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Modelling and Rendering of American Chopper Introduction: The project is about modelling of different parts of American Chopper, assembly of chopper and rendering of the model to get photorealistic images of Assembly model. Objective: The objective of the project is to design the various parts of American…
Vinayak Amle
updated on 12 Mar 2021
Modelling and Rendering of American Chopper
The project is about modelling of different parts of American Chopper, assembly of chopper and rendering of the model to get photorealistic images of Assembly model.
The objective of the project is to design the various parts of American Chopper, assembly of the parts and final rendering of assembly. During this modelling process, various sketching tools will be explored to model complex parts with ease and keeping models easy to revise for any changes in future.
For this project, we will be using a bottom-up design approach. First modelling of separate parts will be done. Then appearances will be given to each part individually. After that, assembly of the parts will be done to get the final complete model of American Chopper. Then decals will be added and scene setup will be done to get the perfect environment. The final rendering will be done in photo view 360 and Solid works visualise to get the photorealistic images of the final product.
American Chopper assembly contains the following parts:
The transmission belt is made of rubber or similar flexible material. It is used to transmit power from one shaft to another.
Design procedure and features used:
The outline is made by doing a sketch on the front plane. Sketch tools used for this sketch are 3-point arc for both ends and line tool for joining two ends.
An off-set value is given to get the thickness of the belt. Dimensions are given to all entities to fully define the sketch.
The sketch is then extruded to width of belt using Boss Extrude feature. Sharp corners are smoothened by giving fillet using Fillet feature.
Matt Rubber appearance is applied to part from the appearances tab.
b. Front Fender
It is a part which covers the front wheel and prevents mud and other dirt which could splash on the frame and chopper body.
Design procedure and features used:
First a profile of fender is sketched on front plane using 3-point arc. Thickness is given to the fender using offset entity tool.
This sketch is then revolved in both directions to the required value to get fender body.
Then 2 sketches at top and bottom part of the fender are used to cut the fender body in required shape. This is done using split tool in solid works which uses sketch or surface entity to split single body in multiple bodies. Fillet is given to edges to get rid of sharp edges.
Painted Sienna appearance is applied to the fender body.
c. Rear Fender
Rear Fender works same as front fender for rear wheel. It covers the rear wheel and prevents dirt splashing from rear wheel.
Design procedure and features used:
Similar to front fender, first a profile of fender is sketched on front plane using 3-point arc. Thickness is given to the fender using offset entity tool.
This sketch is then revolved in directions to the required value to get fender body.
Split tool is again used to give shape to the fender. Then fillet is applied to the sharp edges. Also, top and bottom corners are also given fillet to get aesthetic look of fender. Then Shell command is applied to get cover shape of fender. Shell feature is used to get a hollow body with specified thickness from the complete solid body.
Similar to front fender, painted Sienna appearance is applied to the fender body.
d. Kickstand
As name suggests, it is a stand used to support the chopper to stand when it is not in used. It is kept in horizontal position to avoid its contact with ground when chopper is moving.
Design procedure and features used:
First two ellipses are drawn using ellipse sketch tool on different planes. Then a spline joining the two centres is drawn using spline tool. Dimensions are given as per requirement to fully define the sketch.
These two ellipses are joined using lofted boss feature. Loft feature creates a solid body between the two selected sketches. Guide curve can be given specify curvature of solid body. In this case, spline joining the two centres is used as centreline reference. Due to this, the spline will be in centre of the solid body giving it body the curvature of spline.
The ends of the kickstand are made rounded with the help of dome feature. Dome feature creates a dome like structure on flat surfaces. At the top end one slot is cut using cut extrude feature and a solid cylindrical body is made in slot using boss extrude to connect kickstand with chassis.
All sharp edges are treated with fillet. A flat surface is created at lower end to ensure proper contact with surface. This is done using split tool. A line is used to split the bottom part and give flat surface at bottom.
Chromium plate appearance is given to kickstand body.
e. Chain
Chain is a connecting link used to transmit power from one shaft to another with help of sprockets. Chain is made up of various small links and can transmit high amount of power compared to belt.
Design procedure and features used:
The main feature used in modelling of chain is blocks. Since chain is made of number small similar links connected together, same sketch or body needs to be used multiple times.
