fender

Front fender is the part present on the top of the front wheel to prevent the mud, sand, liquids, rocks from being thrown in the air by the rotating wheel.

Features Used:

1. Revolve

2. Split

• Revolve:

This feature is used to make a revolve around an axis to make a hollow rounded portion in a part.

 

The various views of the component are presented below:

 

Procedure used to make the component:

• First sketch was make using sketch tools like lines and splines.

• After making the sketch proper dimensions were given in order to make the sketch fully defined.

• Revolved boss was used to make the rounded portion of the fender

• Split was the used to remove the unwanted portion of the fender and then desired shape was given at the ends to give proper shape the fender at the ends.

 

4. Rear Fender:

Rear Fender is the component present on top of the rear wheel in order to prevent the mud, sand, liquids, rocks from being thrown in the air by the rotating wheel.

Feature used

1. Revolve

2. Fillet

3. Split

4. Shell

• 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.

The various views of the component are presented below:

Procedure used to make the component:

• This component is made using sketch tools like lines, splines etc.

• Proper dimensions were given in order to make the component fully defined.

• Features of revolve, split, fillet and shell were then applied to the sketch to make it into desired shape.

• Decals was then applied on the fender to give it a better look.

 

5. Chain

Chain is the mechanical component used in the motorcycle to transmit the power from the engine to the rear wheel.

Features used:

1. Boss Extrude

2. Curve Driven pattern

3. Blocks

4. Fillets

5. Mirror

6. Trim

• Curve Driven Pattern:

Curve driven pattern is used to make a pattern along the curve or a planar.

To define the pattern, you can use any sketch segment, or the edge of a face (solid or surface), that lies along the plane. You can base your pattern on an open curve, or on a closed curve, such as a circle.

• Blocks:

In order to use this feature first a sketch needs to be made and then it is saved as a block in a file, after this it can be brought in any sketch in which we want to insert that block any number of times.

• Trim

This entity is used to remove unwanted lines, surfaces which is not required.

• Mirror

Mirror is used to make the same sketch in the opposite side by selecting any reference or a plane in the direction in which we want the mirrored sketch to be placed.

The various views of the component are presented below:

Procedure used to make the component:

• The chain is made by using arcs and then connecting the curves with each other to create the desired shape and then tangent constraints are applied between the arcs.

• After this chain plates and pins are made using features like extruded boss, fillets with proper dimensions to make the sketch fully defined.

• Curve driven pattern feature is then used to put the chain link plates and the pins on the desired complete curve.

• The chain link plates are then mirrored along the front plane to put the chain link on both sides of the pin to complete the chain.

6. Oil Tank

Oil tank is the storage unit of oil for the bike. It is made hollow with a thickness of 3 mm.

Features used:

1. Boss Extrude

2. Combine

3. Fillet

4. Shell

• Combine:

In a multi body part, we can combine multiple solid bodies to create a single-bodied part or another multi body part.

The various views of the component are presented below:

Procedure used to make the component:

• This component is made by first making to different sketches and the adding material to it using boss extrude.

• After this combine feature is used to keep the portion which contained both the structures and the remaining part is removed.

• Fillet is then applied to the edges and then shell feature is used to make the tank hollow.

• Appearance and decals are applied to the oil tank after completion of the component.

7. Pedal

Pedal is the component where the rider can rest their leg, it is also used for gear shift purpose which is used to change the speed of the bike.

Features used:

1. Boss Extrude

2. Fillet

3. Chamfer

4. Linear pattern

5. Dome

6. Revolve

• Chamfer:

The chamfer tool creates a beveled feature on selected edges, faces, or a vertex. 

• Linear Pattern:

Linear pattern feature is used to make a sketch repeat itself on a straight line.

The various views of the component are presented below:

Procedure used to make the component:

• Sketch for this component is made in the form of support plate first giving proper dimensions and then extruded.

• Circles are then drawn on the support plate and then these are extruded on either side of the plate.

• Rings are then made on the pins using circles and fillet and then making for few instances of it on the same linear axis.

• Appearance is then applied to the component in the final stage.

8. Front Wheel

This wheel is present on the front portion of the bike, it is guided along with the movement of the front fork to take the vehicle to the desired direction.

Feature used:

1. Boss Extrude

2. Circular Pattern

3. Fillet

4. Chamfer

5. Cut extrude

6. Revolve

7. Combine

• Circular Pattern:

This feature is used to make a structure repeat itself along a circular path.

The various views of the component are presented below:

Procedure used to make the component:

• Sketch is made to make a revolve to make the shape of the rim of the tyre using revolve feature.

• Spokes are then sketched on this and then it is given desired shape using extrude, combine features. 3 instances of the spokes are made at equal distance using circular pattern.

• Rotor is made fixed to the rim and then holes are made on it and then circular pattern feature is used to put the holes in the circular form.

• Caliper is made on the rotor using lines and circles and then removing unwanted material to give desired shape.

• Tyre is then sketched on top of the rim and then desired cuts are given to the tyre for the purpose of friction.

• Appearance are then given to each part when the component is ready.

 

9. Rear Wheel

Rear wheel is present at the back side of the bike where the chain is also attached so that gear can be changed.

Features used:

1. Boss Extrude

2. Circular Pattern

3. Fillet

4. Chamfer

5. Cut extrude

6. Revolve

7. Combine

The various views of the component are presented below:

 

Procedure used to make the component:

• Sketch is made to make a revolve to make the shape of the rim of the tyre using revolve feature.

