Photo Realistic Rendering

Piyush American Chopper

Objective:

The objective of this project is to learn and understand the different tools and commands in SolidWorks.

To create a Model of different parts.

To assemble the different parts in the assembly.

To Render and make realistic view in the SolidWorks Visualize and PhotoView 360.

Part Modeling:

In part modelling first, sketch the Part and build the Part with some graphical visualisation.

Parts Modeled for Chopper:

The following Parts of the Chopper are Modeled and assembled in SolidWorks.

1. Transmission Belt
2. Kick Stand
3. Front Fender
4. Rear Fender
5. Oil Tank
6. Chain
7. Pedal
8. Front Wheel
9. Rear Wheel
10. Front Fork
11. Chassis
12. Engine
13. Gas Tank

1. Transmission Belt

The Transmission Belt in the Chopper is used to transmit the Power from the Engine to Gear Box.

Features used to create a transmission belt:

Sketch

Offset

Extrude

Fillet

Appearances

Sketch:

The sketch is a two-dimensional representation of the model. There are different sketch options in the SolidWorks like Line, Arc, Circle, Rectangle, Spline. These are known as Entities.

Offset:

Offset one or more sketch entities, selected model edges, or model faces by a specified distance. For example, you can offset sketch entities such as splines or arcs, sets of model edges, loops, and so on. You can offset finite lines, arc, and splines.

Extrude:

Extrude is a type of feature available in SolidWorks to convert a 2D sketch into the 3D model.

Fillet:

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

The procedure to create a model of Transmission Belt:

• First, Open the SolidWorks. Then, click on the new part to start modelling.
  
• Before creating the sketch change the names of the planes.
  
• Front Plane - Front Plane Transmission Belt
• Top Plane - Top Plane Transmission Belt
• Right Plane - Right Plane Transmission Belt
• Then, select the front plane to start the sketch.
• The 2D sketch is created in the front plane by giving it dimensions, relations to fully define a sketch. While sketching, the offset command is used to duplicate the sketch to some distance.
• After this process, the sketch is closed. Then, the extrude command is used to convert a 2D sketch into a 3D model.
• Then, the fillet is given to the belt as per the requirements. The model of the transmission belt is created.
• The model is saved with the name of Transmission Belt.

2. Kick Stand:

• The Kick Stand is used to support the chopper. It is also known as Side Stand.
  

Features used to create KickStand:

• Sketch
• Loft
• Dome
• Extrude Boss
• Extrude cut
• Fillet
• Split
• Appearances

Loft:

The loft feature in SOLIDWORKS allows you to 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 as “Loft Profiles”.

Dome:

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

Extrude cut:

Extrude cut is another great feature which helps to remove material from the 3D model. It is just the opposite to extrude boss/base feature, because it cuts a sketch profile while extruding. You can cut it in both directions and mainly used for creating holes, channels, slots etc.

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.

Procedure to create a model of KickStand:

• First, Open the SolidWorks. Then, click on the new part to start modelling.
• Before creating the sketch change the names of the planes.
• Front Plane - Front Plane
• Top Plane - Top Plane
• Right Plane - Mid Plane
• Then, the mid-plane is selected to start the sketch.
• The 2D sketch is created in the front plane by giving it dimensions, relations to fully define a sketch. While sketching we used the spline and trim commands.
• There are two new planes created and the ellipse are drawn in the new plane as per the requirement.
• Then the loft command is used to create a loft for the Kickstand.
• The extrude cut command is used to cut the parts which are not required for the stand.

3. Front Fender :

• The Front Fender is a part mounted on the fork above the wheel to protect the rider and the chopper other parts from debris and foreign particles.

Features used to create Front Fender:

• Sketch
• Offset Entities
• Trim entities
• Revolve
• Dynamic mirror
• Split
• Appearances

Trim entities:

Select the trim type based on the entities you want to trim or extend. All trim types are available with 2D sketches and 2D sketches on 3D planes. You can use any of the following trim options: Power trim.

Revolve:

To create a revolve feature: Create a sketch that contains one or more profiles and a centerline, line, or edge to use as the axis around which the feature revolve can be used.

Dynamic mirror:

Dynamic mirror is an important tool in SolidWorks. As you sketch the entities, they can be mirrored about the pre-selected sketch entity.

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 to create Rear Fender:

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

Appearances:

An Appearance defines the visual properties of a model, including colour and texture. Appearances do not affect physical properties, which are defined by materials. Every material is assigned to a default appearance that emulates the look of the material.

5. Oil-Tank :

The Oil-tank is another part of the Chopper. Oil tank is used to store the oil required to run the Engine. Oil tank is the Hollow one. The thickness of the oil tank is given as 3mm in our chopper.

Features used to create Oil Tank:

• Sketch
• Boss Extrude
• Combine
• Fillet
• Shell
• Appearances

Combine:

Combine feature is used to manually combine the two bodies into the one body.

Shell:

The Shell Definition Property-Manager is used to define the thickness of thin and thick shell elements.

6. Chain:

• Chain is used to transmit the power from the engine to the Rear Wheel. Chain is made of steel. 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 the Chain:

• Sketch
• Trim
• Fillet
• Blocks
• Extrude
• Patterns
• Appearances

Blocks:

We can make, save, edit, and insert blocks for drawing items and sketch entities that We use often, such as standard notes, title blocks, label positions, and many more. We can attach blocks to geometry or drawing views, and We can insert them into sheet formats.

