MODELLING & PHOTO-REALISTIC RENDERING OF AN AMERICAN CHOPPER

DESIGN OF AN AMERICAN CHOPPER AND PHOTO-REALISTIC RENDERING USING SOLIDWORKS

OBJECTIVE:

The objective of this project is to create part models of The American chopper and assemble the parts using SOLIDWORKS.

To add Decals, Camera View, and Environment Scenes of the Assembly.

To create the Photorealistic Model of this Assembly Chopper and Render the modeling using Solidworks Photoview 360.

INTRODUCTION: 

This project report is about the design of the American Chopper, Assembly using SOLIDWORKS, and Photorealistic Rendering using Solidworks Visualize & Solidworks Photoview 360.

DESIGN METHODOLOGY:

1. Modeling of Parts
2. Assembly of Parts
3. Applying Decals, Camera Setup, and scenes
4. Final Rendering

1. MODELING OF PARTS:

 List of Parts to be Designed For American chopper:

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

Boss Extrude:

Extrude tool is used to extend a sketched profile in one or two directions as either a thin feature or a solid feature. An extrude operation can either add material to a part or remove material from a part.

Extrude Cut:

The Extrude tool is to remove material by projecting a sketched section normal to the sketching plane. Can be used open or closed sections to create a cut. Removing material using a closed section creates a slot.

Revolved Boss/Base:

Revolves add or remove material by revolving one or more profiles around a centerline. You can create revolved boss/bases or revolved surfaces. The Revolve feature can be a solid, a thin feature, or a surface.

Revolved Cut: 

Revolved cut can remove material by revolving one or more profiles around a centerline. The revolved cut may be a solid, a thin surface, or a Surface.

Fillet: 

A fillet or round connects two objects with a tangent arc in 2D or creates a rounded transition between the adjacent faces of a 3D solid.

Chamfer: 

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

Shell: The shell tool hollows out a part, leaves open the faces you select, and creates thin-walled features on the remaining faces. If we do not select any face on the model, we can shell a solid part, creating a closed, hollow model. we can also shell a model using multiple thicknesses.

Dome:  

The software calculates the distance using the radius of the arc as a basis for the dome. It creates a dome that is tangent to the adjacent cylindrical or conical face.

Linear Pattern: 

A linear pattern is to create multiple instances of one or more features that you can space uniformly along one or two linear paths.

Circular Pattern:

A circular pattern is to create multiple instances of one or more features that you can space uniformly around an axis.

Mirror: 

Creates a copy of a feature, or multiple features, mirrored about a face or a plane. Can select the feature or Can select the faces that comprise the feature and Bodies to Mirror.

Swept Boss:

The Swept Boss is used to create a solid path along the path of an opened curve using the selected profile.

Swept Cut: 

The Swept cut is used to remove the material through the guided path normal to the profile.

Combine: 

The Combine Feature is used to Combine multiple bodies into a single body.

Split:

The split feature is to create multiple parts from an existing part. You can create separate part files, and form an assembly from the new parts. You can split one or more solid or surface bodies.

Project Curve: 

The Project curve is to create a 3D curve with reference to two arcs from different planes.

Composite Curve: 

Can create composite curves by combining curves, sketch geometry, and model edges into a single curve. Can use a composite curve as a guide curve when creating a loft or a sweep.

SURFACE TOOLS

Swept surface: Sweep Surfaces are the surfaces that are generated from a section curve positioned along a path.

Surface Trim:  We Can also use a surface in conjunction with additional surfaces, as mutual trim tools. The trim surface includes the following options: To trim a surface: Create two or more surfaces that intersect at one or more points or create a surface that intersects with a plane or has a sketch on its face.

Lofted surface: Loft Surfaces are surfaces generated by multiple 3D Curves or existing edges creating a smooth tangency between the selected curves. Match Points are created between each selection denoting the orientation and path of the loft surface.

Boundary Surface: The boundary surface feature lets you create surfaces that can be tangent or curvature continuous in both directions and all sides of the surface.

Knit Surface: Use the Knit Surface tool to combine two or more faces and surfaces into one. Knit surfaces absorb the surface bodies you used to create them.

