Photo Realistic Rendering

 DESIGN AND ASSEMBLY OF AMERICAN CHOPPER BIKE WITH PHOTO REALISTIC RENDERING USING   SOLIDWORKS

 

OBJECTIVE

The main objective of this project is to understand the basics of SOLIDWORKS part modeling and assembly by designing and assembling of AMERICAN CHOPPER BIKE and also creating Photo realistic rendering

INTRODUCTION

Computer aided design (CAD) is the method of using a computer with CAD software for design and drafting applications. CAD has taken the place of manual drafting. The drafter or designer creates a   3-D model or 2-D engineering drawing of a part using CAD Software

The SOLIDWORKS CAD software is a mechanical design automation application that lets designers quickly sketch out ideas, experiment with features and dimensions, and produce models and detailed drawings.

DESIGN INTENT

It determines how your model should behave as a result of the changes made to the model. For instance, if you make a boss with a hole in it, the hole should move along with the boss, whenever it is moves.

DESIGN APPROACH

                                              

DESIGN METHODOLOGY

Understanding of the general design process will help you to design the products considering the impacts on other stages. The structure of a typical design process is given below:

 

                            

MODULES IN SOLIDWORKS

• PARTMODEL
• DRAFTING
• MOULD
• WELDMENTS
• SHEETMETAL
• SURFACING
• ASSSEMBLY
• SKETCH

 

A sketch is a 2D profile or cross section of the 3D models drawn in the sketcher module.

Creating a module usually begins with a sketch. Sketch entities are used to create features.

The features are the basic models of a model. To create a 2D sketch, use a plane or a planar face. In addition to 2D sketches, you can also create 3D sketches that can be controlled by all three axes             (X, Y, Z axes)

 

SKETCH ELEMENTS

ORIGIN

In many instances, you can start to sketch at the origin, which provides an anchor for the sketch

 PLANES

Planes are the references widely used to place or refer a feature. you can sketch on planes with sketch entities such as line, rectangle, arc etc. Planes can be crated in part or assembly environment

DIMENSIONS

Dimensions in sketch environment allow you to specify dimensions between entities such as length, radius, etc. When you change dimensions, the size of the and the shape of the sketch entities will change. Depending on how you dimension the part, you can preserve the design intent. the software uses two types of dimensions Driving dimensions and driven dimension

SKETCH DEFINITIONS

Fully defined – black colour

Under defined – blue colour

Over defined – yellow colour

SKETCH ENTITIES

We can create a sketch with the help of these sketch entities. Some of the sketch entities are Line, Arc, Circle, Rectangle.

LINE

Line entity is used to draw lines in many ways on the plane

CENTRELINE

Centreline entity is used to sketch a centreline for reference purpose. use centreline entity as a reference for creating symmetrical sketch and revolved features.

MIDPOINT LINE

Midpoint line entity is used to create a line that is symmetrical from its midpoint.

CIRCLE

 Circle tools is used to create circle entities. There are two types of circle 2point circle and perimeter circle

ARC

 Arc tool is used to create an arc entity for different situation. There are three types of arc

CenterPoint arc, Tangent arc, 3Point arc

ELLIPSE

Ellipse tool is used to create an ellipse entity. We can specify any appropriate combination of the following parameters to define the ellipse centre X Coordinate, Centre y Coordinate, Radius 1, Radius 2

RECTANGLE

 A rectangle tool entity is used to create various types of rectangles for different situation

Types of rectangles are Corner rectangle, Centre Rectangle, 3 Point Centre Rectangle, 3Point corner Rectangle, Parallelogram.

SLOT

 A Slot tool is used to create various types of slot entities for different situation Types of slots

Straight slot, Centre point Straight slot, 3 Point Arc Slot, Centre point Arc slot

POLYGON

 A polygon Tool is used to create equilateral polygons with any number of sides between 3 and 40

Parameters of Polygon are

Number of Sides, Inscribed and Circumscribed circle, Circle diameter, Angle

PARABOLA

A parabola tool is used to create parabola curve entity. Specify the parabola parameters in the property manager.

SPLINE

A spline tool is used create the curved spline entity. there are two types of spline available. They are B-splines and Style splines. B – Splines are used to create complex curves. you can define and modify them using several controls including spline points, spline handles and control polygons

SKETCHING POINT

Point tool is used to create the point entities in sketches and drawings.

