Design of American Chopper with high Realistic Rendering

DESIGN OF AMERICAN CHOOPER

INTRODUCTION

This Report Contains brief explanation of designing of American chooper using solid works 3D modelling cad software ; from intial sketch to Final rendering including Solid Modeling, Surface Modeling tools explanation

OBJECTIVE

The main objective of this designing is to obtain sustainable knowledge in solid part

modeling and surface modeling

• Get clear vision of solid works interface and make custom shortcuts of tools ,tool bar , command manager commands
• Detail designing of Each components of chooper with sketch dimensions
• Accurate Assembly of designed parts with proper relations of all part model
• Became professional in using Decals, Lights, Appearance, Environment, Backplates
• Obtain Knowledge in Solidworks Visualize and Photoview 360 Rendering tools to make realistic render of the modeled chooper .

PART MODELING

Part modeling is the process of which modeling of a componentObject in 3D by using the 2d Sketch by using tools and sketch constraints, features of solid works like Extrude, revolve boss..etc

METHODOLOGY

COMPONENTS TO DESIGN

1. Transmission belt
2. Kick stand
3. Front fender
4. Rear fender
5. Chain
6. Oil tank
7. Pedal
8. Front wheel
9. Rear wheel
10. Front fork
11. Chassis
12. Engine
13. Gas tank

Features and Tools used for modeling will be explained in separate topics each component design

TRANSMISSION BELT

Component Description : Transmission Belt is used to transmit power from one end to another end of pulley

Features

1.Boss Extrude - Used to expand the object in 3D according to sketch plane

2.Fillet - Fillet is a feature used for making round edges to avoid sharp edges

Constraints used

1.Tangent

2.Midpoint

Tools used

1.Line tool – used to draw straight and tangent arcs

Methodology

Using Line and arc constraints making a sketch with given dimensions offset the sketch with offset entities after get defined sketch make extrude using Boss extrude. After making Extrude of belt model Make 1mm Fillet at edges of Transmission belt

Images

KICKSTAND

Component Description : Kick stand is a Supporting Mechanism which is used to prevent the chooper lean on ground and makes upright with out interfere with a person or Object .

Features

1 Extrude BossBase - Used to expand the object in 3D according to sketch plane

2.Fillet - Fillet is a feature used for making round edges to avoid sharp edges

3.Lofted BossBase - Lofted boss is a feature used to achieve Complex Shapes .Which basically

extruded loft surfaces by means of two lofted profiles along with guided

curves direct the path of lofting

4.Split - Split tool is used to split single solid part into two solid parts

Constraints used

1.coincident

2.Midpoint

Tools used

1.Ellipse - Used to make elliptical sketches as per dimension

2.Spline - Spline tool use to make spline curves and complex geometry shapes

3.Center point - It is used to make Rectangle based on center point

Rectangle

Methodology

Create a Ellipse according to vertical and horizontal dimensions after that make a spline in perpendicular plane. With reference of spline and its end point creating another plane for draw another loft profile after sketching by using loft bossbase feature create a loft profile spline as guide curve to make perfect loft needed after that make a dome in the side of stand which going to lean in ground and finally make a flat surface to lean in ground by using split tool

Image

FRONT FENDER

Component Description : Fender is a frame like structure which is laying over a wheel is used to prevent the mud, liquids ,slippery things will be flown into air while rotating at high speed also it prevents the small stones will be flown over a rider because of acceleration cover a tyre

Features used

1.Revolve bossbase – Revolve feature is used to make cylindrical or circular 3D extrude

along with a given reference axis as per drawn sketch

2.Split - Split tool is used to split single solid part into two solid parts

3.Fillet - Fillet is a feature used for making round edges to avoid sharp edges

4.Dome - Dome is a feature used to make dome shaped extrude including elliptical dome

5 .Extrude Cut - Extrude cut feature used to cut the 3d object in linear path according to sketch

Constraints used

1.Reference axis for revolve

Tools used

1.3point Arc - 3point arc used to draw a arc with make center point as reference

Point draw an arc.

