Photo Realistic Rendering

Modeling and rendering of American Chopper using Solidworks

Objective :

The main objective of this project is

• To create individual part models of American chopper
• To create Assembly of an American chopper
• To create the rendering images using the Photo view 360 tools.
• To create an real-time rendering images with Solidworks Visualize by using required appearances and environments

Introduction :

SolidWorks is a 3D mechanical CAD program that suddenly spikes in demand for MicrosoftWindows which was created by SolidWorks partnership, headquartered in the USA, an auxiliary of Dassault Systemes. SolidWorks furnishes engineers, designers, and other imaginative experts with the devices they need to plan the world's most prominent items. SolidWorks gives a full scope of coordinated displaying, reproduction, perception, correspondence, and approval devices that item planners need to grow better items quicker and at a lower cost. Also, its special capacities empower the mechanical architect to focus on the item plan.

Origin of American Chopper: Paul Teutul and his son Paul Jr. create some of the world's most original custom motorcycles called American Choppers. Paul Sr operates Orange County Choppers, and Junior leads his staff at Paul Jr. Designs. Both shops are located a stone's throw from each other in Orange County, NY.

Design Flow Chart :

Important Procedures used in modeling all individual parts

• The Common Template of Metric values(MMGS - millimeter, gram, second) is used to model all parts.
• All sketch drawings will be fully defined in all the part models.
• All part models are defined with appropriate material, appearance, and color.
• Solidworks version used for modeling: 2019-20.

Features used for Modeling of American Chopper :

2D Sketch: A 2D drawing view consists of two-dimensional elements. A 2D drawing view allows you to quickly create or modify a drawing view without making changes to a part or assembly document.

Extruded Boss/Base: Extrudes a sketch or selected sketch contours in one or two directions to create a solid feature.

That means, if you have a closed contour sketch drawing, then you can materialize that contour and convert it into 3D model.

Revolved Boss/Base: Revolved Boss/Base is a Solidworks feature tool that is used to create a solid 3D model around an axis. You can revolve the sketch around an axis to add materials to it.

Swept Boss/Base: Swept Boss/Base is one of the useful features which help to sweep a closed profile through an open or closed path.

Lofted Boss/Base: Loft Boss/Base mainly helps to add materials between two or more profiles with ease. The profile should be closed and you can use it for a profile different or similar in shape.

Boundary Boss/Base: Boundary Boss/Base is a tool used to create features by adding materials in two directions. That means you can add materials between two profiles between two Boundaries.

Extruded Cut: Extrude cut is another cool feature that helps to remove materials from the 3D model. It is just opposite to extrude boss/base features because it cuts a sketch profile while extruding.

You can cut in both directions and mainly used for creating holes, channels, slots, etc.

Revolved Cut: Revolved cut feature is one of the very useful Solidworks feature tools, which helps to remove materials from 3D models possessing axis symmetry.

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

Swept Cut: Solidworks swept cut is mainly used to cut a solid model or part by sweeping a completely closed profile along an open or closed path. To use swept cut, you should need a closed profile and open or closed path, which may be a line, helix, and circle, rectangular or arc, etc.

Projected curve: Projected curve is a type of curve available in Solidworks which is used to create/project a curve onto the face of the model or to create a 3D curve in Solidworks.

We can also create a 3D by creating two different sketches in two different sketches in two different planes, the intersection between the two sketches is converted as a Projected curve

Linear Pattern: Linear pattern feature tool is used to create patterns of closed profiles in extruded parts. For linear patterning, there is a parent pattern (base pattern) which is used to create the array of patterns in one or two dimensions.

Fillet: A fillet is a feature tool that is used for rounding of interior or external face along with one or more edges of your design. The radius of fillet or round radius is deciding the amount of filleting in the design part.

Chamfer: The chamfer tool is one of the useful tools, which helps to cut (like the 45-degree angle with the normal surface) or make edges or corners (vertex) of a 3D model straight.

Shell: Solidworks shell tool is mainly used for the shelling process, in which the material is removed from the inner body of the model by keeping a small thickness and results in a hollow model.

Using this tool, you can make either a completely closed hollowed model or one face opened type.

Mirror: Mirror feature tool is used to create a copy of your sketch/model on its opposite side. If you have to make the same copy or mirror image, on the other hand, the Solidworks Mirror function helps to do it instantly.

Reference Plane : The planes which are used other than the default Top, Right, and Front Planes are known as reference plane.

Modeling of Transmission Belt :

Transmission Belt: A belt is a loop of flexible material used to link two or more rotating shafts mechanically, most often parallel. Belts may be used as a source of motion, to transmit power efficiently or to track relative movement. Belts are looped over pulleys and may have a twist between the pulleys, and the shafts need not be parallel.

Features used for Modeling of Transmission Belt :

• 2D Sketch
• Extruded Boss/Base

Modeling of Chassis :

Chassis: The base frame of a motor vehicle or other wheeled conveyance.

