Photo Realistic Rendering
DESIGN OF AMERICAN CHOPPER USING SOLIDWORKS
OBJECTIVE
There are three main objectives of this project. They are as follows;
- To model different parts of an American chopper using SOLIDWORKS.
- To assemble the parts created in the assembly
- To render the assembly in SOLIDWORKS Visualize to create a photo realistic view.
By doing these we can learn about the solid modelling and surface modelling tools of SOLIDWORKS.
INTRODUCTION
This project explains the designing of American chopper using the CAD software SOLIDWORKS from sketching the parts and modelling them to final rendering of the assembly to give a photo realistic view.
METHODOLOGY
PART MODELLING > ASSEMBLY > RENDERING
PART MODELLING
In part modelling, first the 2D sketch of the component is created using the tools in sketch tab and then the component is modelled in 3D using features like extrude, revolve boss etc.
The features used to create the parts are described below;
Boss Extrude - This feature is used to expand the object in 3D according to sketch plane.
Extrude Cut - Extrude cut feature used to cut/remove the 3d object in linear path according to sketch.
Fillet - Fillet is a feature used for making round internal or external edges to avoid sharp edges and make it smooth.
Lofted Boss/Base - Lofted boss is a feature used to achieve Complex Shapes. It does this by interpolating surfaces between various cross-sections of a model. These cross-sections can be sketches, faces, or edges.
Split - Split tool is used to split single solid part into two solid parts. It is used to project an entity onto other surfaces or curved/planar faces.
Dome - Dome is a feature used to make dome shaped extrude including elliptical dome.
Shell - Shell feature is used to make to hollow space in solid part by selecting outer wall of the solid part and so removes the inner parts. It is also used to reduce the specific thickness.
Combine - Combine tool is used to make integration of two solid parts which intersect each other as same solid part.
Chamfer - Chamfer is used to make a sharp edge or corner slightly tapered rather than being a perfect square.
Linear Pattern - The linear parent is used to create a different number of instances required to create the pattern linearly.
Curve Driven Pattern - Curve driven pattern is used to make any pattern which followed by the curve is sketched before.
Circular pattern - Circular pattern is a feature used to make 3d feature into circular pattern according to number of insistence.
Revolve bossbase - Revolve feature is used to make cylindrical or circular 3D extrude along with a given reference axis as per drawn sketch.
Revolve cut - Revolve cut is used to cut or reduce the extrude of cylindrical round surface.
Move/copy body - This feature is used to move/copy the 3D body to one place to another place.
Mirror - Mirror is used to mirror a feature or body by refernce of the selected plane.it reduces the working timing.
Sweep - This feature is used to sweep any kind of fully defined sketch along with the path.
Sweep cut - Sweep cut is same as sweep feature but its directly proportional to sweep which makes a cut along with the sweep path.
Swept Surface - It is used to make a surface along with a path the curve is driven.
Boundary Surface - Boundary surface is used to make a surface in between two finished surface.
Loft Surface - Loft surface is used to make loft in between two profiles along with guide path.
Knit surface - Knit surface is used to knit the two free edges or open edges of the surfaces together. Also it reduces the gap between the two edges of the surface.
Surface Trim - Primarily used to cut away material from a surface, and provides two modes: Standard and Mutual.
COMPONENTS OF THE AMERICAN CHOPPER 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
COMPONENTS DESCRIPTION
1.TRANSMISSION BELT
A transmission belt is used to transmit power from the engine to gear box.
Features
Boss Extrude
Fillet
Tools used
Line tool - used to draw straight lines and tangent arcs.
Constraints used
Tangent
Midpoint
Methodology
The profile or sketches of the transmission belt is created as per the dimensions in the front plane. Once the sketch is completed the belt is extruded. The square edges are given fillet. The transmission belt is made of matte rubber.
2.KICK STAND
Kick stand is a supporting mechanism which is used to prevent the chooper from falling and help it to stand in vertical position when stationary.
Features
Extrude Boss/Base
Fillet
Lofted Boss/Base
Split
Tools used
Ellipse - Used to make elliptical sketches as per dimension.
Spline - Spline tool use to make spline curves and complex geometry shapes.
Center point rectangle - It is used to make rectangle based on center point.