2.Spline - Spline tool use to make spline curves and complex geometry shapes

3.Dynamic mirror- Dynamic mirror used to mirror the entire feature of the plane

selected for mirroring

4.Extent entities - It is used to extend the end point lines to make closed sketch

5.Trim entities - Trim is used to trimdelete the additional lines in the geometry

Methodology

Creating 3 point arc as per dimension with offset and using extend entities to make complete the sketch by making a reference axis by means mid plane which by means of axis using revolve feature by two direction at specific angle

After that making a spline to obtain required shape with dynamic mirror option

Images

REAR FENDER

Component Description : Fender is a frame like structure which is laying over a wheel is used to prevent the mud, liquids ,slippery things will be flown into air while rotating at high speed also it prevents the small stones will be flown over a rider because of acceleration cover a tyre

Features used

1.Revolve bossbase – Revolve feature is used to make cylindrical or circular 3D extrude

along with a given reference axis as per drawn sketch

2.Split - Split tool is used to split single solid part into two solid parts

3.Fillet - Fillet is a feature used for making round edges to avoid sharp edges

4.Shell - Shell feature is used to make to hollow space in solid part by selecting outer wall

of the solid part is to make remove the inner parts also used to reduce the

specific thickness

Constraints used

1. Horizontal
2. Vertical

Tools used

1.3point Arc - 3point arc used to draw a arc with make center point as reference

Point draw an arc.

2.Spline - Spline tool use to make spline curves and complex geometry shapes

3.Extent entities - It is used to extend the end point lines to make closed sketch

4.Trim entities - Trim is used to trimdelete the additional lines in the geometry

Methodology

Creating a 3 point arc at midplane of rear fender at offset a line at a given distance at end of the arc line draw and extend using extend entities , as reference of construction line making a revolve feature at two direction and angle needed to achieve fender after that make split at end of the fender to get curvature by using 3 point arc at last by selecting face of fender to make full fillet at edges at last to make shell command to reduce the thickness of the fender at given dimension

Images

CHAIN

Component Description : Chain is used to transmit power from engine to sprocket at rear wheel for acceleration of vehicle

Features used

1 Extrude BossBase - Used to expand the object in 3D according to sketch plane

2.Fillet - Fillet is a feature used for making round edges to avoid sharp edges

3. Curve

Driven pattern- Curve driven pattern is used to make any pattern which followed by the

curve is sketched before

Constraints used

1.Concentric

2.Coincident

3.Tangent

Tools used

1.Circle – Circle is the tool used to draw a circular sketch

2. 3point Arc - 3point arc used to draw a arc with make center point as reference

Point draw an arc.

3.Blocks - Block are the tool which make a particular sketch as blocks that we can get a

sketch as block able to insert in geometry and sketch any time.

4.Trim- Trim is used to trimdelete the additional lines in the geometry

Methodology

Started with a two circles which located as construction line reference after that draw a 3 point curve which is tangent with two circles with specific radius then trim additional lines after that create a chain pin block

By using that block to make coincident and concentric relation which the chain block make path with the curve which is drawn . After fixing block with curve make extrude the pin and chain plate at offset then make a curve driven pattern by curve as reference By following the same rhythm to create a complete chain model .

Image

OIL TANK

Component Description : Oil tank in an Engine is used to maintain the internal temperature at cylindrical blocks because of ignition for which the oil stored in a tank is known as oil tank

Features used

1. Extrude BossBase - Used to expand the object in 3D according to sketch plane
2. Fillet - Fillet is a feature used for making round edges to avoid sharp edges
3. Shell - Shell feature is used to make to hollow space in solid part by selecting outer wall

of the solid part is to make remove the inner parts also used to reduce the

specific thickness

4. Combine – Combine tool is used to make integration of two solid parts which intersect

Each other as same solid parts

Constraints used

1.Tangent

2.Coincident

Tools used

1. Arc - Arc used to draw a arc with make center point as reference

Point draw an arc.

2.Spline - Spline tool use to make spline curves and complex geometry shapes

3.Dynamic mirror- Dynamic mirror used to mirror the entire feature of the plane

selected for mirroring

4.Line tool – used to draw straight , construction line and tangent arcs

Methodology

In oil tank start with top plane making line and make tangent arc coincident with construction line make a straight line coincident with sketching point to get fully defined sketch and make a dynamic mirror after that make a extrude

Then make a line with midplane to make a oil tank and extrude after that make combine both shapes to obtain a oil tank

Make a fillet with all ends

Finally make a shell command without selecting body to get hollow tank inside

Images

PEDAL

Component description : Pedal is used to make support for rider to spread his foot on apedal and make rider comfortable while travelling and prevent the foot contact with road

Features used

1.Extrude BossBase - Used to expand the object in 3D according to sketch plane

2.Fillet - Fillet is a feature used for making round edges to avoid sharp edges

3.Revolve bossbase – Revolve feature is used to make cylindrical or circular 3D extrude

along with a given reference axis as per drawn sketch

4.Dome - Dome is a feature used to make dome shaped extrude including

elliptical dome

5.Chamfer - Chamfer is used to make a edges sharp edge to make angled tapering

6.Linear

Pattern - Linear pattern is to make a solid feature pattern in path as linear

Constraints used

1.Tangent

2,Coincident

Tools used

1. Fillet - Fillet is a feature used for making round edges to avoid sharp edges
2. Line tool – used to draw straight , construction line and tangent arcs

3.3point Arc - 3point arc used to draw a arc with make center point as reference

Point draw an arc.

4.Offset – offset is used to make a same sketch which is selected at point of given

Dimension

Methodology

Making a fully defined sketch filled with lots of relation and sketch ended with fully defined sketch as like to get a exact dimension of a pedal

Then extrude a fixing pin using a contour selection make pedal frame same as that after that make a Revolve of leg rest from the same sketch to get a rest finish making a fillet and chamfer at end of the rest and make a dome a end

Finally a pattern in a leg support at a pedal is extruded by using linear pattern command

Images.

FRONT WHEEL

Component description : Wheel is used as locomotive component of every vehicle .The wheel

generally rotated based on the axis fixed with the vehicle. Its built with hard rim cover with

nylon tyre

Features used

1.Extrude BossBase - Used to expand the object in 3D according to sketch plane

2. Fillet - Fillet is a feature used for making round edges to avoid sharp edges.
3. Revolve bossbase – Revolve feature is used to make cylindrical or circular 3D extrude

along with a given reference axis as per drawn sketch .

4.Revolve cut - Revolve cut is a method to cutreduce the extrude of cylindricalround

Surface.

5. Chamfer - Chamfer is used to make a edges sharp edge to make angled tapering.

6.Linear

Pattern - Linear pattern is to make a solid feature pattern in path as linear

7. Extrude Cut - Extrude cut feature used to cut the 3d object in linear path according to

sketch

8.Circular pattern – Circular pattern is a feature used to make 3d feature into circular

pattern according to number of insistence

Constraints used

1.Coincident

2.Midpoint

3.Horizontal

Tools used

1. Fillet - Fillet is a feature used for making round edges to avoid sharp edges
2. Line tool – used to draw straight , construction line and tangent arcs

3.3point Arc - 3point arc used to draw a arc with make center point as reference

Point draw an arc.

4.Spline - Spline tool use to make spline curves and complex geometry shapes

5.Trim – Used to trim the extra lines

6.Extend entities – Used to extend line to the next sketch with relation along to the

sketch

Methodology

For front wheel it consistent of Tyre ,Rotor, Caliper, Wheel rim

For rim

The rim is made by extrude revolve in the front plane reference by making sketch and revolve to achieve the rim after making a revolve bossbase

Then making a sketch to do make a spider web like forks by using circular pattern and other sketch entities according to dimensions

For Rotor

Rotor is extrude offset from midplane to offset at specific dimension and make a circular patterned holes for grip to calipers

For caliper

Caliper is extrude along with mid plane extrude at both direction and make fillet and chamfer to achieve caliper

For Tyre

Tyre is done by making revolve with front plane as per dimension to achieve pattern in tyre making a circular pattern feature

Images

REAR WHEEL

Wheel is used as locomotive component of every vehicle .The wheel

generally rotated based on the axis fixed with the vehicle. Its built with hard rim cover with

nylon tyre. It also include sprocket, Caliper , Rotor, Tyre

Features used

1.Extrude BossBase - Used to expand the object in 3D according to sketch plane

2. Fillet - Fillet is a feature used for making round edges to avoid sharp edges.
3. Revolve bossbase – Revolve feature is used to make cylindrical or circular 3D extrude

along with a given reference axis as per drawn sketch .

4.Revolve cut - Revolve cut is a method to cutreduce the extrude of cylindricalround

Surface.

5. Chamfer - Chamfer is used to make a edges sharp edge to make angled tapering.

6.Linear

Pattern - Linear pattern is to make a solid feature pattern in path as linear

7.Extrude Cut - Extrude cut feature used to cut the 3d object in linear path according to

sketch

8.Circular pattern – Circular pattern is a feature used to make 3d feature into circular

pattern according to number of insistence

Constraints used

1.Coincident

2.Midpoint

3.Horizontal

Tools used

1. Fillet - Fillet is a feature used for making round edges to avoid sharp edges
2. Line tool – used to draw straight , construction line and tangent arcs

3.3point Arc - 3point arc used to draw a arc with make center point as reference

Point draw an arc.

4.Spline - Spline tool use to make spline curves and complex geometry shapes

5. Trim – Used to trim the extra lines

6.Extend entities – Used to extend line to the next sketch with relation along to the

sketch

Methodology

For Rear wheel it consistent of Tyre ,Rotor, Caliper, Wheel rim, Sprocket

For rim

The rim is made by extrude revolve in the front plane reference by making sketch and revolve to achieve the rim after making a revolve bossbase

Then making a sketch to do make a spider web like forks by using circular pattern and other sketch entities according to dimensions

For Rotor

Rotor is extrude offset from midplane to offset at specific dimension and make a circular patterned holes for grip to calipers

For caliper

Caliper is extrude along with mid plane extrude at both direction and make fillet and chamfer to achieve caliper

For Tyre

Tyre is done by making revolve with front plane as per dimension to achieve pattern in tyre making a circular pattern feature

For Sprocket

Sprocket is made by extrude from the midplane of wheel with offset from a distance which is parallel to sprocket at engine block the sprocket is made by circular pattern to achieve the teeth at sprocket

Images

FRONT FORK

Components Description : Front fork is consists two narrow tube consists of two shock absorbers along with axis of front wheel and tope end fixed with handle bar to control direction of vehicle with head light

Features used

1.Revolve bossbase – Revolve feature is used to make cylindrical or circular 3D

extrude along with a given reference axis as per drawn sketch

2.Dome - Dome is a feature used to make dome shaped extrude including elliptical dome

3.Extrude BossBase - Used to expand the object in 3D according to sketch plane

4.Split - Split tool is used to split single solid part into two solid parts

5.Combine – Combine tool is used to make integration of two solid parts which intersect

Each other as same solid parts

6 Movecopy body – This feature is used to movecopy the 3D body to one place to

another face

7.Mirror – Mirror is used to make a mirroring a feature or body by refernce of the selected

plane it makes reduce the working timing of the model

8.Sweep – This feature is used to sweep any kind of fully defined sketch along with the

Path

Constraints used

1.Midpoint

2.Coincident

3.Horizontal

Tools used

1.Projected curve – Projected curve is a special tool to make work easier projected used to

combine a curves from different plane in to single plane sketch my

means of integration

2.Convert Entities – This tool is used to make sketch according to the plane which under

sketch makes a trace of single line

3. Line tool – used to draw straight , construction line and tangent arcs

4.3point Arc - 3point arc used to draw a arc with make center point as reference

Point draw an arc.

5.Spline - Spline tool use to make spline curves and complex geometry shapes

Methodology

Starting with the long barrel which where suspension located make a revolve feature as per sketch sketched at front plane

From top plane extrude the center part of fork where head light and speedo meter located offset from some distance , After extrude making right plane make a revolve of head light using movecopy feature move a head light towards z direction to make head light center

Make a fillet at the end of the head light to get soft round edges ,

Make a mirror as plan as right side of solid part which mounted upside of fork make a mirror feature to get complete fork , making revolve of handle bar the a make a composite curve to get break wire connected with fork at last make a new for front fork used to assembly.

Images

CHASSIS

Components description : Chassis is a skeleton of bike which is main frame that is used to hold everything like Engine, gas tank , pedal.. each and every parts .

Features used

1.Mirror – Mirror is used to make a mirroring a feature or body by reference of the

selected plane it makes reduce the working timing of the model

2.Sweep – This feature is used to sweep any kind of fully defined sketch along with the

Path

3.Revolve bossbase – Revolve feature is used to make cylindrical or circular 3D

extrude along with a given reference axis as per drawn sketch

4.Dome - Dome is a feature used to make dome shaped extrude including elliptical

dome

5.Extrude BossBase - Used to expand the object in 3D according to sketch plane

6.Split - Split tool is used to split single solid part into two solid parts

7.Combine – Combine tool is used to make integration of two solid parts which intersect

Each other as same solid parts

8.Chamfer - Chamfer is used to make a edges sharp edge to make angled tapering.

9. Fillet - Fillet is a feature used for making round edges to avoid sharp edges.

Constraints used

1.Midpoint

2.concentric

3.coincident

Tools

1.Projected curve – Projected curve is a special tool to make work easier projected used to

combine a curves from different plane in to single plane sketch my

means of integration

2.Convert Entities – This tool is used to make sketch according to the plane which under

sketch makes a trace of single line

3. Line tool – used to draw straight , construction line and tangent arcs

4.Spline - Spline tool use to make spline curves and complex geometry shapes

5.Circle – Used to make circles according to given radiusdiameter

Methodology

Need of reference blue print for make chassis by importing chopper blue print using image sketch feature after importing image make sketch with reference of imported image by using splines to make projected curve of bottom part of chassis make sweep along with curve.

Images

ENGINE

Components description

Engine is the power house of the vehicle it transmit the power to rear wheel through chain and sprocket

Features used

1.Mirror – Mirror is used to make a mirroring a feature or body by reference of the

selected plane it makes reduce the working timing of the model

2.Sweep – This feature is used to sweep any kind of fully defined sketch along with the

Path

3.Revolve bossbase – Revolve feature is used to make cylindrical or circular 3D

extrude along with a given reference axis as per drawn sketch

4.Dome - Dome is a feature used to make dome shaped extrude including elliptical

dome

5.Extrude BossBase - Used to expand the object in 3D according to sketch plane

6.Split - Split tool is used to split single solid part into two solid parts

7.Combine – Combine tool is used to make integration of two solid parts which intersect

Each other as same solid parts

8.Chamfer - Chamfer is used to make a edges sharp edge to make angled tapering.

9. Fillet - Fillet is a feature used for making round edges to avoid sharp edges.
10. Extrude Cut - Extrude cut feature used to cut the 3d object in linear path according to

sketch

11.Circular pattern – Circular pattern is a feature used to make 3d feature into circular

pattern according to number of insistence

12. Linear

Pattern - Linear pattern is to make a solid feature pattern in path as linear

Constraints used

1.Coincident

2.concentric

3.Horizontal

4.Vertical

Tools Used

1. Fillet - Fillet is a feature used for making round edges to avoid sharp edges
2. Line tool – used to draw straight , construction line and tangent arcs

3.3point Arc - 3point arc used to draw a arc with make center point as reference

Point draw an arc.

4.Offset – offset is used to make a same sketch which is selected at point of given

Dimension

5.Projected curve – Projected curve is a special tool to make work easier projected used to

combine a curves from different plane in to single plane sketch my

means of integration

6.Convert Entities – This tool is used to make sketch according to the plane which under

sketch makes a trace of single line

7. Trim- Trim is used to trimdelete the additional lines in the geometry

8.Composite curve- Composite curve is used to make to composite two curves into single

curve

Methodology

Engine part modeling need a reference image same as chassis after that using engine

Blue print make line and tangency for pulley used to drive , after that making an extrude from a new plane from the reference to make a engine block using cut extrude cut the fins in engine and make mirror after that make an air intake using revolve and projected curve finally making a composite curve to sweep the exhaust and make a spark plug cable at end of the engine block

Images

GAS TANK

Component description

Gas tank is used to store the fuel which is need for making power engine in combustion process .

Features used

1.Swept Surface – Its used to make a surface along with a path curve is driven

2.Boundary Surface – Boundary surface which make surface in between two finished

surface

3.Loft Surface – loft surface is used to make loft in between two profiles along with guide

path

4.Knit surface- knit surface is used to make knitzipped two surface

5.Sweep cut- sweep cut is same as sweep feature but its directly proportional to sweep

which make a cut along with the sweep path

6.Combine – Combine tool is used to make integration of two solid parts which intersect

Each other as same solid parts

7. Shell - Shell feature is used to make to hollow space in solid part by selecting outer

wall of the solid part is to make remove the inner parts also used to reduce the

specific thickness

8.Fillet - Fillet is a feature used for making round edges to avoid sharp edges.

Constraints used

1.Tangent

2.Coincident

Tools used

1 . Line tool – used to draw straight , construction line and tangent arcs

2.3point Arc - 3point arc used to draw a arc with make center point as reference

Point draw an arc.

4.Projected curve – Projected curve is a special tool to make work easier projected used to

combine a curves from different plane in to single plane sketch my

means of integration

5.Convert Entities – This tool is used to make sketch according to the plane which under

sketch makes a trace of single line

6. Mirror – Mirror is used to make a mirroring a feature or body by reference of the

selected plane it makes reduce the working timing of the model

Methodology

In gas tank which is make an surface extrude along with blue print by making sweep surface extrude making a tangential spline curve along with sweep path to make a outer tank wall

After that to make projected curve to extrude loft surface using guided curve and make complete gas tank finally make a shell for gas tank because of hollow object to make fully modeled design model

Images

ASSEMBLY OF CHOOPER

Assembly of chooper which is make a assembly of components which is designed before

For an assembly import all components at assembly environment of solid works

Constraints used

Constraints play a major role for assembly which is used to assemble each parts

1.concentirc

2.coincident with planes

3.tangent with planes

4.parallel

5.perpendicular

Etc…

Mates

Mates is a feature used to make mate with each other components properly used to make accurate assembly of a components. There is a type of Components

1. Advanced mate
2. Mechanical Matte

Finally apply decals for all the components

Fully assembled chooper

RENDERING

Rendering is process of making real time products

Rendering consists of following features

1.Environment settings

2.Light settings

3.colours and material editing

4.Scene Composition

Setup of Solid works photo view 360 with above mentioned Aspects with proper Environment

Solid works visualize is advanced individual rendering setup to make a Real time rendering Experience

RENDERING IMAGES

CONCULSION

In end of this American chooper project learn to use a new features and tools

And learn about assembly according to planes of models including advanced mates

Finally learning about Light, environment setup , colour , Decals , Back plates

Using Photo view 360 and solid works Visualize