Photo Realistic Rendering

Objective:  To Learn and Explore the feature and tools available in SolidWorks 2020 CAD software to design and create prototype model 3-D American Chopper                     Cruiser bike from a 2-D Concept sketch.

Aim:      i) To convert the 2-D concept Sketch to 3-D model using SolidWorks 2020 Software.

            ii) To learn different workbench of SolidWorks to apply the tools to achieve the desired shapes and profile in 3-Dimensional environment.

            iii) Creating Individual parts and assembling of same to check the overall fitment and integrity of model.

            iv) To study appearance of model by applying cosmetic changes like colour, decals and scene to perform rendering operation using SW Photoview 360                    and SW Visualize.

 

Pre-requisite: 2-D Sketch of Cruiser Bike, Operating System (Windows 10), SolidWorks 2020.

 

Introduction

Here American Chopper Cruiser Bike is modelled with reference taken from a 2-D concept Sketch. Modelling including sketching profile, appropriate dimensioning and creating concept 3-Dimensional model using solid part modelling and surface modelling tools to achieve desired shape and features.

 

Flow Chart for American Chopper Model

 

 

 

Step 1:

To setup the Concept Sketch with proper scaling parameters to trace outline and shape of bike and setting appearance in partial transparency.

 

 

 

Step 2 :

Creating Solid models of following Parts:

1. Chassis
2. Transmission belt
3. Kickstand
4. Front Fender
5. Rear Fender
6. Oil tank
7. Transmission Chain
8. Paddle
9. Front Wheel
10. Rear wheel
11. Front Fork
12. Gas Tank
13. Engine

Commands and tools used:

• 2D SKETCH

A 2D drawing view consists of two-dimensional elements. It is not associative to a 3D model. A 2D drawing view allows you to quickly create or modify a drawing view without making changes to a part or assembly document.

• 3D SKETCH

A 3D sketch plane is a 2D plane that only exists inside the 3D sketch. When activated, sketching will happen exclusively on that plane and you will get behaviour similar to when working in a 2D sketch.

• SPLINE

Spline is a special function defined piecewise by polynomials. Splines are popular curves in these subfields because of the simplicity of their construction, their ease and accuracy of evaluation, and their capacity to approximate complex shapes through curve fitting and interactive curve design.

• SKETCH FILLET

The Sketch Fillet tool trims away the corner at the intersection of two sketch entities to create a tangent arc. This tool is available for both 2D and 3D sketches. The Fillet tool on the Features toolbar fillets entities such as edges in parts.

• ELLIPSE

The ellipse tool to create a complete ellipse. Use the partial ellipse tool to create an elliptical arc.

• FILLETS

Fillet/Round creates a rounded internal or external face on the part. you can fillet all edges of a faces, selected sets of faces, selected edges or selected loops.

• BOSS EXTRUDE

Creates a solid base on the sketch.

• CUT EXTRUDE

Makes a cut out of the existing body.

• REVOLVE BOSS

This feature is used to revolve a 2D sketch along an Axis or Centreline.

• REVOLVE CUT

Revolved cut removes materials by revolving a closed profile a along an axis.

• SWEEP

Sweep is the one feature in SolidWorks that helps sweep a closed profile along a closed or open path.

• LOFT

The loft feature in SolidWorks allows you 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”.

• CHAMFER

The chamfer tool creates a bevelled feature on selected edges, faces, or a vertex. Set the Distance and Angle in the Chamfer Property Manager or in the graphics area. A manipulator arrow appears that points in the direction in which the distance is measured.

• SHELL

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

Use linear patterns to create multiple instances of one or more features that you can space uniformly along one or two linear paths.

• CIRCULAR PATTERN

Use circular patterns to create multiple instances of one or more features that you can space uniformly around an axis. Pattern instances inherit the feature colour of the original feature when the Pattern is based on one feature.

• SKETCH DRIVEN PATTERN

Using sketch points within a sketch, you can specify a feature pattern. The seed feature propagates throughout the pattern to each point in the sketch. You can use sketch driven patterns for holes or other feature instances.

• 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.

• PROJECTED CURVE

It is a tool you are going to use to form 3D curves from two 2D curves from two different planes

• EXTEND

You can add to the length of a sketch entity (line, centreline, or arc).