SKETCH TEXT

Text tool is used to create the texts as sketch entities. you can sketch the text on any set of continuous curves or edges, circles, lines, arcs or splines and also on the part of the face. It is also possible to extrude or cut the text     

SKETCH RELATION TYPES

• Coincident
• Collinear
• Concentric
• Co-Radial
• Equal
• Equal curvature
• Fix
• Horizontal
• Intersection
• Merge
• Midpoint
• Normal
• Parallel
• Offset
• Perpendicular
• Symmetric
• Tangent
• Vertical

DIMENSIONS

Sketches are displayed in various states. In order to fully define the sketch, you add relation and apply dimensions using the smart dimension tool.

SMART DIMENSION

Smart Dimension Tool is used to dimension the 2D or 3D Sketch entities you can drag or delete a dimension while the smart dimension tool is active

SKETCH EDITING TOOLS

Sketch Tools are commonly used to edit the sketch entities. Some of the sketch tools are Fillet, Chamfer, Trim, Mirror etc

SKETCH FILLET

The sketch Fillet tool is used to trim the corner at the intersection of two sketch entities to create a tangent arc. you can use the fillet tool in both 2D and 3D sketches

CHAMFER

A Chamfer tool is used to apply a chamfer to the sketch entities in 2D and 3D sketches

Parameters of chamfer are Angle -Distance, Distance – Distance

OFFSET

An offset tool is used to offset the sketch entities to the specified distance

CONVERT ENTITIES

The convert Entities tool is used to create one or more curves in a sketch by projecting a edge, loop, face, curve, or external sketch contour, set of edges or set of sketch curves onto the sketch plane/face

TRIM ENTITIES

The trim tool is used to delete the unwanted sketch entities select the trim type based on the entities you want to trim. Types of trim tool Power Trim, corner, Trim away inside, trim away outside, Trim to closet

EXTEND ENTITIES

The extend tool is used to add the length of the sketch entity up to another point of the entity

MIRROR ENTITIES

The mirror tool is used to mirror the pre-existing 2D sketch entities with respect to some reference

SKETCH PATTERNS

Sketch patterns are used to create linear or circular sketch patterns using elements from sketch entities

TWO TYPES OF SKETCH PATTERNS

Linear Sketch patterns

Circular sketch patterns

SKETCH BLOCKS

Sketch blocks in solidworks provide a simple and useful method of grouping the entities together. More than just grouping you can perform conceptual design, testing the function before committing to the form

MODELING FEATURES

Features are the individual building blocks that, when combines, make up the part. Some of the common features are extrude, revolve, loft, and sweep features

EXTRUDE

Extrude are used to create a feature (boss/base) by protruding a section in the normal direction. As with the base, all extrudes begin with a section sketch.

REVOLVE

The revolve tool is used to add a material by revolving one or more profiles around a centerline. you can create revolve boss/base, revolved cuts or revolved surfaces. The revolve feature can be solid, a thin feature, or a surface

SWEPT

A Swept/sweep is used to create a base, boss, cut or surface by moving a profile (section) along a path and controlling the shape with the guide curves (optional). it can be simple or complex

HELIX AND SPIRAL TOOL

The helix and spiral tool is used to create a helix or spiral curve in a part. The curve can be used as a path or guide for the swept feature or as a guide curve for a lofted feature

LOFTS

A Loft is used to create a feature by making transmissions between profiles. It can be a base, boss, cut or surface you can create a loft using two or more profiles

DOME TOOL

The dome tool is used to create dome like shapes in the model

EDIT FEATURES

Edit features are the secondary features; means they can be created only on the already existing features. these include cut, fillets, shells, ribs and other features

CUT FEATURES

The cut features is used to remove material from a part or an assembly. with multibody parts, you can use cut features to create disjoint parts. Also, you can control which parts to keep and which parts to effect by the cut

EXTRUDED CUT TOOL

The Extruded cut tool is used to remove all the materials, defined by a sketch profile protruded in the normal direction to a specified distance

SWEPT CUT TOOL

The swept cut tool is used to removes the materials by sweeping a profile along the defined path

SURFACE MODELLING

Surface modelling gives you the ability to build out a visual representation of an objects exterior and its contours. In other words, it’s a surface.