Constraints used
Coincident
Midpoint
Methodology
First two ellipses are created on the right plane, one at the top end and one at the bottom end of the kick stand. A path is sketched on the front plane which joins the center points of the two ellipses created before using pierce relation between the center of the ellipses and the path. Using loft, the body of the kick stand is created. Elliptical dome feature is used to create the rounded end of the kick stand. A slot with an extruded boss is created at the top end of the stand using which it is connected to the chassis. Fillets are provided to the sharp edges of the stand. Chrome plate appearance is applied to the kick stand.
3.FRONT FENDER
The front fender is a part mounted above the wheel to protect the rider and the chopper parts from debris and foreign particles.
Features used
Revolve boss/base
Split
Fillet
Dome
Extrude Cut
Tools used
3 point Arc - 3point arc used to draw a arc with make center point as reference point draw an arc.
Spline - Spline tool use to make spline curves and complex geometry shapes.
Dynamic mirror - Dynamic mirror used to mirror the entire feature of the plane selected for mirroring.
Extent entities - It is used to extend the end point lines to make closed sketch.
Trim entities - Trim is used to trimdelete the additional lines in the geometry.
Constraints used
Reference axis for revolve
Methodology
A sketch of required dimensions is created in the front plane using a three point arc and offset it to meet the thickness of the fender. An axis at the origin is created. Revolve boss is used to create the required front fender. Two different sketches are created in the top plane and the right plane to cut the front fender in to required shape. Fillets are created on the sharp edges of the fender. Desired appearance is applied to the fender.
4.REAR FENDER
The use of the rear fender is the same as the front fender. The rear fender is mounted on the chassis of the rear part above the rear wheel to protect the body from mud.
Features used
Revolve boss/base
Split
Fillet
Shell
Tools used
3point Arc - 3point arc used to draw a arc with make center point as reference Point draw an arc.
Spline - Spline tool use to make spline curves and complex geometry shapes.
Extent entities - It is used to extend the end point lines to make closed sketch.
Trim entities - Trim is used to trimdelete the additional lines in the geometry.
Constraints used
Horizontal
Vertical
Methodology
A sketch of required dimensions is created in the front plane using a three point arc and offseted to meet the thickness of the fender. An axis is created at the origin. Using revolve boss the required rear fender is created. Fillets are created on the sharp edges of the fender. Desired appearance is applied to the fender.
5.CHAIN
Chain is used to transmit power from the engine to the rear wheel. It passes over toothed member known as sprockets.
Features used
Extrude Boss/Base
Fillet
Curve Driven pattern
Constraints used
Concentric
Coincident
Tangent
Tools used
Circle - Circle is the tool used to draw a circular sketch.
3point Arc - 3point arc used to draw a arc with make center point as reference point draw an arc.
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.
Trim - Trim is used to trimdelete the additional lines in the geometry
Methodology
The chain is created using three point arc and tangent relations between the arcs using the given dimensions. Two throwaway sketches are created which are used to create the inside and outside links of the chain. The plates of the chain links are extruded using the throwaway sketches and the connecting pins are created using the same sketch. Only one side of the plates of the chain links are created. The created chain links are pins are then populated on the main sketch using the linear pattern and circular pattern features. All the chain link plates are then mirrored on the front plain. All the components of the chain are combined as a single part using combine feature. Chrome steel appearance is applied to the chain.
6.OIL TANK
Oil tank is used to store the oil required to run the engine. Oil tank is hollow inside. It is used to avoid wear and tear due to extreme heat.
Features used
Extrude Boss/Base
Fillet
Shell
Combin
Tools used
Arc - Arc used to draw a arc with make center point as reference point draw an arc.
Spline - Spline tool use to make spline curves and complex geometry shapes.
Dynamic mirror - Dynamic mirror used to mirror the entire feature of the plane selected for mirroring.
Line tool - Used to draw straight, construction line and tangent arcs.
Constraints used
Tangent
Coincident
Methodology
On the top plane a sketch is created by using a 3 point arc and few lines and tangent relations are applied. Then the profile is extruded to obtain a structure. On the front plane, another sketch is createdvand extruded using mid plane extrude. The bodies are split and the unwanted part is removed to obtain the oil tank. Fillets are applied.Uusing shell feature the oil tank is made hollow of required thickness. Then desired appearance is applied.
7.PEDAL
Pedal is the part of the motorcycle where the foot of the rider rests and the place where the gears and brakes are available easily to the rider.
Features used
Extrude Boss/Base
Fillet
Revolve boss/base
Dome
Chamfer
Linear Pattern
Tools used
Fillet - Fillet is a feature used for making round edges to avoid sharp edges.
Line tool - used to draw straight , construction line and tangent arcs.