Use Extend Entities to extend a sketch entity to meet another sketch entity.

• BLOCKS

This feature is help to use same profile in the sketch workbench without creating it again.

• CONVERT ENTITIES

The Convert Entities tool allows users to make a copied projection of a given sketch, face, or set of edges onto the active sketch plane. These sketch entities will update their size and/or positioning if either of these characteristics changes in the source sketch.

• TRIM

You can use Power trim to trim multiple, adjacent sketch entities by dragging the pointer across each sketch entity. To trim with the Power trim option: Right-click the sketch and select Edit Sketch. Continue to hold down the pointer and drag across each sketch entity you want to trim.

• MIRROR

Creates a copy of a feature, (or multiple features), mirrored about a face or a plane. You can select the feature or you can select the faces that comprise the feature. Bodies to Mirror. Select a body in a single model or multibody part to create a mirror entity.

• SKETCH PICTURE

To insert and resize a picture on a sketch plane: In an open sketch, click Sketch Picture. (Sketch toolbar) or click Tools > Sketch Tools > Sketch Picture. In the dialog box, browse to the picture file and click Open. When you insert a picture, the scale tool automatically displays.

• SKETCH PATTERN

Using sketch points within a sketch, you can specify a feature pattern. The seed feature propagates throughout the pattern to each point in the sketch. You can use sketch driven patterns for holes or other feature instances.

• DYNAMIC MIRROR SKETCH ENTITIES

This tool allows the user to mirror a sketch about a line while the user is creating their sketch. Depending on design intent this tool can save an immense amount of time.

 

 

1. Chassis:

As we know chassis or motorcycle frame is core structure in bike which support engine mounting, rear wheel, carrying load of passenger and providing location for front forks and handle. Thus, considering all the above frame is designed using Steel hollow tube of 40mm dia. With 4 mm thickness and 22mm & 6mm steel plate contributing mass of total 47.38 kgs.

Following commands are used to finish this part:

2D Sketching, Spline, Projected curve, Sweep, Dome, Combine, Revolve, Cut Extrude, Split, Extrude, Fillet, Appearance.

 

 

 2.Transmission Belt:

Flat belt is type of belt drive use friction between belt and pulley to transmit the power and motion from Engine output shaft pulley to gear box input shaft pulley, with centre distance of 350mm, width 88 mm and thickness 3.50mm.

Following commands are used to finish this part:

2-D Sketch, Offset entities, Extrude, Fillet, Appearance.

 

 

3. Kickstand:

It is used to support the bike weight to keep it upright position while not riding. It has given an angle of 75 degree rotation about boss axis to engage and disengage the side stand.

Following commands are used to finish this part:

2-D Sketch, Spline, Loft, Dome, Cut-Extrude, Split, Extrude, Fillet, Appearance.

 

 

4. Front Fenders:

Front fenders act as protective casing for front wheel which safe guard engine and riders legs from  sand, mud, rocks, liquids, and other road spray from being thrown into the air by the rotating tire.

It is designed with 4 mm thickness sheet metal keeping 280 mm centre of radius matching with the profile curvature of front Tyre and having reinforced edges adds to 4.3kg total mass.

Following commands are used to finish this part:

2-D Sketch, Revolve, Split, Fillet, Shell, Appearance.

 

 

 

5. Rear Fender:

Rear Fender is broader compare to front fender in order to match the rear wheel parameters and style. It is designed with 4 mm thickness sheet metal with reinforced edges to avoid bending having centre of radius 290mm summing up a mass of 11.2kgs.

Following commands are used to finish this part:

2-D Sketch, Revolve, Split, Fillet, Shell, Appearance.

 

 

 

6. Oil Tank:

Oil Tank is used to store the top-up oil required for minimize the friction and dissipate heat from  gear box and engine, it is enclosed hollow container with a wall thickness of 3 mm and 0.4Litre oil capacity.

Following commands are used to finish this part:

2D Sketch, Extrude, Combine, Fillet, Shell, Appearance.

 

 

7. Transmission Chain:

Chain Drive is used to transmit power and motion from gear box output shaft sprocket to Rear wheel sprocket using successive engagement and disengagement between chain and sprocket.

