3D MODELLING AND RENDERING OF AMERICAN CHOPPER

PHOTO REALISTIC RENDERING OF AMERICAN CHOPPER:

INTRODUCTION:

        SolidWorks 2018 is a 3D modelling CAD software by Dassault Systems used by Automobile Design Engineers to create Automobile parts, machines, and other components which needs to be designed prior to production and manufacturing. This Software is a High Professional CAD software where including modelling, there are numerous other options like Sheet metal designing, Surface modelling, Drafting, Rendering etc., which has a professional way of approach. It is a prominent software in which from modelling of a product to final rendering is done inside this only software without any third party applications until its necessity. In this project, I learnt almost every method from creating models to final rendering of a product in many ways which are easy and in a professional way of approach.

OBJECTIVE:

        The main objective of this project is to:

                            Create individual components of American Chopper.

                            Give appearances to every part and add Decals whenever necessary.

                            Assemble the designed parts to make an American Chopper prototype                         

                            Create a rendered image of the assembly using PhotoView 360                        

                            Final render in Solidworks Visualize using Camera and light setup and produce Photo-Realistic Images of American Chopper.

DESIGN METHODOLOGY/APPROACH:

PART MODELLING PROCESS:

Points to remember while creating any sketch for a part:
         Edit the name of reference planes as per your convenience.
         Select a plane and click sketch tool to draw 2D sketches.
         Dimension each and every entity to make it fully defined.
         Exit the sketch once the 2D sketch process is completed.

KICK STAND
    Kick Stand is used to give side support to a bike when it is resting on the ground. It is also known as side stand.

Features Used:
  Sketch
  Loft
  Dome
  Extrude Boss
  Extrude Cut
  Fillet
  Split

Sketch:
Sketch is a command used to create 2D representation of a part model before producing a 3D Feature. This is the first and foremost part of creating any part model.
Loft:
Loft is a 3D feature which allows you to create a solid part using two or more sketches. This feature is used when the part has different shapes from both ends. It uses reference planes as its reference to create complex extrudes.
Dome:
Dome is a 3D feature used to create dome shaped solids on flat surfaces of the part model.
Extrude Boss/Base:
It is a solid feature which converts 2D sketch into 3D solids.
Extrude Cut:
This 3D feature is used to remove material in a solid part. For example, a hole can be cut inside a solid cylinder to make it a hollow part. The 2D sketch must be a closed loop.
Fillet:
This is both a 2D and 3D feature used to make a rounded corners on any edges of a solid part.
Split:
This tool is used to cut material from a solid. Unlike Extrude cut, this tool can work even if the sketch is not a closed loop.

PROCEDURE:

1. First of all, select Mid Plane and click sketch.
2. Create a sketch in the front plane and give dimensions. Make the sketch fully defined, while sketching, use spline and trim commands.
3. Create two new planes as reference and draw ellipse in the new plane as per the requirement.
4. Then the loft command is used to create loft for the kickstand.
5. The extrude cut is used to cut parts which are not required for the stand.
6. Dome feature is used for the smallest face to make the face round and smooth.
7. Fillets are applied as required.
8. Finally, the part is saved to some location.

TRANSMISSION BELT:

    Transmission Belt is used to transmit the power from the engine to gear box. It is usually made of rubber or leathers.

Features Used:
  Sketch
  Offset
  Extrude Boss
  Fillet
 
Sketch:
Sketch is a command used to create 2D representation of a part model before producing a 3D Feature. This is the first and foremost part of creating any part model.
Offset:
Offset is a 2D tool used to copy a specific sketch entity to some distance for further sketching. Offset can be used on any 2D shapes such as lines, circle, spline, etc.
Extrude Boss/Base:
It is a solid feature which converts 2D sketch into 3D solids.
Fillet:
This is both a 2D and 3D feature used to make a rounded corners on any edges of a solid part.
 
