Photo Realistic Rendering

Objective:

To design an American Chopper and rendering its each and every component.

Introduction:

Project report is about designing of American Chopper - Components, Assembly using Solid works & Final Rendering of Assembly using Solid works Visualize and Photoview 360.

Plan of action for designing an American Chopper:

1. Designing of Components/Parts
2. Assembly of Designed Components/Parts
3. Applying Decals, Camera Set-up & Scenes
4. Final Rendering

Designing of Components/Parts:

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

1. Transmission Belt
2. Kick Stand
3. Chain
4. Rear Fender
5. Rear Wheel
6. Pedal
7. Front Fender
8. Front Wheel
9. Oil Tank
10. Front Fork
11. Chassis
12. Engine
13. Gas Tank

1. Transmission Belt:

A belt is a loop of flexible material used to link two or more rotating shafts mechanically. In this chopper it is used for transmission of power from Engine to Gearbox. Feature Tools : Extruded Boss/Base & Fillet.

Sketch Tools : Sketch Geometry like Line. & Offset Entities

Appearance : Matte Rubber

Render Image : Photo View 360

Procedure:

1. Sketch on Front Plane by selecting it, draw a horizontal line from Origin and a 3 Point arc. Apply relations like Tangent with line,etc. & give dimensions to make it fully defined.
2. Make an Offset of 3.5mm of the sketch inward direction.
3. Extrude the created sketch by giving appropriate dimensions.
4. Apply fillets to all sides of Extrude sketch for Smooth finish.
5. Give Appearance to the part.

2. Kick Stand:

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

Feature Tools : Lofted Boss/Base, Dome, Extruded Cut, Split & Fillet. Sketch Tools : Sketch Geometry like Line, Circle, 3 point Arc & Ellipse. Appearance : Chrome Steel

Render Image : Photo View 360

Procedure:

1. Sketch on the Front Plane, by drawing an ellipse which is horizontal to origin and give dimensions and relations to make it fully defined. Then Sketch on the Right Plane, by drawing a spline from origin, activate handle and dimension it.
2. Create a new Plane at the end of Spline, sketch on it by drawing an ellipse and make Pierce relation between Spline and Ellipse mid point.
3. Now Loft the Part using both sketches. Active loft on spline and check coincidence for desired output.
4. Apply Elliptical Dome to the end of spline and remove the unnecessary Portion using Extruded cut.
5. Apply Fillet & Appearance to the Part.

3. Chain:

Chain acts as a connecting bridge between the Engine & Rear Wheel which helps in transmitting power.

Feature Tools : Extruded Boss/Base, Curve driven Pattern,Mirror, Blocks (for links) & Fillet.

Sketch Tools : Sketch Geometry like Line, Circle, Straight Slots & 3 Point arc.

Appearance : Chrome Steel

Render Image : Photo View 360

Procedure:

1. Sketch on Front Plane, by drawing two circles of different diameter, separated by a distance & connect them using 3 point arc on both sides,trim the unwanted portion.
2. Create a throwaway sketch which is used to create inside and outside chain links. Make a block of these and save it.
3. Insert Blocks on the larger end of the drawn circle and make a coincident relation. Extrude the sketch by selecting holes in inserted blocks as contours to create Pins. Extrude again to create Plates by selecting the remaining part in blocks & apply fillet. Repeat the Process.
4. Use a Curve driven pattern to get required number of Pins & Plates over the curve.
5. Repeat the process over other curves to get desired output.

• Give appropriate Appearance to the part.

4. Rear Fender:

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

Feature Tools : Revolve Boss/Base, Split, Fillet & Shell.

Sketch Tools : Sketch Geometry like Line, 3 Point Arc.,Trim Entities & Offset Entities.

