Design of American chopper and photo realistic rendering

Title- Designing of American Chopper & it’s Components With Photo Realistic Rendering in Solid works visualize.

-Introduction: The project report is about designing American Chopper all the major components via solid works and its final assembly. Solid Works Visualize & Photo View 360 is used for generating final rendered images.

-Objective: Design Engineering is the very first step to every product in the industry, being passionate about design it led me to design American chopper from scratch to final rendering of its each and every component.

Methodology for the design of American Chopper

• Designing of components and parts.
• Assembly of designed components /parts.
• Applying decals, camera setup, and scenes.
• Final rendering.

1. Designing of Components/parts.

American Chopper consists of 13 parts, they are as follows.

• Transmission Belt.
• Kickstand.
• Chain.
• Rear Fender.
• Rear-wheel.
• Pedal.
• Front Fender.
• Front-wheel.
• Oil tank.
• Front Fork.
• Chasis.
• Engine.
• Gas Tank.

a) Transmission Belt.

A belt is a loop of flexible material which is used to link two or more rotating shaft mechanically. In this Chopper, it is used for the transmission of power from the engine to the gearbox.

Feature tools: Extruded boss/base& fillets.

Sketch Tools: Sketch Geometry like line and offset entities.

Procedure:

• Select the front plane and start sketching on it draw horizontal lines from the origin and two-three point arcs apply tangent relations to make it fully defined.
• Make an offset of 3.5mm of the sketch in an inward direction.
• Extrude the created sketch by giving appropriate dimensions.
• Fillet all the sides of the extruded sketch for a smooth finish.
• Give appearance to the part.

b)Kick Stand.

A metal rod attached to bicycle or motorcycle, lying horizontally when not in use that maybe kicked into vertical position to support the vehicle when it is stationary.

Feature Tools: lofted boss/base , dome, extruded cut , split and fillet.

Sketch Tools: Sketch Geometry line,circle, 3 point arc and ellipse.

Appeareance:Chrome steel.

Render Image: Photo view 360

Procedure:

• sketch an eclipse on front plane which is horizontal to origin, dimension and add relations to make it fully defined. Sketch again on right plane to make a spline from origin, activate the handles of spline and dimension it.
• Create a plane at the end of spline, sketch on it by drawing an eclipse and make pierce relation between spline and eclipse mid point.
• Now loft to the part using both sketches, activate the loft on spline and check for the desired coincidence to get the desired output.
• Apply eliptical dome to the end of spline , remove the unnecessary portion using extruded cut.
• Apply fillet and appeareance to the part.

• c)Chain:

Chain drive is a way of transmiiting mechanical power from one part to another, in this case it is used to transmit power from engine to wheel.

Feature tools:Extruded boss/base, curve driven pattern, mirror, Blocks(for links)& fillet.

Sketch Tools: Sketch Geometry line, circle, straight slots, and 3 point arc .

Appeareance: Chrome Steel.

Render Image: Photo View 360

Procedure:

• Sketch on front plane by drawing two circles of different diameter seprated by a distance and connect them using 3 point arc on both sides trim the unwanted portion.
• Create a throwaway sketch which is used to creaye inside and outside chain links, make a block of these and save it.
• Insert block on the larger end of sketch and make coincident relations. Extrude again to create plates by selecting the remaining parts in block and apply fillet. Repeat the process.
• Use curve Driven patternto get the required number of pins and plates over the curve.
• Repeat the process over the curves to get the desired output.
• Give appropriate appeareance to the part.
• Repeat the process over the curves to get the desired output and give the appropriate appeareance to the part.

d) Rear Fender.

It is situated over rear wheel which protects from foreign particles like sand, mud, rocks, liquids etc.

Feature Tools: Revolve boss/base, split, fillet and shell.

Sketch Tools: sketch Geometry like line, 3 Point arc, trim entities& offset entities.

Procedure:

• Sketch on Front plane by drawing a 3 point arc above the origin apply the vertical relation with origin.
• Apply offset inward to extrude and make it closed sketch using extended entities and trim entities.
• Revolve the sketch across horizontal construction line at origin by giving proper direction angle.
• Remove the unwanted area using split tool and apply fillet.
• Give the desired appeareance to make it more realistic.

e) Rear Wheel.

A circular component connected to the rear side of chaisi which power from engine. It consist of various components like Rim, Calliper, Rotor, tyre & sprocket. Engine and Rear wheel are connected via chain.

The Rear Wheel consist of various Components like : rim, rotor, calliper, sprocket and tyre.

Feature Tools: Revolved Boss/Base, extruded cut, Revolved Cut, Circular Pattern, Combine, Chamfer and Fillet, Mirror.