Parts like seat, fuel tank of classic 350 are surface modelled.

FEATURES DESCRIPTION

LOFTED SURFACE

Loft surfaces are surfaces generated by multiple 3D curves or existing edges creating a smooth tangency between the selected curves.

SWEPT SURFACES

Sweep Surfaces are surfaces that are generated from a section curve position along path.

FILLED SURFACE

The filled surface features construct a surface patch with any number of sites, with in a boundary defined by existing model edges, sketches, or curves, including composite curves.

SURFACE TRIM

Primarily used to cut away material from a surface, and provides to modes: standard and mutual.

EXTEND SURFACE

Extend surface is used to extend the surface which is already created. There are different options available on the extended surface. We can extend the surface as same surface or we can extend the surface tangent to the surface.

SURFACE KNIT

Surface knit is used to knit the two free edges/open edges of the surface together. Also it reduces the gap between the two edges of the surface.

The Revolved cut tool is used to remove material by revolving one or more profiles around a centerline

LOFTED CUT

The Lofted cut tool is used to material by transitions between different profiles

ENGINEERING FEATURES

FILLET TOOL

The Fillet tool is used to create 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

CHAMFER TOOL

The Chamfer tool is used to create a beveled feature on selected edges, face or a vertex

SHELL TOOL

The Shell tool is used to hollow out a par, leaves open the faces you select and create thin walled feature on the remaining faces.

If You do not select any face on the model, you can shell a solid part, creating a closed and hollow model. you can also shell a model using multiple thickness

RIB TOOL

The Rib tool is a special type of extrude feature created from open or closed sketched contours. It adds material of a specified thickness in a specified direction between the contour and a existing part. you can create a rib using single or multiple sketches.

You can also create rib features with the draft or select a reference contour to draft

WARP TOOL

The Warp tool is used to warp a sketch onto a planar or non – planar face. The warp feature supports contour selection and sketch reuse. you can project a wrap feature onto multiple faces

HOLE WIZARD

The Hole tools are used to creates different types of hole feature on the model.

PATTERNS

A pattern repeats the selected features in an array based on a seed feature. You can create a linear pattern, a circular pattern, a curve driven pattern, a fill pattern, or use sketch points or table coordinates to create the pattern. When a pattern or mirror features split single bodies into multiple bodies, you can select which bodies to keep and specify which configuration to keep up to date. The software also supports a full preview of pattern and mirror features

LINEAR PATTERN TOOL

Linear pattern tool are used to create multiple instances of one or more features that you can space uniformly along one or two linear paths

CIRCULAR PATTERN TOOL

Use circular pattern tool to create multiple instances of one or more features that you can space uniformly around an axis

SKETCH DRIVEN PATTERN TOOL

Using sketch points within a sketch, you can specify a feature pattern. The seed feature propagates throughout the pattern to each point in the sketch. you can use sketch driven patterns for holes or other feature instances

CURVE DRIVEN PATTERN TOOL

The Curve driven pattern tool allows you to create patterns along a planar or 3D curve. 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

SPLIT LINE TOOL

The Split line tool is used to project an entity (sketch, solid, surface, face, plane or surface spline) on to surfaces or curved/planar faces. It divides a selected face into multiple separate faces. You can split curves into multiple bodies with one command. You can create split lines using sketched text. This is useful creating items like decals.

PROJECTED CURVE TOOL

The projected curve tool is used to project a sketched curve onto a model face to create a 3D curve. You can also create a D curve that represents the intersection of two extruded surface generated by creating sketches on two intersection planes

COMPOSITE CURVE TOOL

The Composite curve tool is used to join the sketch entities, edges and so on

SURFACE MODELLING

Surface modelling gives you the ability to build out a visual representation of an objects exterior and its contours. In other words, it’s a surface.

Parts like seat, fuel tank of classic 350 are surface modelled.

FEATURES DESCRIPTION 

LOFTED SURFACE

Loft surfaces are surfaces generated by multiple 3D curves or existing edges creating a smooth tangency between the selected curves.

SWEPT SURFACES

Sweep Surfaces are surfaces that are generated from a section curve position along path.

FILLED SURFACE

The filled surface features construct a surface patch with any number of sites, with in a boundary defined by existing model edges, sketches, or curves, including composite curves.

SURFACE TRIM

Primarily used to cut away material from a surface, and provides to modes: standard and mutual.

EXTEND SURFACE

Extend surface is used to extend the surface which is already created. There are different options available on the extended surface. We can extend the surface as same surface or we can extend the surface tangent to the surface.

SURFACE KNIT

Surface knit is used to knit the two free edges/open edges of the surface together. Also it reduces the gap between the two edges of the surface.

PARTS IN AMERICAN CHOPPER

• Transmission Belt
• Kickstand
• Front Fender
• Rear Fender
• Chain
• Oil Tank
• Pedal
• Front Wheel
• Rear Wheel
• Fork
• Chassis
• Engine
• Gas Tank

TRANSMISSION BELT

It is a loop of flexible material used to link two or more rotating shaft mechanically, most often parallel. Belts may be used as a source of motion, to transmit power efficiently or to track relative movement.

FEATURES USED

• Boss Extrude
• Fillet

                                                      

 

 

KICK STAND

A kick stand is a device on a motor cycle that allows the bike to be kept upright without leaning against another object or the aid of the person. A kick stand is usually a piece of metal that flips down from the frame and makes contact with the ground.

FEATURES USED

• Loft
• Dome
• Cut Extrude
• Boss Extrude
• Fillet
• Split

               

                                                    

FRONT FENDER

Fender is the American English drum for the part of an automobile, motor cycle its primary purpose is to prevents sand, mud, rocks, liquids and other road spray from being thrown into the air by rotating the tire.

FEATURES USED

• Revolve
• Split
• Fillet

                                                   

 

REAR FENDER

Fender is the American English drum for the part of an automobile, motor cycle its primary purpose is to prevents sand, mud, rocks, liquids and other road spray from being thrown into the air by rotating the tire.

FEATURES USED

• Revolve
• Split
• Fillet
• Shell

                                               

CHAIN

The chain on the bike is responsible for transferring the mechanical power from the engine to the rear wheel of the bike

FEATURES USED

• Boss Extrude
• Fillet
• Curve Driven Pattern
• Block
• Mirror

                                          

OIL TANK

An oil tank has the purpose of storing lube oil to lubricate the engine parts to avoid wear and tear.

FEATURES USED

• Boss Extrude
• Combine
• Fillet
• Shell

                                        

PEDAL

A pedal has the function of shifting the gears to get the desired speed from the engine and also applying the breaking force.

FEATURES USED

• Boss Extrude
• Fillet
• Revolve
• Dome
• Chamfer
• Linear Pattern

                                                     

                              

 

FRONT WHEEL

A wheel is a circular block of a hard and durable material where the center has been bored with the circular hole through an axle bearing about which the wheel rotates.

FEATURES USED

• Revolve
• Boss Extrude
• Cut Revolve
• Combine
• Circular Pattern
• Chamfer
• Fillet

                                                     

REAR WHEEL

A wheel is a circular block of a hard and durable material where the center has been bored with the circular hole through an axle bearing about which the wheel rotates.

FEATURES USED

• Revolve
• Boss Extrude
• Cut Extrude
• Cir Pattern
• Combine
• Cut Revolve
• Chamfer
• Fillet

                                              

 

FORK

A motor cycle fork is a part of a bike that holds a front wheel. The fork consists of bearings and hydraulic oil which also acts as a suspension. The handle bar of the bike is mounted on fork.

FEATURES USED

• Revolve
• Boss Extrude
• Fillet
• Linear Pattern
• Dome
• Sweep
• Combine

                                                     

CHASSIS

The chassis is the skeleton of the motor cycle which consists of all the parts mounted on it

It is constructed using the hollow pipes.

FEATURES USED:

• Curve
• Sweep
• Mirror
• Boss Extrude
• Cut Extrude
• Chamfer
• Fillet
• Dome
• Split
• Combine

                    

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

FEATURES USED:

• Boss Extrude                          
• Fillet
• Revolve               
• Cir Pattern                           
• Dome
• Cut Extrude
• Chamfer
• Linear Pattern
• Mirror
• Split
• Combine
• Sweep
• Composite curve

                      

                                                       

GAS TANK

A  gas tank is a safe container for flammable fluids. Though any storage tank for fuel may be so called, the term is typically applied to part of an engine system in which the fuel is stored and propelled fuel pump  or released (pressurized gas) into an engine. Fuel tanks range in size and complexity from the small plastic tank of a butane lighter to the multi-chambered cryogenic space shuttle external tank.