Features used for Modeling of Chassis

• 2D sketch
• Projected curve
• Swept Boss/Base
• Mirror
• Extruded Boss/Base
• Extruded Cut
• Fillet
• Champer
• Dome
• Combine
• Split line
• Revolved Boss/Base

Modeling of Front Fork :

Features used for Modeling of Front Fork :

• 2D sketch
• Revolved Boss/Base
• Fillet
• Linear Pattern
• Extruded Boss/Base
• Extruded Cut
• Dome
• Revolved Cut
• Projected Curve
• Swept Boss/Base
• Mirror
• Combine
• Reference Plane

Dome: Dome is a hollow half of a sphere. Domes are one of the most familiar features in architecture, frequently used for government and religious buildings. A dome is a curved formation or structure. It is shaped like half of a sphere

Combine: The Combine function allows you to add two bodies together, and keep the area that is common to them.

Reference Plane : The planes which are used other than the default Top, Right, and Front Planes are known as reference plane.

Modeling of Engine :

Engine: An engine or motor is a machine designed to convert one form of energy into mechanical energy.

Features used for Modeling of Engine :

• 2D sketch
• Extruded Boss/Base
• Fillet
• Revolved Boss/Base
• Circular pattern
• Dome
• Extruded Cut
• Chamfer
• Reference Plane
• Linear Pattern
• Mirror
• Split Line
• Chamfer
• Revolved Boss/Base
• Combine
• Projected Curve
• Swept Boss/Base

Dome: Dome is a hollow half of a sphere. Domes are one of the most familiar features in architecture, frequently used for government and religious buildings. A dome is a curved formation or structure. It is shaped like half of a sphere

Circular Pattern: Circular pattern feature tool is the same as the Linear pattern, used to create patterns of closed profile in extruded parts.

But In circular Patterns, Patterns are created in reference with 360 degrees or circular.

Split Line: The Split Line. the tool projects an entity (sketch, solid, surface, face, plane, or surface spline) to surfaces, or curved or planar faces. It divides a selected face into multiple separate faces. You can split curves on multiple bodies with one command

Modeling of Gas Tank:

Gas Tank: A fuel tank (also called a petrol tank or gas tank) is a safe container for flammable fluids. Though any storage tank for fuel may be so-called, the term is typically applied to part of an engine system in which the fuel is stored and propelled (fuel pump) or released (pressurized gas) into an engine.

Features used for Modeling of Gas Tank:

• 2D sketch
• Surface-Swept Boss/Base
• Trim
• Reference Plane
• Projected Curve
• Surface-Lofted Boss/Base
• Boundary Boss/Base
• Mirror
• Knit
• Split Line
• Surface-Extruded Boss/Base
• Fillet
• Swept Cut
• Shell

Trim: The Trim entities tool is mainly used for removing unwanted parts or portions from your design sketch

Knit: Knit Surface tool is used to combine two or more faces and surfaces into one. Edges of the surfaces must be adjacent and not overlapping. Surfaces do not need to be on the same plane.

Modeling of Front Wheel :

Wheel: In its primitive form, a wheel is a circular block of a hard and durable material at whose center has been bored a hole through which is placed an axle bearing about which the wheel rotates when torque is applied to the wheel about its axis.

Features used for Modeling of Front Wheel :

• 2D sketch
• Revolved Boss/Base
• Extruded Boss/Base
• Extruded Cut
• Revolved Cut
• Circular Pattern
• Combine
• Fillet

Circular Pattern: Circular pattern feature tool is the same as the Linear pattern, used to create patterns of closed profile in extruded parts.

But In circular Patterns, Patterns are created in reference with 360 degrees or circular.

Combine: The Combine function allows you to add two bodies together, and keep the area that is common to them.

Modeling of Rear Wheel :

Wheel: In its primitive form, a wheel is a circular block of a hard and durable material at whose center has been bored a hole through which is placed an axle bearing about which the wheel rotates when torque is applied to the wheel about its axis.

Features used for Modeling of Rear Wheel :

• 2D sketch
• Revolved Boss/Base
• Extruded Cut
• Extruded Boss/Base
• Circular Pattern
• Combine
• Revolved Cut
• Fillet
• Chamfer

Modeling of Chain :

Chain: A chain is a serial assembly of connected pieces, called links, typically made of metal, with an overall character similar to that of a rope in that it is flexible and curved in compression but linear, rigid, and load-bearing in tension. A chain may consist of two or more links.

Features used for Modeling of Front Wheel :

• 2D sketch
• Block
• Extruded Boss/Base
• Fillet
• Curvature Pattern
• Mirror

Block: 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.

Blocks can include the following items:

• Text (Notes)
• Dimensions
• Sketch entities
• Balloons
• Imported entities and text
• Area hatch

Curvature Pattern: The Curve Driven Pattern tool allows you to create patterns along a planar or 3D curve. To define the pattern, you can use any sketch segment, or the edge of a face (solid or surface), that lies along the plane. You can base your pattern on an open curve, or on a closed curve, such as a circle.