Sketch Tools: Sketch Geometry line, 3 point arc, circle, Spline, rectangle, trim entities, , extended entities, convert entities, & offset entities.

Appeareance: Rim - Chrome steel.

Rotor - Chrome Steel.

Calliper- Painted Siena

Sprocket- Chrome Steel

Tyre - Matte Rubber.

Render Image: Photo View 360.

Procedure:

• Select Front plane and Start sketching on the outer part of wheel and dimension it to make it fully defined.
• Revolve the sketch across the temporary axis.
• Sketch on Right plane by drawing a vertical construction line from the origin and another line at an angle. Draw a spline & mirror all the three entities across vertical construction line and extrude them.
• For Creating spider webbed design , offset all the drawn three entities & remove the unwanted part using cut extrude. Join all the spokes using 3 point arc , offset them and make it closed sketch.
• select the front plane and draw a spline from origin to remove unwanted area using extruded cut.
• Select the spokes and use a circular pattern. combine them to make a single solid body.
• rotor- sketch on the front plane by drawing a circle & extruding it removed the unwanted portion. Use Circular pattern to create hole over the rotor.
• Calliper- Draw a circle and lines as per the design of the body and remove the unwanted area by using power trim and extrude it to apply chamfer .
• sprocket- draw a circle & extrude it . Now appply Chamfer to outer part and create teeth by cut to extrude . Remove the unwanted portion by by using cut extrude and & appply fillet.
• tyre- use convert entities option and apply dimension. Draw rectangles & apply dimensions. Relations to make it fully defined, extrude cut and apply fillet.
• Give appeareance to rotor, rim , calliper, sprocket and tire.

f)Pedal:

The external part attached to chasis which is used for foot resting & gear changing.

Feature Tools: Revolve Boss/Base, Extruded Boss/base, dome , linear Pattern, chamfer and fillet.

Sketch Tools: sketch Geometry like line, circle & spline.

Appeareance : chrome Steel

Render Image: photo view 360

Procedure:

• Draw & sketch on front plane, line & spline from origin and give dimensionto make it fully defined. Extrude it to make it fully defined.
• Extrude it and apply fillet, select the front surface of the extruded part and sketch on it drawing two circles. Use a dome circular feature.
• Apply linear pattern across tjhe boss extrude. Use distance-distance chamfer to it.
• Give appeareance to the part.

g)Front Fender:

It is situated over the front wheel which protects from the foreign particles sand. mud, rocks, liquid.

Feature Tools: Revolved Boss, split & fillet.

Sketch Tools: Sketch Geometry like line, spline & point arc. Extended entities & trim entities.

Appeareance : Painted siena.

Render Image: Photo view 360

h)Front Wheel:

A circular object connected at the front end of vehicle which helps for its movement.

Solid Bodies: Rim, Rotor , Calliper & tire.

Feature Tools: Revolved Boss/Base, extruded boss/base, extruded cut, Revolved cut, circular pattern, combine, mirror,chamfer, fillet.

Sketch Tools: sketch Geometrylike line, 3 point arc, circle , spline , rectangle , trim entities , extended entities and opffset entities.

Appeareance:Rim- Chrome Steel

:Rotor - Carbon Steel

:Calliper- Painted Siena

:Tyre-Matte Rubber

Procedure:

• Sketch on top plane by drawing line , 3 point arc and give the relation and dimmension them for fully defining and extrude it .
• Sketch on Front plane by drawing a splinen line dimension them to make it fully defined & extrude it mid plane, through all and combine.
• Apply Fillet and give appeareance.

i) Front Fork:

A fork is part of Chopper that holds the front wheel. It consist of two rods which are joined via the means of triple clamp. It acts as a shock absorber which allows just the front wheel to react during imperfection by isolating other components from that motion.

feature Tools:extruded Boss /base, extruded cut , dome, revolved cut , project curve, swept boss/base ,combine mirror.

sketch tools: Line, spline, circles , offset entities , convert entities.

Procedure:

• Layout a horizontal line. Start sketching out the fork tube and apply dimmension to make the sketch fully defined, select the revolve and rotate about the horizontal line.
• Now select the upper face , construct a circle and apply certain dimensions, use power trim to edit the sketch and deselect the merge results.
• Keep fork tube seprate from the fork tube & triple clamps, use linear pattern by selecting bodies, please make sure we have two instances, use extrude feature to genrate axle by sketching at the end of circle.
• Draw a circle to connect the two clamps and start sketching head lamp geometry on front plane and use revolve operations by selecting the line and do not combine the headlight with fork tube.
• For handle and brake wires - select top plane & draw the handle using spline & make it fully defined and draw a circle at the end of spline & sweep along the path.
• use the mirror options to combine the bodies and mirror it.
• give appeareance to the fork.

j)Chasis:

One of the most important components of the bike is chasis, all of the above components like the wheels gas tank, oil tank, fork tube etc are all connected to the chasis.

chasis is a rigid structure that holds up all the major components of the bike.