1. BELT:

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

Features and Sketcher Tools Involved: 

• Sketcher Tools
• Boss Extrude
• Fillet

Appearance: Matte Rubber 

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

Different Orientations of the Part:

2. KICKSTAND: 

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

Features and Sketcher Tools Used:

• Sketcher Tools
• Spline
• Pierce Relation
• Loft
• Dome
• Extruded Cut
• Split
• Boss Extrude
• Fillet

Appearance: Chrome Steel

Procedure: 

Sketch on the Front Plane has drawn, Created a new Plane at the end of Spline, sketched on it by drawing an ellipse and made Pierce relation between Spline and Ellipse midpoint. Now Lofted the Part using both sketches. Activated loft on spline and checked coincidence for the desired output. Applied Elliptical Dome to the end of spline and removed the unnecessary Portion using Extruded cut. Applied Fillet & Appearance to the Part.

Various Orientational Views of the Part:

3.FRONT FENDER:

The fender is a part of an automobile, motorcycle, or other vehicle body that frames a wheel. Its primary purpose is to prevent sand, mud, rocks, liquids, and another overspray from being thrown into the air by the rotating tire.

Features and Tools Used:

• Sketcher Tools
• Revolve
• Split
• Fillet

Appearance: Painted Siena

 Procedure: The Cross-Sectional Sketch of Fender has drawn with thickness and constrained. Using the Revolve Feature, the cross-Sectional Sketch has been Revolved with Required Revolution. Then drawn conical-shaped Splines in other planes and Using the Split Feature, With reference to Splines the fender Notches has been Removed. Then Applied fillets to the edges.

Various Orientational Views of the Part:

4.REAR FENDER:

The Rear fender is a part of an automobile, motorcycle, or other vehicle body that frames a wheel. Its primary purpose is to prevent sand, mud, rocks, liquids, and another overspray from being thrown into the air by the rotating tire.

Features and Tools Used:

• Sketcher Tools
• Revolve 
• Split
• Fillet
• Shell

Appearance: Painted Siena

Procedure: 

The Cross-Sectional Sketch of Fender has drawn with thickness and constrained. Using the Revolve Feature, the cross-Sectional Sketch has been Revolved with Required Revolution. Then drawn conical-shaped Splines in other planes and Using the Split Feature, With reference to Splines the fender Notches has been Removed. Then Applied fillets to the edges. Applied Shell to the Inside face.

Various Orientational Views of the Part:

5. OIL TANK: An Oil tank used to store flammable fluids in a container and called a fuel tank.

Features and Tools Used:

• Sketcher Tools
• Boss Extrude
• Combine
• Fillets

Appearance: Painted Siena

Fillets Appearance: White Colour

Procedure: First the Orthographic projections of the Side view have drawn on the front plane and Extruded, Then the front view projection has drawn on the front plane and extruded, Both extruded materials has been Combined Using Combine Feature. Then Applied Fillets To edges and Applied Shell to make the Tank hollow.

Various Orientational Views of the Part: 

6. PEDAL:

The pedal is a footrest for going on long rides and exploring new places on your bike, then a comfortable footrest is what you need to make your journeys comfortable and hassle-free.

Features and Tools Used:

• Sketcher Tools
• Boss Extrude
• Fillet
• Revolve 
• Chamfer
• Linear Pattern

Appearance: Chrome Steel

Procedure: Drawn a sketch on the front plane, Extruded it, and applied fillet. Selected the front surface of the extruded part and sketch on it by drawing two circles. Used a dome circular feature. Applied Linear Pattern across the boss extrude. Used distance - distance chamfer to it. Gave Appearance to the part.

Various Orientational Views of the Part:

7. CHAIN:  A Chain drive is a way of transmitting mechanical power from one place to another. Most often, the power is conveyed by a roller chain, known as the drive chain or transmission chain.

 Features and Tools Used:

• Sketcher Tools
• Boss Extrude
• Fillet
• Curved Pattern
• Mirror

Appearance: Chrome Steel

Procedure: 

Sketch on Front Plane has drawn,  Created a throwaway sketch that was used to create inside and outside chain links. Made a block of these and saved it. Inserted Blocks on the larger end of the drawn circle and made a coincident relation. Extruded the sketch by selecting holes in inserted blocks as contours to create Pins. Extruded again to create Plates by selecting the remaining part in blocks & applied fillet. Repeated the process. Used a Curve driven pattern to get the required number of Pins & Plates over the curve. Repeated the process over other curves to get the desired output.

Various Orientational Views of the Part:

8.FRONT WHEEL:

Front-wheel is a wheel, most commonly a wire wheel, designed for a bike. A pair is often called a wheelset, especially in the context of ready built "off the shelf performance-oriented wheels.

Features and Tools Used:

• Sketcher Tools
• Revolve
• Boss Extrude
• Cut Revolve
• Circular Pattern
• Extrude Cut
• Combine
• Fillet

Appearance: Matte Rubber, Painted Siena, Chrome Steel.