First outline of chain is drawn on front plane. Two chain links are drawn separately and saved as blocks. Then these blocks will be used over the periphery of chain outline and extruded to given thickness. Since in this case, the outline is made of 4 curves, curve driven pattern can be used to replicate multiple bodies of chain link. Only first pair of chain link need to be drawn and extruded at start of the curve. Then with the help of curve driven pattern feature, multiple bodies can be patterned on the curve.
All sharp edges need to be operated with fillet before pattern body feature to avoid inconvenience. Chromium plate appearance is applied to the chain body.
f. Pedal
Pedal is a part used as foot rest for the rider. Most of the times, gear shifting mechanism is attached to this pedal.
Design procedure and features used:
The pedal is created using all the basic sketch and feature tools, starting from its side face on front plane. This sketch is given a thickness using extrude. On the newly generated face, circles are drawn and extruded to get foot rest. Collar made on cylindrical surfaces and patterned using linear pattern feature. Chamfer feature is used to get pointed end and dome is used to create elliptical face.
g. Oil Tank
Oil tank is used to store lubricating/cooling oil which flows over the moving parts, reducing friction and heat generated.
Design procedure and features used:
Oil tank is modelled using different approach rather than normal sketch and extrude to get its rounded surface. First solid bodies are made one over other and then combine feature is used to get the intersection part of those 2 bodies and a single solid body. In combine feature, common option is selected so that the intersecting parts of the solid bodies are obtained as one single solid body.
Corners are then treated with fillet. Painted sienna appearance is applied to the tank body and white colour is applied to the fillet feature to get white border on tank body. Shell feature is used to make the tank body hollow with given thickness.
h. Front Wheel
Front wheel is attached to the front of Chopper body with the help of front fork.
Design procedure and features used:
In the front wheel model, there are 4 parts; Tyre, Rim, Rotor disc and Calliper.
To model front wheel first Rim outline is created by creating circular body with the help of single sketch and revolve boss tool. Then Rim pattern is extruded on the revolved body by using sketch on plane. To multiply the pattern on rim, circular pattern feature can be used. Then combine feature is used to combine patterned bodies and keep the rim as single solid body.
For Tyre, profile is drawn using 3-point arc and other sketch tools. Then this profile is revolved over the circumference of rim to get the tyre body. Treads are cut on tyre profile with help of sketch and cut extrude feature.
Rotor disc and calliper is drawn on side face of rim and extruded as per required dimensions. Rotor body and calliper body are kept separate solid bodies to give appearance to individual body. All sharp edges are treated with fillet.
Sienna appearance is applied to calliper, matt rubber to tyre and chromium plate appearance is applied to rim and rotor disc.
i. Rear Wheel
Rear wheel is connected to chopper body at rear side of chassis. Power from engine is transmitted to rear wheel with help of chain drive which results in motion of chopper.
Design Procedure and features used:
Rear wheel includes 5 separate bodies; Rim, tyre, rotor, calliper and sprocket.
The design procedure is similar to the front wheel. First Rim profile is revolved. Then, pattern of rim spoke is created and patterned on the circular path.
For Tyre, profile is drawn on side plane and is revolved around circumference of rim. Treads are cut on tyre surface.
Rotor disc, calliper and sprocket are modelled on one side of the rim. To cut the teeth on sprocket, first single tooth is cut and then this cut feature is patterned over the circular profile of sprocket body. Similar is done to the pattern on sprocket face.
Similar to front wheel, sienna appearance is applied to calliper, matt rubber to tyre and chromium plate appearance is applied to rim, sprocket and rotor disc.
j. Front Fork
Front fork is a part of chopper which is connected to front wheel. Direction in which the chopper is moving can be controlled by handle of the front fork. Also, acceleration and braking controls are fitted on handle of the front fork.
Design Procedure and features used:
While modelling the front fork, mirror body feature is used for simplicity. First the half part of front fork is modelled as shown in image below. For fork rod, revolve feature is used. For headlight part, similarly sketch is revolved to get conical shape body. This is then adjusted on fork using move body feature.
For handle and wires, sweep boss feature is used. Using sweep boss feature, any closed sketch can be extruded or swept on a 2D path created using 2D sketch.
For the path of wires, we need a 3D sketch as they are not parallel to any single plane. We can draw a 3D sketch but giving constraints to the curve will be difficult. So, to avoid that, projected curve option is used.
In the projected curve feature, we can create a 3D curve using two 2D curves. The intersection of these 2 curves is given as resulting 3D curve.
Then this half body is mirrored across the plane. This plane is created using the reference of the flat surface of fork at middle. Then these two separate bodies are combined to form one single body.