Feature tools: extruded boss/base , extruded cut, dome split , project curve , swept boss/base , combine, revolved boss/base , chamfer mirror and fillet.

sketch tools: sketch geometry line, spline, 3 point arc and circle , convert entities and offset entities.

Appeareance: painted siena Render Image : photo view 360

Procedure:

• insert the blueprint nof chopper and dimension it or locate it with respect to origin and set the transperancy value.
• Draw two concentric circles with an offset of 4mm.
• Draw a horizontal& vertical line from the origin, then a spline that connects the circle centre and tangent to horizontal line and gets a projected sketch.
• sketch on top plane , draw a horizontal line parallel to the line and draw on front plane connected with spline to make it fully defined .
• Next sketch on right plane , draw a spline from top to bottom with relations.
• make the above sketch fully defined.
• Remove the unwanted area using extrude , mirror bodies and combine , apply fillet chamfer and give appeareance to it.

k)Engine:

An engine or motor is a machine designed to convert one form of energy into mechanical energy. Heat engines, like the internal combustion engine, burn a fuel to create heat which is then used to do work.

Feature Tools:extruded boss/base, extruded cut, dome, split, project curves, composite cirves, swept boss/base, circular pattern, revolved boss/base, chamfer, mirror, fillet.

Sketch Tools: sketch geometry like line , spline, 3 point arc & circle, convert entities& offset entities.

Appeareance: chrome Steel

Render image: photo view 360

Procedure:

• Start by sketching on front plane, use sketch picture tools, mark it with refrence to the origin.
• Start again by sketching on front plane use lines and draw circles , keeping them distance 350 mmm , apply tangent relations & make them fully defined.
• use extrude mid plane option and construct the back of the engine.
• Give vertical dimension as well use extrude dimension , use extrude .
• Apply the fillets.
• Now start by sketching on the right plane.
• We need to create a revolve sketch for the front pulley.
• For the back pulley we would be using a refrence plane.
• Select the front plane to create the cylindrical part of the engine, draw a line from origin draw a line which will be collinear to line. Genrate the new plane by selecting the line and end point of the line. Sketch in a new plane , draw a rectangle and extrude it upward , use fillet as well.
• Draw a curve sketch by using sketch on sketch option by ensuring the end point should be the same , use the feature like convert entities, construction line , spline after getting projected curve , draw two consecutive circles, use pierce relation and sweep the curve.

l) gas tank:

A sorage tank which supplies fuel to the engine. The tank is usually hollow.

Feature Tools: Swept surface , loft surface , boundary surface , project curves , knit surface , sweep cut, combine shell, mirror and fillet.

Sketch Tools: Sketch Geometry like line, spline and circle, convert entities and offset entities.

Appeareance: Painted Siena-gas tank.

: driver seat- fabric.

Render Image-Photo View 360.

Procedure:

• Use the blueprint and place it with respect to origin. Sketch on front plane by drawing construction lines. spline as per the sketch and give dimension to make it fully defined, its five point spline
• insert another refrence plane , sketch another spline on this plane , and make apierce relation with the above splie multiple point spline then use sweep surface option.
• Sketch on top plane by drawing a spline and lines. Trim outside portion using trim surface.
• Create one more refrence plane using the front plane and the end point of surface as refrence , sketch on it by drawing spline and vertical construction line to dimension it.
• Use projected curve option and use lofted surface along the projected curve.
• Repeat the procedure for sketching all the remaining portion, mirror it and apply knit surface , For seat select the out6er edge and offset it and then extrude , apply fillet.
• For seat i select the outer edge and offset it and then extrude apply fillet.
• Remove the unwanted surface using sweep cut and apply shell to the body.
• Give appeareance to the body.

2) Assembly of all the components:

Procedure:

1. All the parts which are designed can now be assembled in solid works assembly by creating new assmebly, aseemble al the parts one by one mbringing them into the assembly , the very first part is the Chasis.
2. mates are the most important part of an aseembly we need to define our assembly in relation to our chasis, mates are some fixed coincident , parallel or angle based relations that are important and that make our components at welll defined position within the asembly.
3. Apply mates condition to wheel and kick stand with top plane to snap it to floor.

render Image: photo view 360

3) Applying different decals:

Applying Decals: In this section decals are applied to the gas tank, rear fender and the oil tank.

4) final rendering:

Conclusion:

At the end of the project everything is assembled and rendered well and assembled them to complete the chopper and added a few lights and scenes to give it a more realistic look.