Photo Realistic Rendering

Modelling of American Chopper in Solidworks

Introduction:

Solidworks is one of the prominent modelling software available. This software is mainly used to model 3D parts using 2D sketch. It also has the option to specify the material and look for the model which we create. It has other Add-in features like photoview360 which helps in rendering of the final model to make it look photo realistic. In this project we learnt about detailed design of American chopper parts and assembling them and rendering the final chopper after the assembly.

Objective:

The main objectives of this project are:

• To create individual parts of chopper using Solidworks
• To assemble all the individual parts into a chopper
• To know the application of decals, lights, camera etc.
• To create photorealistic model and render it using photoview 360 and Solidworks Visualize.

Design Methodology/Approach:

Kickstand:

It is also known as side stand. It is used to support the chopper while it needs to rest on the ground.

Features used to create kickstand:

• Sketch
• Loft
• Dome
• Extrude boss
• Extrude cut
• Fillet
• Split

Sketch:

The sketch is a 2D representation of the model. These are known as entities in Solidworks. e.g.: line, rectangle, spline, circle, arc etc.

Loft:

The Loft feature allows you to generate complex geometry. It does this by interpolating surfaces between various cross section of the model. These cross sections can be sketches, faces or edges. In the Loft interface the cross sections are considered as Loft profiles.

Dome:

This feature is majorly applied to faces. Select one or more planar or non-planar faces. You can apply dome to faces whose centroid lies outside the face. This allows you to apply domes to irregularly shaped contours.

Extrude Boss/Base:

This feature is used to convert a 2D sketch into 3D model

Extrude Cut:

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

Fillet:

This feature creates a rounded internal or external face on the part. You can Fillet all the edges of a face, edges , loops etc.

Split:

This tool is used to project an entity onto other surface or curved or planar faces. You can also split faces on multiple bodies with one command.

Procedure followed to create a model of Kickstand:

• First open a new Solidworks part.
• Before creating the sketch change the default planes as follows:

1.Front Plane- Front plane

2.Top Plane- Top Plane

3.Right Plane-Mid Plane

• Then, select mid Plane and start sketch
• Then 2D sketch is created in the front plane and dimensions are given and sketch is fully defined, while sketching we use spline and trim commands
• There are two new planes created and ellipse is drawn in the new plane as per the requirement.
• Then the loft command is used to create loft for the kickstand.
• The extrude cut is used to cut parts which are not required for the stand.
• Then the dome feature is applied to the smaller face of the kickstand to make the face round and smooth.
• Fillets are applied on the sharper edges for required radius.
• Then finally the part is saved by the name “Kickstand”.

TRANSMISSION BELT:

This is used to transmit power from engine to gear box.

Features used to create Transmission Belt:

• Sketch
• Offset
• Extrude
• Fillet
• Appearances

Offset:

Offset one or more sketch entities, selected model edges or model faces by specified distance. For e.g. You can offset sketch entities such as splines or arcs, set of model edges, loops and so on. You can offset finite lines, arcs and splines.

Procedure to create a model of transmission belt:

• Firstly, open a new Solidworks Part.
• Then, select the Front Plane and select the sketch
• The 2D sketch is created in the Front plane and dimensions and relations are given to make the sketch fully defined. While sketching offset command is used to make a duplicate sketch to some distance.
• After this process the sketch is closed. Then the extrude command is used to convert 2D sketch to 3D model.
• Then Fillet is given to the belt as per the given dimensions
• Then finally the model is saved on the name “Transmission Belt”.

FRONT FENDER:

The front fender is the mounted on the front fork above 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:

Create a sketch that contains one or more profiles and a Centre line or an edge to use as the axis around which the feature revolve tools.

Dynamic Mirror:

Dynamic mirror, it is used as you sketch the entities, they are mirrored about the presketched sketch entity.

Rear Fender:

The use of rear fender is the same as front fender. The rear fender is mounted on the Chasis of the rear part above the Rear Wheel.

Features used to model Rear Fender:

• Sketch
• Offset Entities
• Trim Entities
• Revolve
• Appearances

Chain:

Chain is a type of transmission system that is used to transmit a power from the Engine to the Rear wheel. 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 (tools>block>make block)
3. Select the entity you want to make as a block for Block entities
4. Click ok and save the first block
5. Repeat steps 2-4 for another block
6. With the sketch in edit mode, add necessary relations.
7. Finally 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 circle. In the chain part curve driven pattern is used.