Chromium plate appearance is applied to the body of fork and matt rubber appearance for the handle grips and wires. To simulate the headlight, White LED appearance is given to the face of headlight.
k. Chassis
Chassis is the main frame of chopper body which holds all parts together and distributes the load on chopper evenly. All components are attached to chassis to form a complete chopper body.
Design Procedure and feature used:
Chassis is designed using multiple 3D projected curves and sweep profiles. For a reference, blueprint of chopper is placed on a plane and with reference to this image, 2D sketches are drawn. All sketches are constrained with dimensions to fully define the sketch. Then these sketches are used along with other sketches to create 3D projected curve. On this curve, a sketch profile is extruded using sweep feature. All sharp edges are treated with fillet to get smooth surface.
Engine mounting plates, fixture for pedal and kickstand etc is modelled on chassis body. Painted Sienna appearance is given to chassis body.
l. Engine
Engine is a main powerhouse of Chopper. Engine provides power to chopper to drive the transmission which ultimately drives the chopper. Thermal energy is converted into mechanical energy by internal combustion method. Fuel is used to perform internal combustion process.
Design procedure and features used:
For modelling of Engine, again blueprint of chopper is used to get some reference sketches. Engine is designed using various features used in modelling of other parts of the chopper.
The main transmission pulleys are modelled using extrude feature. Sprocket on the pulley is designed in similar way as it is designed on rear wheel. For engine cylinder, first one cylinder is modelled completely and then it is mirrored to get a second one. Fins on the engine are modelled using pattern feature. First single fin is created and fillets are applied to its edges. This single fin is then patterned on the surface of cylinder to get multiple fins. For exhaust pipes and filter pipes, projected curves feature is used. These curves are then converted into pipes of required diameter using sweep boss feature. For other detailing, Dome and fillet features are used.
m. Gas Tank
Gas Tank is a storage tank for fuel which is used to drive the engine. It is a specially designed storage tank as it needs to hold the flammable fuel safely to avoid any hazard.
Design procedure and features used:
In the modelling of Gas tank, mainly surfacing tools are used to create different surfaces. Again, blueprint of chopper is taken on front plane and reference curve is drawn for gas tank. Then a line sketch is drawn on the perpendicular plane and this line sketch is extruded as surface along the curve. This is done using extruded surface tool. Then a sketch on top plane is drawn which will be used to trim the generated surface. This is done using trim surface tool.
Then with the use of projected curve feature, outline for bottom part of gas tank is created. To generate a surface, surface loft tool is used. For back part, again projected curve method is used. To get the surface, boundary surface tool is used. In boundary surface tool, boundaries to generate the surface are specified to get surface. These surfaces are then mirrored to get other part of body. Knit surface command is used to join surfaces.
For seat part, first the seat part is separated using trim surface tool and then it is given a thickness using extrude surface feature. Rounded edges are treated with fillet to give seat a aesthatic look. A slot at bottom is cut using sweep cut tool for attachment of gas tank with chassis. Painted Sienna appearance is used for gas tank body and grey cotton appearance for the seat.
2. Assembly of parts.
All the parts of the chopper are assembled in an assembly file. While doing assembly, first all the parts are brought into assembly file. The chassis is fixed and all the parts are assembled by giving mates with reference to chassis.
The various mates used are as Coincident, concentric, parallel, width mate, angle mate, distance mate, Limit angle, tangent mate etc. These mates are applied to respective faces, edges and surfaces.
3. Adding decals and setting up scene.
Decals are graphic arts printed on body for aesthetic looks. It can be added on the model surface in solid works. Below are some samples of decals added to various parts of chopper.
For setting up scene, various pre-set scenes can be used which are available in solid works. Other values like brightness, environment, shadows can be adjusted in edit scene tab. Multiple lights can be setup as per requirements. Cameras can be added to get a view of a specific angle while rendering.
Below is the example of a chopper model set up in a 3-point white scene available in solid works.
4. Final Rendering of Assembly.
Rendering is a process of generating photo realistic images of model. Rendered images is a simulation of model is real world. This can be done using various software and tools. The tools mainly used here are Photo view 360 and Solid works Visualise.
During this project, various sketch tools and feature tools are explored to simplify the design process of complex parts. Understanding of assembly mates for final assembly of product.
Also, setting up decals and scene for rendering of photorealistic images for presentation or display purpose was learned during this project.
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