3 point Arc - 3point arc used to draw a arc with make center point as reference point draw an arc.
Offset - offset is used to make a same sketch which is selected at point of given dimension.
Constraints used
Tangent
Coincident
Methodology
A sketch is made on the front plane in the form of the support plate along the a few circles of required dimensions on either side of the profile which are later used to produce the extruded cylinder structures for foot rest and attachments to the chassis. The required fillets and linear patterns are provided to produce the ring structures on the pedal.Chrome steel appearance is provided to the pedals.
8.FRONT WHEEL
A circular object that revolves on an axle and is fixed below a vehicle or other object to enable it to move easily over the ground.
Features used
Extrude Boss/Base
Fillet
Revolve Boss/Base
Revolve cut
Chamfer
Linear Pattern
Extrude Cut
Circular pattern
Constraints used
Coincident
Midpoint
Horizontal
Tools used
Fillet - Fillet is a feature used for making round edges to avoid sharp edge.
Line tool - Used to draw straight, construction line and tangent arcs.
3 Point Arc - 3point arc used to draw a arc with make center point as reference point draw an arc.
Spline - Spline tool use to make spline curves and complex geometry shapes.
Trim - Used to trim the extra lines.
Extend entities - Used to extend line to the next sketch with relation along to the sketch.
Methodology
First the rim is created by sketching on the front plane and the revolved extruded using an imaginary axis at the origin. A spider web design of the rim is created on the front plane and is extruded using mid plane extrude feature. And this spider web is circular patterned to required numbers and the rim is completed. The spider web spokes and the rim are combined to form a single solid body. For Rotor a sketch on the front plane is created and extruded to the required dimensions. The required holes are created using circular pattern. For Caliper a profile is created using lines and circles and the unwanted sketch is removed and the caliper profile is mid plane extruded. Fillets and chamfers are given to complete the caliper. For Tyre a sketch is created by converting entities of the rim and the tyre is revolve extruded. Profiles are created on the surface of the tyre to give the grips to the tyres. The required appearances are applied to each part of the wheel.
9.REAR WHEEL
A circular object that revolves on an axle and is fixed below a vehicle or other object to enable it to move easily over the ground.
Features used
Extrude Boss/Base
Fillet
Revolve boss/base
Revolve cut
Chamfer
Linear Pattern
Extrude Cut
Circular pattern
Tools used
Fillet - Fillet is a feature used for making round edges to avoid sharp edges.
Line tool - Used to draw straight, construction line and tangent arcs.
3 point Arc - 3 point arc used to draw a arc with make center point as reference point draw an arc.
Spline - Spline tool use to make spline curves and complex geometry shapes.
Trim - Used to trim the extra lines.
Extend entities - Used to extend line to the next sketch with relation along to the sketch.
Constraints used
Coincident
Midpoint
Horizontal
Methodology
First the rim is created by sketching on the front plane and the revolved extruded using an imaginary axis at the origin. A spider web design of the rim is created on the front plane and is extruded using mid plane extrude feature. And this spider web is circular patterned to required numbers and the rim is completed. The spider web spokes and the rim are combined to form a single solid body. For Rotor a sketch on the front plane is created and extruded to the required dimensions. The required holes are created using circular pattern. For Caliper a profile is created using lines and circles and the unwanted sketch is removed and the caliper profile is mid plane extruded. Fillets and chamfers are given to complete the caliper. For Tyre a sketch is created by converting entities of the rim and the tyre is revolve extruded. Profiles are created on the surface of the tyre to give the grips to the tyres. The required appearances are applied to each part of the wheel.
10.FRONT FORK
Front fork is used to control the entire vehicle. It holds the front wheel and other control device operated by rider. It consists of two columns along with shock absorber which is held together by triple clamp.They allow the front wheel to react to imperfections in the road while isolating the rest of the motorcycle from that motion.
Features used
Revolve boss/base
Dome
Extrude Boss/Base
Split
Combine
Move/copy body
Mirror
Sweep
Tools used
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.
Convert Entities - This tool is used to make sketch according to the plane which under sketch makes a trace of single line.
Line tool - Used to draw straight, construction line and tangent arcs.
3 point Arc - 3point arc used to draw a arc with make center point as reference point draw an arc.
Spline - Spline tool use to make spline curves and complex geometry shapes.
Constraints used
Midpoint
Coincident
Horizontal
Methodology
A long tube is created on the front plane by creating the sketches with appropriate dimensions and then by revolve extruding it. Then the half of the triple clamp is created using appropriate dimension sketch. On the same plane the headlight is craeted by revolve extrusion. On the top plane a sketch is drawn for creating the handle using spline and sweep patterns. All the created bodies is selected and mirrored along the front plane and the entire object is combined. An appropriate appearance to the front fork is given.
11.CHASSIS
It is the supporting frame of the vehicle to which all the components or body of the motorcycle are attached.
Features used
Mirror
Sweep
Revolve boss/base
Dome
Extrude Boss/Base
Split
Combine
Chamfer
Fillet
Tools used
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.
Convert Entities - This tool is used to make sketch according to the plane which under sketch makes a trace of single line.
Line tool - Used to draw straight, construction line and tangent arcs.
Spline - Spline tool use to make spline curves and complex geometry shapes.
Circle - Used to make circles according to given radiusdiameter.
Constraints used
Midpoint
Concentric
Coincident
Methodology
First the blueprint of the motorcycle is imported to the part design, by adjusting the location, transparency and the sketch of the chassis is carried over this blueprint using it as a reference. This chassis is made of tubes bent and joined using splines and created/projected curves. At the end all the tubes are connected to a plate and further this chassis is extended till the rear wheel hub.
12.ENGINE
Engine is the main component of the vehicle where the power is generated by burning fuel and later transmitted to wheel to create the required motion. The engine converts a chemical energy into the heat energy and then the heat energy is converted into mechanical work.
Features used
Mirror
Sweep
Revolve boss/base
Dome
Extrude Boss/Base
Split
Combine
Chamfer
Fillet
Extrude Cut
Circular pattern
Linear Pattern
Tools Used
Fillet - Fillet is a feature used for making round edges to avoid sharp edges.
Line tool - Used to draw straight, construction line and tangent arcs.
3 point Arc - 3point arc used to draw a arc with make center point as reference point draw an arc.
Offset - offset is used to make a same sketch which is selected at point of given dimension.
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.
Convert Entities - This tool is used to make sketch according to the plane which under sketch makes a trace of single line.
Trim - Trim is used to trimdelete the additional lines in the geometry.
Composite curve - Composite curve is used to make to composite two curves into single curve.
Constraints used
Coincident
Concentric
Horizontal
Vertical
Methodology
Using the inserted picture and choosing the front plane, the base of the engine is created using three point circle and lines and extruded to required dimensions. Again using the same sketch the two circles is extruded. Again on the front plane, the twin engines in the V-shape are created. The sketch for pulley is created and the pulley is revolve extruded. The cylindrical part is created in the front of the engine on the front plane. Using the curves created and projected curves, the profile of the exhaust pipes is created and the swept boss feature is used. Then the spark plugs are created at the end. The appropriate material to the engine is given.
13.GAS TANK
Gas tank is the fuel storage component of the American Chopper and it supplies the required fuel to the engine. Gas tank is used to store the fuel gas. Fuel gas is required to drive the engine.
Features used
Swept Surface
Boundary Surface
Loft Surface
Knit surface
Sweep cut
Combine
Shell
Fillet
Tools used
Line tool - Used to draw straight, construction line and tangent arcs.
3 point Arc - 3 point arc used to draw a arc with make center point as reference point draw an arc.
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.
Convert Entities - This tool is used to make sketch according to the plane which under sketch makes a trace of single line.
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.
Constraints used
Tangent
Coincident
Methodology
In the front plane using splines, construction lines and projected curves, a surface sweep is created to create half of the tank. Another surface extrude is used to create the seat. Now the created part of the tank is mirrored and the entire surface is knitted together. Appropriate materials to the gas tank and the seat are applied.
ASSEMBLY
All the designed components are taken into the assembly section in Solid Works and using different mating features such as concentric, coincident, parallel, etc., the entire assembly of the American Chopper is created. Mates create geometric relationships between assembly components. After assembly the Decals are applied to the Chopper.
Constraints used
Concentirc
Coincident
Tangent
Parallel
Perpendicular
RENDERING
Once the application of the decals is finished, the assembled motorcycle is taken into Solid Works Visualize or using Photo-view 360. Here various aspects such as appearance, camera, external lightnings, background scenes, etc. are taken into consideration before the creation of the final rendering. Then the final render is done to bring a photo realistic view of the chopper.
CONCLUSION
In this project, the basics of SOLIDWORKS, including part modelling, assembly modellings, photo realistic renderings are learnt. The parts are modelled and assembled using mates. Then Photoview 360 was used to render a photo realistic image of the chopper.