OIL TANK:

The oil tank is used to store the oil required to run the Engine. It is a hollow one. The thickness of the oil tank is given by 3 mm in our chopper model.

Features used to create oil tank:

• Sketch
• Boss Extrude
• Combine
• Fillet
• Shell

Shell:

The shell feature is used to define the thickness of thin and thick shell elements.

Combine:

Combine feature is used to manually combine two bodies like add, subtract etc.…

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.

Features used to create Pedal:

• Sketch
• Extrude
• Fillet
• Linear pattern
• Dome
• Chamfer

Chamfer:

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

Linear pattern:

It is also same as circular pattern. The feature or the bodies are patterned linearly.

Front Wheel:

A wheel is a circular block made of steel/alloy material. On the top of wheel, the Tire is covered. The tire is made of rubber and it has thin wires within it.

Features used to create Front Wheel:

• Sketch
• Revolve
• Trim
• Fillet sketch
• Boss Extrude
• Revolve Cut
• Linear Pattern
• Chamfer
• Cut Extrude
• Circular Pattern

Circular Pattern:

Circular pattern is used to create a pattern of spokes and the pattern of groves available in the tire. It is also used to create holes in the discs of the front wheel. The parent bodies/features are used to create number of instances required to create the pattern circularly.

REAR WHEEL:

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

The disc and sprocket are attached with rear wheel.

The chain is connected between the Engine and rear wheel.

Features used to create rear wheel

• Sketch
• Revolve
• Trim
• Sketch fillet
• Extrude Boss
• Planes
• Revolve cut
• Linear pattern
• Chamfer
• Fillet feature
• Extrude Cut
• Circular pattern

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
• Move/copy bodies
• Dome
• Mirror
• Combine
• Projected curve
• Sweep

Move/Copy Body:

This feature is used to move/copy the body from one place to another place

Mirror

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

Projected curve:

Peojected curve is a kind of 3D curve which is projected based on 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.

CHASIS:

A chasis or a frame forms its skeleton. All the components of a motorcycle like suspension, wheels, fuel tank, seats, handle bars etc. are attached to this base structure which lends a motorcycle its strength and ability to handle well.

Features used to create Chasis:

• Sketch
• Offset
• Convert Entities
• Project Curve
• Trim
• Sweep
• Split
• Revolve
• Cut Extrude
• Fillet
• Combine

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 converted to mechanical work.

The mechanical work in the engine is a rotational motion. This rotation is transmitted to wheel with the help of chain and sprocket through the gear box and clutch.

Features used to create engine:

• Sketch
• Trim
• Revolve
• Boss Extrude
• Extrude Cut
• Offset
• Dome
• Fillet
• Projected Curve
• Composite Curve
• Sweep
• Mirror
• Circular pattern
• Split

Composite curve:

This feature is used to join two curves and make them a single curve. Eg combining a projected curve to another curve etc.

GAS TANK:

Gas tanks are used to store gas and its gives gas to the engine when required.

Features used to create Gas tank

• Trim
• Projected curve
• Sweep surface
• Loft surface
• Fill surface
• Surface Trim
• Surface Knit
• Sweep Cut
• Fillet

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.

Fill surface:

The fill surface feature constructs a surface path with any number of sides with in 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 two free edges / open edges of the surface together. Also it reduces the gap between two edges of the surfaces.

ASSEMBLY OF THE CHOPPER:

• Initially the Chasis 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 Chasis.
• After that other parts of the chopper are inserted into the assembly and given passible mate conditions.

Features used to assemble chopper:

• Inserting Parts
• Mates

Mates:

Mates create geometric relationship between the 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, visualising the assembly behaviour.

RENDERING

• Rendering is a process of creating realistic images of the photorealistic model with the environment.
• Rendering has been done in two ways in Solidworks:
• Photoview 360
• 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 designs vision, passion and emotion.

CONCLUSION:

• The parts of the chopper are modelled.
• The parts are inserted into the assembly environment and the chopper is assembled.
• The realistic image was rendered with the use of the Photoview 360 and Solidworks Visualize.