Procedure: Selected Front Plane and sketched the outer part of the wheel. Revolved the sketch across the temporary axis. Sketched on the Right plane, by drawing a vertical Construction line from the origin. Drawn a spline and mirrored all the three entities across the vertical construction line, extruded them. For Spider webbed design, Offsetted all the drawn three entities and removed the unwanted part using cut extrude. Connected the spokes using 3 point arcs, offset has given them, and made it a closed sketch by using lines. Extruded the sketch. Selected the front plane and drawn a spline from origin to remove unwanted area using extrude cut. Selected Spokes and used a circular pattern. Combined them to make a single solid body. For Rotor, sketched on the front plane, and extruded it, removed the unwanted portion. Used a circular pattern to create holes over the rotor. Drawn circles and lines as per the design of the body. Removed the unwanted area by trimming & extruded it. Applied Chamfer.

For Tyre - Used Rim as Convert Entities & revolved. Drawn rectangles and applied dimensions, relations to make it fully defined. Extruded cut it & applied fillets.

Various Orientational Views of the part:

9.REAR WHEEL:

The power from the engine is delivered to the Rear wheel, The rear wheel gives the motion to the vehicle. The weight of the vehicle is transferred off the front wheels and onto the rear wheels to improve traction. FWD cars typically lose traction in these situations.

Features and Tools Used: 

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

Appearance: Matte Rubber, Painted Siena, Chrome Steel.

Procedure: For Sprocket - Drawn a circle and extrude it. Applied chamfer to the outer part & created teeth by cut extrude to it. Removed the unwanted portion by using cut extrude & Applied fillet.

 Various Orientational Views of the Part:

10.FORK:

A motorcycle fork connects a motorcycle's front wheel and axle to its frame, typically via a yoke, also known as a triple clamp, which consists of an upper yoke joined to a lower yoke via a steering stem, a shaft that runs through the steering head, creating the steering axis.

Features and Tools Used:

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

Appearance: Chrome Steel

Procedure: For the Fork tube, Sketched on the Front plane, by drawing a cylindrical diagram using a line, then revolved it. For Triple Clamps - Selected Top Plane and drawn a concentric circle to the fork tube and drawn another circle left and upward. Connected the circles, then extruded it. For Bulb - Selected Front Plane, drawn a horizontal construction line, spline, and revolved it. Moved the bulb in z-direction then applied fillet to it. For Handle & Brake wires - Selected Top plane and draw the handle using a spline, made it fully defined. Drawn a circle at the end of the spline and used sweep along the path. Selected the Bodies Mirrored it and combined.

 Various Orientational Views of the Part:

11.CHASSIS: 

A motorcycle's chassis or frame forms its skeleton. 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.

Features and Tools used:

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

Appearance: Painted Siena

Procedure: Inserted Blueprint of the chopper in the front plane, adjusted the location, transparency & sketched on it. Drawn two concentric circles with an offset of 4mm. Drawn a horizontal & vertical line from origin. Then a spline connects the circle center and tangent to the horizontal line and gets a projected sketch. Sketched on Top Plane, drawn a horizontal line parallel to the line, and drawn on the front plane connected with the spline to make it fully defined. Next Sketched on the Right plane, draw a spline from top to bottom with relation to origin and make it fully defined. Removed the unwanted area using cut extrude, Mirrored the bodies, and combined. Applied fillet, Chamfer, and gave the appearance to it.

Various Orientational Views of the Part:

12. ENGINE:

A machine for converting thermal energy into mechanical energy or power to produce force and motion. a railroad locomotive. a fire engine.

Features and Tools Used:

• Sketcher Tools
• Boss Extrude
• Fillet
• Revolve
• Circular Pattern
• Dome
• Extrude cut
• Linear Pattern
• Mirror
• Chamfer
• Sweep
• Combine
• Curve
• Composite Curve
• Split

Appearance: Chrome Steel

Procedure: Inserted Blueprint into the plane, The Sketch on the front plane has drawn and Extruded it through Midplane, Created a Plane normal to the Cylinder, Dawn Cylinder Sketch, and Extruded. Using Extrude Cut, removed the portion for cooling, Using linear Pattern, Removed with uniform distance, Applied Fillets, Mirrored Cylinder, Using Curve and Composite Curve, exhaust pipes has been created. By Selection required planes, Sketched and Extruded Procketd and air filters.

Various Orientational Views of the Part:

13.GAS TANK: