Photo Realistic Rendering

TITLE OF THE PROJECT :                 DESIGN OF AMERICAN CHOPPER

 INTRODUCTION : 

In this project we are gonna know about the detailed design of the American Chopper parts, how they are assembled together and part modeling to final rendering of the assembly.

OBJECTIVE :

The main objectives of this project are 

. To create a model of individual parts of the chopper using SOLIDWORKS.

. To assemble the individual parts modeled for the chopper.

. To know the applications of decals, setting up the scene, lights and cameras.

.  To create a photorealistic model of the chopper and Render the model using the SOLIDWORKS PHOTOVIEW 360 OR SOLIDWORKS VISUALIZE.

DESIGN METHODOLOGY/APPROACH :

The American Chopper is made up of the following parts:

1. Transmission Belt

2. Kick Stand

3. Chain

4. Front Fender

5. Rear Fender

6. Oil Tank

7. Pedal

8. Front Wheel

9. Rear Wheel

10. Front Fork

11. Chassis

12. Engine 

13. Gas Tank

1. TRANSMISSION BELT : 

. The Transmission Belt in the chopper is used to transmit the power from the Engine to Gear Box.

 

 Features used to create Transmission Belt 

.  Sketch 

.  Offset

.  Extrude

.  Fillet

.  Appearances 

Sketch

The sketch is a two-dimensional representation of the model. There are different sketch options available to create a Sketch. These are kown as Entities in the Solidworks. The following are the Entities available in solidworks Line, Arc, Circle, Rectangle, Spline.

Offset

Offset one or more sketch entities, selected model edges, or model faces by a specified distance. For example, you can offset sketch entites such as splines or arcs, sets of model edges, loops, and so on. You can offset finite lines, arcs, and splines.

Extrude

Extrude is a type of feature available in solidworks to convert a 2D sketch into the 3D model.

Fillet

Fillet/Round creates 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.

Procedures followed to create a model of Transmission Belt :

• First a Solidworks software is opened. Then, the new part is selected to create a new model.
• Before creating the sketch the default plane names are changed as given below,    

1. Front Plane - Front Plane Transmission Belt
2. Top Plane - Top Plane Transmission Belt
3. Right Plane - Right Plane Transmission Belt

• Then, the front plane is selected to sketch.
• The 2D sketch is created in the front plane and dimensions,relations are given to the sketch to fully define a sketch.While sketching the offset command is used to duplicate the sketch to some distance.
• After this process the sketch is closed. Then, the extrude command is used to convert a 2D sketch into 3D model.
• Then, the fillet is given to the belt as per the requirements. The model of the transmission belt is created. 
• The model is saved with the name of Transmission Belt.

2. KICKSTAND :

 . The kickstand is also known as side stand. It is used to support the chopper.

 

Features used to create a Kickstand

. Sketch

. Loft

. Dome

. Extrude Boss

. Extrude Cut

. Fillet

. Split

. Appearances

Loft

The Loft feature in Solidworks alows you to generate complex geometry in a single feature. It does this by interpolating surfaces between various cross-sections of a model. These cross-sections can be sketches, faces, or edges. In the loft interface, these cross-sections are considered LOFT profiles.

Dome

Faces to Dome. Select one or more planar or non-planar faces. You can apply domes to faces whose centroid lies outside the face. This allows you to apply domes to irregularly shaped contours.

Extrude Cut 

Extrude Cut is the another feature which helps to remove materials from the 3D model. It is just the opposite to extrude base/boss feature, because it cuts a sketch profile while extruding. You can cut in both the directions and mainly used for creating holes, channels, slots etc.

Split  

The Solidworks Split Line tool is used to project an entity (sketch, solid surface, face plane, or surface spline) onto other surfaces or curved/planar faces. You are also able to Split faces on multiple bodies with one command.

Procedure followed to create a model of Kickstand 

• First  Solidworks Software is opened. Then, the new part is selected to create a new model.
• Before creating thr sketch the default plane names are changed as given below,       

1.  Front Plane - Front Plane 
2. Top Plane - Top Plane 
3. Mid Plane - Mid Plane         

• Then, the mid plane is selected to sketch 
• Then 2D sketch is created in the front plane and dimenssions, relations are given to the sktech to fully define. While sketching we used the spline and trim commands are used.
• There are two new planes created and the ellipse are drawn in the new plane as per the requirement.
• Then the loft command is used to create a loft for the Kickstand.
• The extrude cut command is used to cut the parts which are not required for th stand. 

3. CHAIN :

. Chain is a type of transmission system that is used to transmit a power from the Engine to the Rear wheel. Chain is made of steel. The sprocket is used to transmit the power to the chain. The sprocket is connected with the shaft with the help of a key.

 

Features used to create Chain 

.  Sketch

.  Trim

.  Fillet

.  Blocks

.  Extrude

.  Patterns

.  Appearances

Trim Entities

You can make, save, edit and insert blocks for drawing items and sketch entities that you use often, such as standard notes, title blocks, label positions, and so on. You can attach blocks to geometry or to drawing views, and you can insert them into sheet formats.

To make Blocks :

1. Create a Sketch.
2. Click Make Block. (Blocks Toolbar) or Tools>Block>Make......
3. Select the Sketch entites you want to make as a block for Block entities.
4. Click.
5. Repeat steps 2-4 for each of the remaning sketch entities.
6. With the sketch in edit mode, add the necessary relations.
7. Save the part.

Patterns

The curve driven pattern tool allows you to create Patterns along a planar or 3D curve. You can base your pattern on a open curve, or on a closed curve, such as a circle. In the chain part Curve Driven Pattern is used.

4. FRONT FENDER :  

.  The Front Fender is a part mounted on the fork abouve the wheel to protect the rider and the chopper other parts from the debris and foreign particles.

 

Features used to create Front Fender 

. Sketch

. Offset entities

. Trim Entities

. Revolve

. Dynamic Mirror 

. Split

. Appearances

Revolve

To create a revolve feature: Create a sketch that contains one or more profiles and a centreline, line, or edge to use as the axis around which the feature revolve tools.

Dynamic Mirror

Dynamic mirror is the important tool in the Solidworks. As you sketch the entities, they are Mirrored about the pre-selected sketch entity.

5. REAR FENDER :

. The use  of the Rear fender is same as the Front Fender. The rear fender is mounted on the chassis of the rear part above the Rear Wheel.

 

Features used to create Rear Fender

. Sketch

. Offset Entities

. Trim Entities

. Revolve

. Appearances

Appearances 

An Appearance defines the visual properties of a model, including colour and texture. Appearances do not affect physical properties, which are defined by materials. Every material is assigned a default appearances that emulates  the look of the material.

6. OIL TANK :

 . The oil tank is one of the part of the chopper. Oil tank is used to store the oil required to run the Engine. Oil tank is the hollow one. The thickness of the oil tank is given as 3mm in our chopper model.

Features used to create Oil Tank

. Sketch

. Boss Extrude

. Combine

. Fillet

. Shell

. Appearances

Combine

Combine is the type of the feature available in Solidworks to manually combine the two bodies.

Shell

The Shell definition Property Manager is used to define the thickness of thin and thick shell elements.

7. PEDAL :

. Pedal is the external part attached to the chassis. The pedal is used to place the leg on top of that. To give comfort to the rider Pedal is used.

Features used to create Pedal 

. Sketch

. Extrude

. Fillet

. Linear Pattern

. Dome

. Chamfer

. Appearances

Chamfer

A cut on the edge or corner of something that makes it slope slightly rather being perfectly square.

Linear Pattern

Linear Pattern is also more like a circular pattern. The features/bodies are patterned lineraly. Pattern is a kind tool like Array avaailable in AutoCAD.

8. FRONT WHEEL :

. A Wheel is a circular block made of the steel/Alloy material. On the top of the wheel the tyre is covered. The tyre is made of Rubber and it has thin wires within it.

Features used to create Front Wheel 

. Sketch

. Revolve

. Trim 

. Fillet Entities

. Boss/Base Extrude

. Revolve Cut

. Linear pattern

. Chamfer

. Fillet features 

. Cut Extrude

. Circuar Pattern

. Appearances

Circular Pattern 

Circular Pattern is used to create a pattern of the sporks and the pattern(Grooves) available in the tyre. Also, it is used to create holes in the discs of the front wheel. The parent bodies/features are used to create a different number of instanaces required to create the pattern circularly.

9. REAR WHEEL :

.  A circular object that revolves on an axis and is fixed below a vehicle or other object to enable it move easily over the ground.

. The disc and sprocket are attached with a rear wheel.