Modeling of Front Fender :

Fender: Fender is the American English term for the part of an automobile, motorcycle, or other vehicle body that frames a wheel well (the fender underside). Its primary purpose is to prevent sand, mud, rocks, liquids, and other roads spray from being thrown into the air by the rotating tire. Fenders are typically rigid and can be damaged by contact with the road surface.

Features used for Modeling of Front Fender :

• 2D sketch
• Revolved Boss/Base
• Split line
• Fillet

Modeling of Rear Fender :

Fender: Fender is the American English term for the part of an automobile, motorcycle, or other vehicle body that frames a wheel well (the fender underside). Its primary purpose is to prevent sand, mud, rocks, liquids, and other roads spray from being thrown into the air by the rotating tire. Fenders are typically rigid and can be damaged by contact with the road surface.

Features used for Modeling of Rear Fender :

• 2D sketch
• Revolved Boss/Base
• Split line
• Fillet
• Shell

Shell: Solidworks shell tool is mainly used for the shelling process, in which the material is removed from the inner body of the model by keeping a small thickness and results in a hollow model.

Modeling of KickStand :

Kickstand: A kickstand is a device on a bicycle or motorcycle that allows the bike to be kept upright without leaning against another object or the aid of a person. A kickstand is usually a piece of metal that flips down from the frame and makes contact with the ground. It is generally located in the middle of the bike or towards the rear.

Features used for Modeling of KickStand :

• 2D sketch
• Lofted Boss/Base
• Dome
• Extruded Cut
• Fillet

Dome: Dome is a hollow half of a sphere. Domes are one of the most familiar features in architecture, frequently used for government and religious buildings. A dome is a curved formation or structure. It is shaped like half of a sphere

Lofted Boss/Base: Loft Boss/Base mainly helps to add materials between two or more profiles with ease. The profile should be closed and you can use it for a profile different or similar in shape.

Modeling of Oil Tank :

Features used for Modeling of Oil Tank :

• 2D sketch
• Extruded Boss/Base
• Combine
• Fillet
• Shell

Modeling of Pedal :

Features used for Modeling of KickStand :

• 2D sketch
• Extruded Boss/Base
• Fillet
• Revolved Boss/Base
• Dome
• Fillet
• Chamfer
• Linear Pattern

Dome: Dome is a hollow half of a sphere. Domes are one of the most familiar features in architecture, frequently used for government and religious buildings. A dome is a curved formation or structure. It is shaped like half of a sphere

Assembly Of American Chopper :

Adding a component to an assembly creates a link between the assembly and the component. When SOLIDWORKS opens the assembly, it finds the component file to show it in the assembly. Changes in the component are automatically reflected in the assembly.

You can build complex assemblies consisting of many components, which can be parts or other assemblies, called subassemblies. For most operations, the behavior of components is the same for both types.

Design Methods (Bottom-up and Top-down Design)

You can create assemblies using bottom-up design, top-down design, or a combination of both methods.

• Bottom-up design: Bottom-up design is the traditional method. Your first design and model parts, then insert them into an assembly and use mates to position the parts. To change the parts, you must edit them individually. These changes are then seen in the assembly.

• Top-down Design: In Top-down design, parts' shapes, sizes, and locations can be designed in the assembly.

For example, You can model a motor bracket so it is always the correct size to hold a motor, even if you move the motor. Solidworks automatically resizes the motor bracket. This capability is particularly helpful for parts like brackets, fixtures, and housings, whose purpose is largely to hold other parts in their correct positions.

Important Feature of Assembly

Mate: Mates create geometric relationships between assembly components. As you add mates, you define the allowable directions of linear or rotational motion of the components. You can move a component within its degrees of freedom, visualizing the assembly's behavior.

Rendering with PhotoView 360

PhotoView 360 is a Solidworks add-in that produces photo-realistic renderings of Solidworks models. The rendered image incorporates the appearances, lighting, scene, and decals included with the model. PhotoView 360 is available with Solidworks Professional or Solidworks Premium.

Camera View Setup :

Rendering with Solidworks Visualize :

The key benefits of SOLIDWORKS Visualize include:

• Improve internal design, engineering, and sales reviews to help make more educated final decisions
• Drastically reduce the cost and number of physical prototypes, helping to arrive at final design decisions much more efficiently
• Deliver photo-quality imagery and content to marketing much earlier to help promote the newest products via the web and printing
• Added time savings allow for more design time, which results in an overall better final product
• Simple, intuitive interface with a minimal learning curve which helps bring better products to the market faster

Conclusion :

• The parts of the chopper were modeled.

• American Chopper Assembly was created successfully.

• The chopper images are rendered with PhotoView 360 and Solidworks Visualize