PROCEDURE:

1. Select the Front Plane and Click sketch tool
2. The 2D sketch is created in the Front plane and dimensions are given as required to make the sketch fully defined. While sketching offset command is used to make a copy sketches to some distance.
3. Now, Extrude command is used to convert 2D sketch into 3D model.
4. Fillet is applied to the edges as per the given dimensions
5. Then finally the model is saved to some location.

FRONT FENDER:
Front fender is used to guard the bike and the rider from mud while riding. It protects from mud, dust and other unwanted particles.

 
Features Used:
  Sketch
  Offset entities
  Trim entities
  Revolve
  Dynamic Mirror
  Split
 
Sketch:
Sketch is a command used to create 2D representation of a part model before producing a 3D Feature. This is the first and foremost part of creating any part model.
Offset:
Offset is a 2D tool used to copy a specific sketch entity to some distance for further sketching. Offset can be used on any 2D shapes such as lines, circle, spline, etc.
Trim Entities:
Trim Entities is used for trimming the extra or unwanted edges or sketches during Sketching process.
Revolve:
Revolve tool is used to make a rotational solid feature which is symmetric about an axis. Revolve tool requires a sketch and a centre line as reference to revolve.
Dynamic mirror:
Mirror tool is used to mirror sketch entities about a centreline.
Dynamic Mirror is same as mirror tool, but it is handy because it lets us to mirror the entities while creating the sketch in parallel.
Split:
This tool is used to cut material from a solid. Unlike Extrude cut, this tool can work even if the sketch is not a closed loop.

PROCEDURE:
1. Select a plane and click sketch.
2. Draw a centerline for a revolve axis.
3. Then construct a three point arc above the line and specify dimensions.
4. Use Dynamic Mirror option to speed up process.
5. Make a revolve feature and use revolve options for easy modelling.
6. Apply fillets to the edges as per the dimensions.
7. Save the part file to some location.

REAR FENDER

    Rear fender is used to protect the rider from mud and debris while riding bike, where it is mounted on the back side of the Rider’s seat, on top of Rear wheel.

Features Used:
  Sketch
  Offset Entities
  Trim Entities
  Revolve
 
Sketch:
Sketch is a command used to create 2D representation of a part model before producing a 3D Feature. This is the first and foremost part of creating any part model.
Offset:
Offset is a 2D tool used to copy a specific sketch entity to some distance for further sketching. Offset can be used on any 2D shapes such as lines, circle, spline, etc.
Trim Entities:
Trim Entities is used for trimming the extra or unwanted edges or sketches during Sketching process.
Revolve:
Revolve tool is used to make a rotational solid feature which is symmetric about an axis. Revolve tool requires a sketch and a centre line as reference to revolve.

PROCEDURE:
1. Select a plane and click sketch.
2. Draw a centerline for a revolve axis.
3. Then construct a three point arc above the line and specify dimensions.
4. Make a revolve feature and use revolve options.
5. Apply fillets to the edges as per the dimensions.
6. Save the part file to some location.

CHAIN
Chain is used to transmit the engine shaft rotation to the rear wheel with the help of small links and pins.

Features Used:
  Sketch
  Trim
  Fillet
  Blocks
  Extrude
  Pattern

Sketch:
Sketch is a command used to create 2D representation of a part model before producing a 3D Feature. This is the first and foremost part of creating any part model.
Trim Entities:
Trim Entities is used for trimming the extra or unwanted edges or sketches during Sketching process.
Fillet:
This is both a 2D and 3D feature used to make a rounded corners on any edges of a solid part.
Extrude Boss/Base:
It is a solid feature which converts 2D sketch into 3D solids.
Blocks:
You can make, save, edit and insert blocks for drawing items and sketch entities that you use often, such as title blocks and label positions and so on. You can attach blocks to geometry or to drawing views and you can insert them into sheet formats.
Pattern:
Pattern tool is used to create the duplicate of entities or block along the path specified.