Appearance : Painted Siena

Render Image : Photo View 360

Procedure:

1. Sketch on Front Plane, by drawing a 3 Point arc above the origin apply vertical relation with origin. Apply Offset inwards, to extrude make it closed sketch using extended entities & trim entities.
2. Revolve the Sketch across the horizontal construction line at origin by giving proper directional angles.
3. Remove the Unwanted area using the Split tool and apply fillet.
4. Give Desired Appearance to make it realistic.

5. Rear Wheel:

A circular component connected to the rear side of chassis which receives power from Engine. It consists of Rim, Caliper, Rotor, Tire & Sprocket. Engine and Rear wheel are connected via. chain.

Solid Bodies : Rim, Rotor, Caliper, Sprocket & Tire.

Feature Tools : Revolved Boss/Base, Extruded Boss/Base, Extruded cut, Revolved cut, Circular Pattern, Combine,Mirror, Chamfer & Fillet.

Sketch Tools : Sketch Geometry like Line, 3 Point Arc, Circle, Spline, Rectangle., Trim Entities, Extended Entities, Convert Entities & Offset Entities.

Appearance : Rim (Chrome Steel), Rotor (Carbon Steel), Caliper (Painted Siena), Sprocket (Chrome Steel), Tire (Matte Rubber)

Render Image : Photo View 360

Procedure :

1. Select Front Plane and sketch the outer part of wheel and dimension it to make fully defined.
2. Revolve the sketch across the temporary axis.
3. Sketch on Right plane, by drawing a vertical Construction line from the origin and one more line at an angle. Draw a spline and mirror all the three entities across vertical construction line, extrude them.
4. For Spider webbed design, Offset all the drawn three entities and remove the unwanted part using cut extrude.
5. Connect the spokes using 3 point arcs, offset them and make it closed sketch by using lines. Extrude the sketch.
6. Select the front plane and a draw a spline from origin to remove unwanted area using extrude cut.
7. Select Spokes and use a circular pattern. Combine them to make a single solid body.
8. For Rotor- sketch on the front plane, by drawing a circle and extruding it, removed the unwanted portion. Use a circular pattern to create holes over the rotor.
9. For Caliper - Draw circles and lines as per design of body. Remove the unwanted area by trimming & extrude it. Apply Chamfer.
10. For Sprocket - Draw a circle and extrude it. Apply chamfer to the outer part & create teeth by cut extrude to it. Remove the unwanted portion by using cut extrude & Apply fillet.
11. For Tyre - Use Rim as Convert Entities & revolve. Draw rectangles and apply dimensions, relations to make it fully defined. Extrude cut it & apply fillet.
12. Give Appearance to Rotor, Rim, Caliper, Sprocker & Tire.

6. Pedal:

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

Feature Tools : Revolve Boss/Base, Extrude Boss/Base, Dome, Linear Pattern, Chamfer & Fillet.

Sketch Tools : Sketch Geometry like Line, Circle & Spline.

Appearance : Chrome Steel

Render Image : Photo View 360

Procedure:

1. Draw a sketch on the front plane, line & spline from origin and give dimension to make it fully defined. Extrude it and apply fillet. Select the front surface of the extruded part and sketch on it by drawing two circles. Use a dome circular feature.
2. Apply Linear Pattern across the boss extrude. Use distance - distance chamfer to it.
3. Give Appearance to the part.

7. Front Fender:

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

Feature Tools : Revolved Boss/Base, Split & Fillet.

Sketch Tools : Sketch Geometry like Line, Spline & 3 Point arc., Extended Entities & Trim Entities.

Appearance : Painted Siena

Render Image : Photo View 360

8. Front Wheel:

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

Solid Bodies : Rim, Rotor, Caliper & Tire.

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

Sketch Tools : Sketch Geometry like Line, 3 Point Arc, Circle, Spline, Rectangle., Trim Entities, Extended Entities, Convert Entities & Offset Entities.

Appearance : Rim (Chrome Steel), Rotor (Carbon Steel), Caliper (Painted Siena), Tire (Matte Rubber)

Render Image : Photo View 360

9. Oil Tank :

A hollow part which stores oil to run the Engine. The designed thickness of the part is 3mm.