. The chain is connected between the Engine and the rear wheel. Chain is a positive drive. Compared to the belt it will be more efficient and losses in the chain will be less comparatively.

Features used to create Rear Wheel

. Sketch

. Revolve

. Trim

. Fillet Entities

. Boss/Base Extrude

. Planes

. Revolve Cut

. Linear Pattern

. Chamfer

. Fillet Features

. Cut Extrude

. Circular Pattern

. Appearances

10. FRONT FORK :

. Most motorcycles today use telescopic forks for the front suspension. The forks can be most easily understood as simply large hydraulic shock absorbers with internal coil springs. They allow the front wheel to react to imperfections in the road while isolating the rest of the motorcycle from that motion.

Features used to create Front Fork 

. Sketch

. Extrude

. Trim

. Revolve

. Split

. Plane

. Convert Entities

. Move/Copy Body

. Dome

. Mirror

. Combine

. Curve(project curve)

. Sweep

. Appearance

Move/Copy Body

Move/Copy body is used to move/copy the body from one place to the other places in the fork.

Mirror

By using mirror faces with a mid-plane selected only the choosen faces within the revolve will be mirrored. Mirroring bodies can be used whether in a single or multi body part and allows you to select solid geometry instead of the features and faces in a body. In the fork part the one part of the fork is created and the other part is mirrored. Then the parts are manually combined.

Projected Curve 

Project curve is the kind of 3D curve which is projected on the bassis of the two different 2D sketches.

Sweep

With the sweep feature we can create a shape by moving a 2D sketch profile along a 2D or 3D sketch path.

11. CHASSIS :

. A 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 used to create Chassis

. Sketch

. Offset

. Convert Entities

. Project Curve

. Trim 

. Plane 

. Sweep

. Split

. Revolve

. Cut Extrude

. Fillet

. Combine

. Appearances 

12. ENGINE :

. Engine is the prime mover for the Bike. The engine converts a chemical energy into the heat energy and then the heat energy is conerted into the mechanical work.

. The mechanical work in the engine is a rotational motion. This rotation is converted to the wheel with the use of the chain and sprocket through the gearbox and clutch.

Features used to create Engine 

. Sketch

. Convrt Entities 

. Trim

. Revolve

. Boss Extrude

. Cut Extrude

. Offset

. Dome 

. Fillet

. Project curve

. Composite Curve

. Sweep

. Mirror

. Circular Pattern

. Split

13. GAS TANK :

. Gas tanks are used to store the gas. To give the gas to the engine whenever its required.

Features used to create Gas Tank 

. Sketch

. Trim

. Project Curve

. Convert Entities

. Sweep Surface

. Loft Surface

. Fill surface

. Surface Trim

. Surface Knit

. Sweep Cut

. Fillet

. Appearances 

Loft Surfaces 

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

Sweep Surfaces

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

Filled Surfaces  

The Filled surface feature constructs a surface path with any number of sides, within 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 two modes : standard and mutual.

Surface Knit 

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

ASSEMBLY OF THE CHOPPER :  

• Initially, the chassis part is inserted in the assembly by using insert parts in the option. After that the part is inserted in the assembly environment and click ok to fix the chassis.
• After that the other parts of the chopper are inserted into the assembly and given possible mate conditions .

Features used to assemble chopper

. Mates 

. Insert parts 

Mates 

Mates create geometric relationships between assembly components. As we add mates, we define the allowable directions of linear or rotational motion of the components. We can move a component within its degree of freedom, visualizing the assembly's behaviour.

RENDERING :

• Rendering is the process of creating realistic images of the Photorealistic model with the environment.
• Rendering has been done in two ways in solidworks. The following are the two ways, 

1. Photoview 360
2. Solidworks Visualize

• In the Photorealistic model some of the mate conditions and positions are changed to render realistic models.
• Then, the photorealistic model is rendered into realistic images with different views .

Photoview 360

Photoview 360 is a visualization and rendering solution includes with Solidworks. Providing a highly interactive environment for viewing designs as well as for creating photo-realistic rendering it can be used to showcase our designs as well.

Solidworks Visualize

Solidworks visualize provides a suite of stand alone 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.

CONCLUSION :

• The parts of the chopper are modeled.
• The parts are inserted into the assembly environment and the chopper is assembled.
• The realistic image was rendered with the use of the Photoview360 and Solidworks Visualize.