PROCEDURE:
1. Select a plane and start sketching.
2. Draw circle and splines to make a 2D model of chain.
3. Create blocks for inside and outside links.
4. Place the blocks one after another using curve driven pattern.
5. Extrude the pins and links and apply fillets
6. Finally, save the part file to some location.

OIL TANK
    Oil Tank is a hollow container which is used to carry oil required for the engine. This hollow part is mounted on top of transmission system.

Features Used:
  Sketch
  Extrude
  Combine
  Fillet
  Shell
 
Sketch:
Sketch is a command used to create 2D representation of a part model before producing a 3D Feature. This is the first and foremost part of creating any part model.
Extrude Boss/Base:
It is a solid feature which converts 2D sketch into 3D solids.
Combine:
Combine feature is used to combine two separate solid into one solid. This feature can also be used to keep the common intersecting material and remove non-intersecting materials.
Fillet:
This feature is used to produce rounded corners to the sharp edges if part.
Shell:
Shell feature is used to convert a Solid part model into a hollow part by specifying the thickness of the hollow part.
 
PROCEDURE:
1. Select a plane and start sketching.
2. Extrude the 2D sketch to some distance as specified in dimensions.
3. Produce another solid extrude inside the part.
4. Use combine feature and under options select ‘common’.
5. After part is created use fillet tool to make rounded edges
6. Use shell feature to make hollow part.
7. Save the file to some location.

PEDAL:
    Pedal is a part mounted on the sides of chassis to place legs. It is usually used for comfortness while riding the bike.

 
Features Used:
  Sketch
  Extrude
  Fillet
  Linear pattern
  Dome
  Chamfer
 
Sketch:
Sketch is a command used to create 2D representation of a part model before producing a 3D Feature. This is the first and foremost part of creating any part model.
Extrude Boss/Base:
It is a solid feature which converts 2D sketch into 3D solids.
Fillet:
This feature is used to produce rounded corners to the sharp edges of part.
Linear Pattern:
This feature is used to pattern a feature to a number of times along a path without changing the dimension,
Dome:
Dome feature is used to create a dome shaped solid surface on a flat surface of solid part.
Chamfer:
This tool is used to cut the edges to some angle. There are additional types of chamfering which helps in features.

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.

Features Used:
  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 along a circular reference. It is also used to create holes in the discs of the front wheel. The features are used to create number of instances required to create the pattern circularly.

REAR WHEEL
    Rear wheel is used for riding the bike. The chain connected to the sprocket is mounted to rear wheel. With the help of shaft rotation of engine, the bike moves.

Features Used:
  Sketch
  Revolve
  Trim
  Sketch fillet
  Extrude Boss
  Planes
  Revolve cut
  Linear pattern
  Chamfer
  Fillet feature
  Extrude Cut
  Circular pattern

FRONT FORK
    Fork is used to place the front wheel and connecting it to the chassis. The front wheel is mounted in bottom of fork and it help in steering the bike.
 

Features Used:
  Sketch
  Extrude
  Trim
  Revolve
  Split
  Move/copy bodies
  Dome
  Mirror
  Combine
  Projected curve
  Sweep

Projected curve:
Projected curve is a 3D curve which is projected based on the two different 2D sketches. It is useful and handy in creating complex splines.
Sweep
Sweep is a feature which uses a 2D sketch profile and a 2D sketch path to create a solid extrude along the path.

CHASSIS
    Chassis is the skeleton of a bike. It holds all the parts the bike needs. For example, the engine, transmission system, fork, gas tank, oil tank, pedal, etc.

Features Used:
  Sketch
  Offset
  Convert Entities
  Project Curve
  Trim
  Sweep
  Split
  Revolve
  Cut Extrude
  Fillet
  Combine

ENGINE
    Engine is a Prime Mover of the bike. It transmits power using the fuel by converting chemical energy into mechanical energy.
 