• Spokes are then sketched on this and then it is given desired shape using extrude, combine features. 3 instances of the spokes are made at equal distance using circular pattern.

• Rotor is made fixed to the rim and then holes are made on it and then circular pattern feature is used to put the holes in the circular form.

• Caliper is made on the rotor using lines and circles and then removing unwanted material to give desired shape.

• Sprocket is then sketched in the form of circle and then extruded after this chamfer is given to both sides. Tooth profile on the sprocket is made using extruded cut and then fillet is then applied to it. Required number of teeth are then applied to the sprocket with the help of circular pattern.

• Tyre is then sketched on top of the rim and then desired cuts are given to the tyre for the purpose of friction

• Appearance are then given to each part when the component is ready.

10. Front Fork

It is one of the most important components of the bike, it is mainly controlled by the rider in order to make movement in the desired direction. It also consists of front lights and indicators which can be turned on and off by the rider. Along with this front fork also has damper which absorbs the shocks due to uneven roads so that the rider does not feel uncomfortable while riding the bike.

Features used:

1. Boss Extrude

2. Fillet

3. Linear pattern

4. Dome

5. Cut Extrude

6. Project Curve

7. Revolve

8. Sweep

9. Revolve cut

10. Mirror

11. Combine

• Project Curve:

This feature is used to make a final curve with the help of 2 different curves in different views.

• Sweep:

Sweep is used to create a 3D profile with the help of 2D sketch.

• Revolve Cut:

In revolve cut a 2D sketch is made and then material is removed in a circular manner in order to get desired shape.

The various views of the component are presented below:

Procedure used to make the component:

• First a long tube is made by sketching it with proper dimensions and then using revolve extrude to make the desired shape.

• Half of the triple clamps and headlights are then made along with that the handle and the wire is also made on top of the triple clamp.

• When half portion is completely designed and fully defined, every part is then selected and mirrored in the opposite direction in order to completely make the component.

• Appearance is then set in the final stage.

11. Chassis

Chassis is the skeleton of the bike, it is used to hold other components of the vehicle. It also gives structure to the vehicle as per design.

Features used:

1. Boss Extrude

2. Fillet

3. Chamfer

4. Sweep

5. Project curve

6. Split

7. Combine

8. Dome

The various views of the component are presented below:

 

Procedure used to make the component:

• The blueprint of the American chopper is first imported using sketch picture tool.

• To insert the sketch picture following steps was used:

       Tools > Sketch Tools > Sketch picture > Browse the picture > Insert

• The blueprint is then given little transparency and then a sketch is drawn on top of it to get desired shape of the chassis by giving appropriate dimensions. Front end of the chassis is connected to the front fork and the bank end is connected to the rear wheel hub.

 

12. Engine
Engine is the most important component of the vehicle in which the energy transformation takes place and hence the wheels rotate which make the vehicle to move. Chemical energy (i.e. fuel) is converted into mechanical energy (i.e. rotation of wheels) with the help of rotation of chains and shafts.

Features used:

1. Boss Extrude

2. Fillet

3. Revolve

4. Circular pattern

5. Project curve

6. Dome

7. Chamfer

8. Cut Extrude

9. Linear pattern

10. Mirror

11. Sweep

12. Split

13. Combine Curve

The various views of the component are presented below:

Procedure used to make the component:

• The Blueprint is imported and then the base of the engine is sketched giving proper dimensions and then boss extrude feature is used to convert it into 3D sketch.

• Shafts are made on the engine where the transmission belt will be placed for rotation.

• Two V shaped engines are then made on top.

• After this exhaust pipes are made with the help of project curves, sweep features.

• At the end the spark plug is sketched on the engine and then converted into 3D sketch which will be connected to the gas tank.

• Proper appearance is given to the engine after complete design of the component.

13. Gas Tank

Gas tank is the storage unit of the fuel for the American chopper. At the back of this the seat is placed.

Features used:

1. Swept Surface

2. Surface trim

3. Lofted Surface

4. Project curve

5. Boundary Surface

6. Mirror

7. Extrude Surface

8. Fillet

9. Knit Surface

10. Sweep Cut

The various views of the component are presented below:

Procedure used to make the component:

• The sketch of this component is made mainly with the help of splines and then proper curves are given to it to make the component in the desired shape using surface features.

• Half of the component is made, and the other half is then mirrored in the opposite direction to get the complete design of the gas tank with the seat placed at the back side.

• At the end Sweep cut feature is used at the bottom of the tank for the connection of spark plug from the engine to the gas tank.

• Appearance and decals are then applied to the component.

 

                                                                                                                 Assembly of American Chopper

The final stage of the project is to assemble all the individual components of the American chopper and then attach them to one another with the help of mates feature using concentric, tangency, angles, etc.

The components are added using he insert component feature and one by one the components are brought in the following way:

                                                                                                                 

 

                                                                                                                                  Rendering

Rendering is the final stage where the American Chopper is given special effects and the final view is created. It was performed in Solidworks Visualize.

Below are the images of the rendered images of the American Chopper.

Conclusion:

1. Each individual component was designed and fully defined in the desired shape in Solidworks software.

2. Components were assembled to each other to model the American Chopper by bringing each part one by one.

3. Rendering was performed successfully to give better view to the American Chopper using Solidworks Visualize software.