Feature Tools : Extruded Boss/Base, Combine, Shell & Fillet.

Sketch Tools : Sketch Geometry like Line, Spline & Circle.

Appearance : Painted Siena

Render Image : Photo View 360

Procedure:

1. Sketch on Top plane by drawing line, 3 point arc and give relation, dimension them for fully defining, extrude it.
2. Sketch on the Front plane by drawing a spline, line dimension them to make it fully defined and extrude it by midplane, through all and combine two separated bodies.
3. Apply Fillet and give appearance.

10. Front Fork:

A fork is a part of chopper that holds the front wheel. It consists of two blades which are joined at the top by a triple clamp. It acts as a shock absorber which allows just the front wheel to react during imperfections by isolating the other components from that motion.

Feature Tools : Extruded Boss/Base, Extruded cut, Dome, Revolved cut, Project Curve, Swept Boss/Base,Combine, Mirror & Fillet.

Sketch Tools : Sketch Geometry like Line, Spline & Circle., Convert Entities & Trim Entities.

Appearance : Chrome Steel (Fork), Matte Rubber (Handle Grip & Brake Wires)

Render Image : Photo View 360

Procedure:

1. For Fork tube - Sketch on the Front plane, by drawing a cylindrical diagram using line and give dimensions, relations to make it fully defined, then revolve it.
2. For Triple Clamps - Select Top Plane and draw a concentric circle to the fork tube and draw another circle left and upward. Connect the circles and make it fully defined by giving dimensions, then extrude it.
3. For Bulb - Select Front Plane, draw a horizontal construction line, spline and revolve it. Move the bulb in z direction then fillet it.
4. For Handle & Brake wires - Select Top plane and draw the handle using spline, make it fully defined. Draw a circle at the end of the spline and sweep along the path.
5. Select the Bodies Mirror it and combine.
6. Give Appearance to the fork to make it realistic.

11. Chassis:

The most essential part of a Vehicle on which all the components of a motorcycle, like the suspension, wheels, fuel tank, seats, handlebars etc, are attached to this base structure which lends a motorcycle its strength and ability to handle well.

Feature Tools : Extruded Boss/Base, Extruded cut, Dome, Split, Project Curve, Swept Boss/Base, Combine, Revolved Boss/Base, Chamfer, Mirror & Fillet.

Sketch Tools : Sketch Geometry like Line, Spline, 3 Point Arc & Circle., Convert Entities & Offset Entities.

Appearance : Painted Siena

Render Image : Photo View 360

Procedure:

1. Insert Blueprint of chopper in the front plane ,adjust the location, transparency & sketch on it. Draw two concentric circles with an offset of 4mm.
2. Draw a horizontal & vertical line from origin. Then a spline connects the circle center and tangent to the horizontal line and gets a projected sketch.
3. Sketch on Top Plane, draw a horizontal line parallel to the line and draw on the front plane connected with the spline to make it fully defined.
4. Next Sketch on Right plane, draw a spline from top to bottom with relation to origin and make it fully defined.
5. Remove the unwanted area using cut extrude, Mirror the bodies and combine.
6. Apply fillet, Chamfer and give appearance to it.

12. Engine :

Engine is the heart of a vehicle. It converts chemical energy to heat energy which is then used to do the work. The rotary motion in the engine is transferred to the rear wheel through chain & sprocket.

Feature Tools : Extruded Boss/Base, Extruded Cut, Dome, Split, Project Curves, Composite Curves,Swept Boss/Base, Combine, Circular Pattern, Revolved Boss/Base, Chamfer, Mirror & Fillet.

Sketch Tools : Sketch Geometry like Line, Spline, 3 Point Arc & Circle., Convert Entities & Offset Entities.