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

Composite Curve:
This tool is used to join two curves which are most likely to be splines to make a single curve or spline. It joins two splines and makes it one for sweep feature.
 
GAS TANK
    Gas Tank is used to store gas and it is also used as the seat holder for the bike. It provides gas required for the bike to run.

Features Used:
  Sweep surface
  Projected curve
  Trim surface
  Loft surface
  Fill surface
  Surface Knit
  Sweep Cut
  Fillet

Sweep surface:
Sweep surface is used to produce a curve along the Sweep surface is used to produce a curve along the path which is sketched for reference.path which is sketched for reference.
Projected Curve:
Projected curve is used to project a curve onto a Projected curve is used to project a curve onto a complex shaped surface or usually on a simple surface.complex shaped surface or usually on a simple surface.
Trim surface:
Trim suTrim surface is used to trim the unwanted surfaces rface is used to trim the unwanted surfaces from the part model.from the part model.
Loft surface:
This tool extrudes a hollow zero dimension surface by This tool extrudes a hollow zero dimension surface by using two are more sketches as reference.using two are more sketches as reference.
Fill surface:
Fill surface tool is used to patch the remaining places Fill surface tool is used to patch the remaining places of the sof the surfacesurfaces. It forms a new surface by connecting the . It forms a new surface by connecting the surface entities together.surface entities together.
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
Sweep cut
This tool is used to cut the material using a sweep feature command. This tool using a profile and path to cut material
Fillet:
This is both a 2D and 3D feature used to make a rounded corners on any edges of a solid part.

ASSEMBLY OF AMERICAN CHOPPER

Procedure:
    First of all, all the part model are open in assembly.
    Then, the chassis part is initially used as the first part.
    After inserting the chassis inside the assembly, click ok to place it in the default plane.
    Insert the other part model one by one and make them mate with each other
    Make sure the part models mates are fully defined.
    After mating all parts the Chopper is assembled.

Features Used:
  Mates
  Appearances
  Decals

Mates:
  Mates are used to keep component in relation to one another and produce the resultant product.
Some of the well-known mates are:
    o Coincident
    o Concentric
    o Parallel
    o Lock
    o centre Width
    o Tangent

Appearances:
  For each and every component the appearance is given. In case of chopper the appearance is chosen as sienna under metals in display manager.
 
Decals:
  Decals are added to chopper to make it more realistic making it a real chopper model. It can be achieved by selecting ‘Add Decals’ under ‘Edit Decal’ option in display manager.

INTRODUCTION TO SOLIDWORKS VISUALIZE

       To make a professional level rendering only SolidWorks is not enough. There are applications which pops the product to next level making ultra HD photo quality image. And that is where the SolidWorks Visualize comes into the picture.

        SolidWorks Visualize allows to leverage 3D CAD models to create photo quality content in the fastest and easiest way. It also let us to create animations, 360 spins, etc.

        By adjusting some options like light and camera and scenes for HD background one can hardly tell the difference between a real image and a photo realistic image done in rendering.

        The Version I am using for rendering models is SolidWorks Visualize 2018. While the later version provides additional features as well.

PHOTO-REALISTIC RENDERING

     Rendering is a process of creating a real life like images of part model by adding scenes, lights, camera views, etc.

    It can be done in both
        1. Photoview 360
        2. SolidWorks visualize.

   Since photoview 360 has limited option available for rendering, solidworks visualize is used since it is created for photo realistic rendering purpose.

CONCLUSION

        o Thus, by using SolidWorks, the part modelling and appearances are successfully designed and pasted in a professional way of approach.

        o By Using SolidWorks assembly, American Chopper parts are assembled using mates and are fully defined in the software.

        o By using Solidworks Visualize, the assembled part of American Chopper is rendered and using camera, setting light and scenes, American chopper is converted into a photo realistic model.

        o By doing this Project, I have learnt the commands, tools and features used in SolidWorks CAD software and SolidWorks Visualize.