Chain having 15.19mm pitch centre and 130 chain links with centre distance 650mm.

Following commands are used to finish this part:

2D Sketching, using block to patter same sketch, extrude, fillet, curve pattern, mirror, Body delete/Keep, Appearances.

 

 

 

8. Pedal:

 Pedal are positioned at an angel of 27 degree to 40 degree to rest the foot towards front side for a comfortable posture.

Following commands are used to finish this part:

2-D Sketch, Revolve, Dome, Extrude, Chamfer, Liner Pattern, Fillet, Appearances.

 

 

 

9. Front Wheel:

Front wheel is integrated part of four bodies tyre, rim, disc brake & callipers.

Treaded tyre is of rubber material with 785.5mm dia. and 152.3 mm wide.

Rim are chrome plated with three web type spokes support

Disc brake of 345 mm cast iron material with 7mm thickness mounted on front wheel rim.

 

Following commands are used to finish this part:

2-D Sketch, Revove, Extrude, Cut-Extrude, Cut-Revolve, Circular pattern, Combine, Fillet, appearances.

 

 

 

10. Rear Wheel:

Rear wheel is integrated part of five bodies tyre, rim, spockets, disc brake & callipers.

Treaded tyre is of rubber material with 695.6 dia. and 347 mm wide.

Rim are chrome plated with three web type spokes support.

Disc brake of 320 mm cast iron material with 7mm thickness mounted on front wheel rim.

Sprockets having 300mm dia with 60 tooth equally spaced.

 

Following commands are used to finish this part:

2-D Sketch, Revolve, Extrude, Cut-Extrude, Cut-Revolve, Circular pattern, Combine, Fillet,Chamfer appearances.

 

 

 

11. Front Fork:

Front fork is integral assembly of front suspension with fork, handle, headlights and mirror.

Front fork is set at rake angle of 59 degree and provision of 30 degree handlebars rotation is considered.

 

Following commands are used to finish this part:

2-D Sketch, Extrude, Pattern, Fillet, Dome, Fillet, Move Body, Combine, Shell, Fillet Sweep Chamfer, Mirror, Split, Appearances.

 

 

 

12. Gas Tank:

It is used for safely storing Gasoline for Chopper bike and provide gives aerodynamic curvature to match the attractive style for rider with integrated seating facility.

Here surface feature and solid modelling feature are used to achieve this profile and shape. Tank is supported on chassis with enclosed fully with wall thickness of 10mm and tank capacity of 8 litres.

Following commands are used to finish this part:

Surface Sweep, Surface Trim, Loft Surface, Boundary Surface, Knitting, Mirror Fillets, Shell.

 

 

13. Engine:

Here twin cylinder engine with twin exhaust pipe setup is considered, this is just outer body and no internal parts of engine are designed. Engine gear box output shaft sprocket have 110mm dia. with 21 teeth equally spaced.

 

Following commands are used to finish this part:

2-D Sketching, Extrude, Pattern, Dome, Fillet, Mirror, Chamfer, Sweep, Combine, Split, Appearance.

  

 

 

 

 

Step 4:

Assembly:

 In the assembly, all individual parts inserted into assembly workbench of SolidWorks. Assembeld the parts of chopper using Standard mates (Coincident, Paraller, Tangent, Perpendicular etc ), Advanced mates (Symmetry, Width, Angle Etc) and Mirroring.

Some parts like Kickstand and Front fork needed a limiting angle which was set while applying the mates. Some parts had to be edited to avoid any bad geometry for showing up in the assembly. Complete assembly mass approximately 208 kg .

While doing assembly keeps remembering that + sign indicates that parts are over defined and – sign under defined.

 

 

 

 

 

 

Step 5:

Rendering and Visualize:

The assembly was imported to SolidWorks visualize and various adjustments of colour were done in case of multiple rendering. The Environment, Backplate and Camera position were chosen and tweaked accordingly to give the image a photorealistic image.

 

 

 

 

 

Conclusion:

• Learnt to use different tools to convert 2-D Concept Drawing to 3-D CAD model using SolidWorks 2020.
• Learnt how to draw defined sketch and create parts also modify same in assembly by checking the physical parameter
• Learnt to do apply material and trying different appearances option to export into rendered images.