Appearance : Chrome Steel

Render Image : Photo View 360

Procedure:

1. Insert the picture according to X,Y,Z reference, Select the front Plane draw a diagram of base of engine by using line and 3 point arc, extrude it. The again extrude it on the large circle and small one.
2. Sketch on the front plane by line entities then extrude it and give fillet to the base of the engine.
3. Select a top plane, draw the pulley by line and then turn on a temporary axis to revolve it.
4. Sketch on Pulley by selecting on edge then draw rectangle and extrude towards outside to next surface then select sketch and make circular pattern.
5. Select the outer face of pulley and sketch on it, draw a circle inward then draw a small circle vertically to origin, use the circular pattern feature , select the center point respectively and coincident. Then use the cut extrude feature to remove the material.
6. Select the front plane to create the cylindrical part of the engine. Draw a line from origin again draw a line which will be collinear to line. Generate 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. Create an angle rectangle to the new plane and use cut extrude.
7. Draw a curve, sketch 2D Diagram in two different plane by ensuring the end point should be same, use the feature like convert entities, Construction line, Spline after getting projected curve, draw two concentric circles, make use of Pierce relation to curve then sweep it.

13. Gas Tank:

It is a storage tank which supplies fuel to the engine.

Feature Tools : Swept Surface, Loft Surface, Boundary Surface, Project Curves, Knit Surface, Sweep Cut, Combine, Shell, Mirror & Fillet.

Sketch Tools : Sketch Geometry like Line, Spline & Circle., Convert Entities & Offset Entities.

Appearance : Painted Siena (Gas Tank), Driver Seat ( Fabric)

Render Image : Photo View 360

Procedure:

1. Insert Blueprint in the front plane and give proper dimensions for locating and rename it.Sketch on front plane by drawing construction lines, Spline roughly as per sketch picture & give dimension to make it fully defined.
2. Create a plane at the end point of the spline and sketch on it, by drawing another spline & make a pierce relation with sketch 1, then sweep the surface.
3. Sketch on Top Plane by drawing a spline & lines. Trim the outside portion using a trim surface.
4. Create one more plane using the front plane & end point of surface 2 as reference. Sketch on it, by drawing a spline and a vertical construction line to dimension it.
5. Draw two sketches on Front Plane & Mid plane, using spline and line, then project curve and use lofted surface along projected curve.
6. Repeat the procedure for sketching the remaining surface, mirror it & apply knit surface.
7. For Seat - Select the outer edges and offset it and then extrude, apply fillet.
8. Remove the unwanted surface using a swept cut & apply shell to the body.
9. Give appearance to tank as well as driver seat.

14. Assembly of Designed Components :

• Step - 1 : All the Parts/Components which are designed in Part file are to be inserted in assembly file one by one as per requirement.
• Step - 2 : Apply Mates to each and every individual Part with other parts for proper Alignment.
• Step - 3: Apply Mates Conditions to Wheels and Kick Stand with Top Plane to Snap it floor.

Render Image: Photoview 360

Applying Decals, Camera Set-up & Scences:

• Applying Decals: In this section Decals (a design prepared on Special Paper) are applied to Gas Tank, Oil Tank & Rear Fender.

Render Image: Photo View 360

Camera Set-up:

Camera Set-up is essential for the final rendering of Chopper which helps in showcasing the realistic image.

Scenes & Lights:

Check for appropriate scenes & proper light set-up to make our chopper realistic in final rendering.

Final Rendering :

In this we are going to render our chopper to make it realistic.

Software used: Solidworks Photo visualize.

Steps to Follow:

• Import - Import the Assembly file into the Solidworks Photo Visualize.
• Appearance - Give/Change Appearance to Parts to make it more realistic.
• Scenes - Add scenes (Environment -3D/ Plate - 2D) as a background & choose proper location.
• Output - Make a fast render & check the output. Ones satisfied with everything go for Final quality rendering.

Conclusion:

At the end of project, each and every component designed individually in part file and assembled them to complete Chopper Design. Additional Appearances/setup like Decals, Scenes, Camera, Lights, etc.. given to make it more realistic & Finally Rendered after placing designed Chopper in decent background Scenes.