FEATURES USED

• Surface Sweep
• Surface Trim
• Surface Loft
• Curve
• Boundary Surface
• Surface Extrude
• Fillet
• Shell
• Cut Sweep

                           

                                                               

ASSEMBLY

An assembly is a collection of related parts saved in one SOLIDWORKS document file with Assemblies:

• Contain anywhere from two to over one thousand components, which can be parts or other assemblies called subassemblies
• Display movement between related parts within their degrees of freedom The components in an assembly are defined in relation to each other using assembly mates. You attach the assembly components using various types of mates such as coincident, concentric, and distance mates. For example, the faucet handle components are mated to the faucet base component using concentric and coincident mates. The mated components create the spigot subassembly. Later, you include this subassembly in the main vanity assembly, mating it to the other components in the vanity assembly.

 

ASSEMBLY DESIGN METHODS

You create assemblies using two basic methods: bottom-up design and top-down design. You can also use a combination of the two methods. With either method, your objective is to mate the components to create the assembly or subassembly

BOTTOM-UP DESIGN

In bottom-up design, you create parts, insert them into an assembly, and mate them as required by your design. Bottom-up design is the preferred technique when you use previously constructed, off-the-shelf parts.

An advantage of bottom-up design is that because components are designed independently, their relationships and regeneration behaviour are simpler than in top-down design. Working bottom-up allows you to focus on the individual parts. It is a good method to use if you do not need to create references that control the size or shape of parts with respect to each other. Most of the vanity cabinet uses bottom-up design. You create the components such as the sink and the spigot in their own part windows. Then you open an assembly document, bring the components into the assembly, and add various mates.

TOP-DOWN DESIGN

In top-down design, you start your work in the assembly. You can use the geometry of one part to help define other parts, to create features that affect multiple parts, or to create machined features that are added only after the parts are assembled. For instance, you can start with a layout sketch or define fixed part locations, then design the parts referencing these definitions. Top-down design is also known as in-context design.

For example, you can insert a part in an assembly, then build a fixture based on this part. Working top-down, creating the fixture in context, allows you to reference model geometry, so you can control the dimensions of the fixture by creating geometric relations to the original part. That way, if you change a dimension of the part, the fixture is updated automatically.

The vanity cabinet also uses top-down design. You create the two supply pipes within the context of the assembly. Then you reference the size and location of the faucet subassembly and the vanity cabinet to define the supply pipes.

MATES

Mates position the components in an assembly precisely with respect to each other. Positioning the components defines how they move and rotate with respect to each other. Mates create geometric relations, such as coincident, perpendicular, and tangent. Each mate is valid for specific combinations of geometry such as cones, cylinders, planes, and extrusions. For example, if you mate a cone to another cone, the valid types of mates you can use include coincident, concentric, and distance

                                          

                                       

                                      

                                                                    

                           

SOLIDWORKS VISUALIZE

SOLIDWORKS Visualize (formerly known as Bunk speed) provides a suite of standalone software tools that combine industry-leading rendering capabilities with visual design-oriented features and workflows, allowing easy and fast creation of visual content that communicates a design’s vision, passion, and emotion.

SOLIDWORKS Visualize helps organizations and nontechnical users leverage 3D CAD data to create photo quality marketing content that is print and web-ready in minutes. From static images to animations, interactive web content and immersive Virtual Reality (VR), SOLIDWORKS Visualize delivers graphical content that depicts products in the real world and elevates the design process. By improving concepts throughout the design, development and marketing phases, SOLIDWORKS Visualize help users select, validate, improve and sell the best and most robust design concepts before committing expensive engineering, prototyping and marketing resources to the project. It helps reduce errors and ensure that products get to market faster than ever before.

RENDERED IMAGES

                                            

                                              

                                            

  

CONCLUSION

Thus the Part modeling, Assembly, Photo realistic rendering of the American chopper bike has completed using SOLIDWORKS 2019