To create blocks:

1. Create a sketch.
2. Click Make Block. (Blocks toolbar) or Tools > Block > Make . ...
3. Select the sketch entities you want to make as a block for BlockEntities.
4. Repeat steps 2-4 for each of the remaining sketch entities.
5. With the sketch in edit mode, add the necessary relations.
6. Save the part.

Patterns:

The Curve Driven Pattern tool allows us to create patterns along a planar or 3D curve. We can base our pattern on an open curve, or a closed curve, like a circle. In the chain part Curve Driven Pattern is used.

7. Pedal:

Pedal is the external part attached to the chassis. The pedal is used to rest the leg on top of that. For the comfort of the rider pedal is used.

Features used to create Pedal

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

Chamfer:

Chamfer is used to cut on the edge or corner of something that makes it slightly slope or rounded rather than being perfectly square or straight.

Linear Pattern:

Linear pattern is also similar to the circular pattern. The features/bodies are patterned linearly. Pattern is a kind tool like Array available in AutoCAD.

8. Front Wheel:

A wheel is a circular block made of the Steel/Alloy material. On the top of the wheel, the tyre is attached. The tyre is made of Rubber and it has thin wires within it. Wheel rotates to move the vehicle.

Features used to create the Front Wheel:

• Sketch
• Revolve
• Trim
• Fillet Entities
• Boss/Base Extrude
• Revolve Cut
• Linear pattern
• Chamfer
• Fillet Features
• Cut Extrude
• Circular Pattern
• Appearances

Circular Pattern:

Circular pattern is used to create a pattern of the sporks and the patterns (Grooves) available in the tyre. Also, it is used to create holes in the brake discs of the front wheel. The parent bodies/ features are used to create a different number of instances required to create the pattern circularly.

9. Rear Wheel:

• A circular object that revolves on an axle and is fixed below a vehicle or other object to move it easily over the ground.
• The disc and sprocket are attached with a rear wheel.
• The chain is connected between the Engine and the Rear Wheel. Chain is a positive drive. Compared to the belt it will be more efficient and losses in the chain drive are comparatively less.
  

Features used to create the Rear Wheel:

• Sketch
• Revolve
• Trim
• Fillet Entities
• Boss/Base Extrude
• Planes
• Revolve Cut
• Linear pattern
• Chamfer
• Fillet Features
• Cut Extrude
• Circular Pattern
• Appearances

10. 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. It filters the bums to give comfort to the rider.

Features used to create the Front Fork:

• Sketch
• Extrude
• Trim
• Revolve
• Split
• Plane
• Convert entities
• Move/copy Body
• Dome
• Mirror
• Combine
• Curve (Project Curve)
• Sweep
• Appearance

Move/copy Body:

Move/ Copy body is used to move/copy the body from one place to other places in the fork.

Mirror:

By using the mirror feature we can mirror body or part to the other side. Mirroring bodies can be used whether in a single or multi-body part and allows you to select solid geometry instead of the features and faces in a body. In the fork part, the one part of the fork is created and the other part is mirrored. Then the parts are manually combined. It helped me to save a lot of time.

Project Curve:

Project curve is the 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.

11. Chassis:

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

Features used to create the Chassis

• Sketch
• Offset
• Convert entities
• Project Curve
• Trim
• Plane
• Sweep
• Split
• Revolve
• Cut Extrude
• Fillet
• Combine
• Appearance

12. 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 into mechanical work.
• The mechanical work in the engine is rotational motion. This rotation is converted to the wheel with the use of the chain and sprocket through the gearbox and clutch.

Features used to create the Engine:

• Sketch
• Convert entities
• Trim
• Revolve
• Boss extrude
• Cut extrude
• Offset
• Dome
• Fillet
• Project curve
• Composite curve
• Sweep
• Mirror
• Circular Pattern
• Split

12. Gas Tank:

Gas tank is used to store the fuel gas. Fuel gas is required to drive the engine.

Features used to create the Gas Tank:

• Sketch
• Trim
• Project curve
• Convert entities
• Sweep Surface
• Loft Surface
• Fill surface
• Surface trim
• Surface knit
• Sweep cut
• Fillet
• Appearances

Loft Surface:

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.

Filled Surface:

The Filled Surface feature constructs a surface patch with any number of sides, within 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 the two free edges/open edges of the surfaces together. It also reduces the gap between the two edges of the surface.

Assembly of the Chopper:

• First, the Chassis part is inserted in the assembly by using insert parts in the option. After that the part is inserted in the assembly environment and clicked ok to fix the chassis.
• After that, the other parts of the chopper are inserted into the assembly and given possible mate conditions.

Features used to assemble the Chopper:

• Mates
• Insert part

Mates:

Mates create geometric relationships between 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 degrees of freedom, visualizing the assembly's behaviour.

Rendering:

• Rendering is the process of creating realistic images of the Photorealistic model with the environment.
• Rendering has been done in two ways in SolidWorks. The following are the two ways,

1. Photoview 360
2. 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.

Conclusion :

• The parts of the chopper are sketched and modelled in the SolidWorks.
  
• The parts are inserted into the assembly environment and by applying the mates' chopper is assembled.
• The realistic image was rendered with the use of the 'Photoview 360 & SolidWorks Visualize'.