Photo Realistic Rendering

MODELLING OF AMERICAN CHOPPER IN SOLIDWORKS

Objective :

• The objective of this project is used to create a model of different parts of the Chopper using solidworks
• To assemble the different parts modeled for the chopper.
• To create a Photorealistic model of the chopper and Render the model using solidworks photoview 360

Introduction :

• An American chopper is customized motorcycles which emerged in California in the late 1950s. Some of the characterstics features of American chopper are

1. Long front ends with extended forks often coupled with an increased rake angle
2. Hardtail frames (frames without suspension)
3. Lengthened or stretched frames
4. Larger than stock front wheels

In this project, an American chopper is modelled using solidworks 2019(student version) using customized dimensions. The whole modelling process is divided into three processes

1. Modelling of following individual parts

1. Chain
2. Front fender
3. Rare fender
4. Transmission belt
5. Kick stand
6. Oil tank
7. Pedal
8. Front-wheel
9. Rare-wheel
10. Front fork
11. Chassis
12. Engine
13. Fuel tank

2. Assembling all the individual parts to form a complete model of the American chopper
3. Rendering the assembled model in photoview 360 and solidworks visualize

Description of the individual parts and procedure for modelling and assembling them is mentioned below.

Modelling of individual parts

1. CHAIN

Chain is a type of transmission that is used to transmit a power from the engine to the rare 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 chain

1. Sketch
2. Trim
3. Fillet
4. Blocks
5. Extrude
6. Patterns
7. Appearance

Blocks

You can make, save, edit and insert blocks for drawing items and sketch entities that you can see 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 or tools>block>make
3. Select the sketch entities you want to make as a block for block entities
5. Repeat steps 2-4 for each of the remaining sketch entities.
6. With the sketch in edit mode, add the necessary relations.
7. Save the part.

Patterns

The curve driven pattern tool allows you to create patterns along planar or 3D curve. You can base your pattern on an open curve or on a closed curve, such as a circle. In the chain part curve driven pattern is used.

2. FRONT FENDER AND RARE FENDER

1. Fender also called as a mudguard, is mainly used to prevent sand, mud, liquids etc. which is thrown into the air by the rotating wheel.
2. It is usually made up of fibres, steel an similar materials.
3. It is kept just above the wheels and fixed on the chassis.
4. Rare fenders are usually bigger in size compared to front fender since rear wheels are usually bigger in size for the case of motorcycles.
5. The front fender is used above the front wheel and is fixed on the front fork.

Procedure for modelling rare fender in brief.

1. The first step for modelling the rare fender is to draw the cross-sectional sketch of the fender and revolve it to form an arc of required dimension.
2. Remove some portion on both sides of the fender for better appearance of the fender as shown in the figure given below.
3. Extra portions are removed by drawing a spline on the appropriate plane and splitting the fender into different portions.
4. Now provide fillet to all the sharp edges.
5. Now give the appropriate colour for the fender.
6. Three-dimensional view of the rare fender is shown in the figure given below.

Procedure for modelling front fender in brief.

1. The first step for modelling the front fender is to draw the sketch of the cross-sectional view of the fender and revolve it to form an arc of required dimension.
2. Remove some portion on both sides of the fender for better appearance of the fender as shown in the figure given below.
3. Extra portions are removed by drawing a spline on the appropriate plane and splitting the fender into different portions.
4. Now provide appropriate colour for the fender.
5. Three-dimensional view of the front fender is shown in the figure given below.

3. TRANSMISSION BELT

The belts are used to transmit power from one shaft to another by means of pulleys which rotate at the same speed or at the same speed or at different speeds. In this chopper, transmission belt is used for transmitting power from crankshaft to sprocket. From sprocket power transmitted to wheels using chain.

Different types of belt used are,

1. Flat belt
2. V-belt
3. Circular belt or rope.

Common materials used for belts are,

1. Leather belts.
2. Cotton of fabric belts.
3. Rubber belt.
4. Balata belts.

Procedure for modelling transmission belt in brief.

1. The first step for modelling the transmission belt is to draw the sketch of the cross-sectional view of the belt.
2. Extrude the sketch drawn in the previous step up to required dimensions.
3. Provide fillet to the sharp edges.
4. Apply material properties to the belt as per requirement.
5. Three-dimensional view of the transmission belt is shown in the figure given below.

4. KICKSTAND

1. Kick stand or commonly called as side stand used to balance the motorcycle when it is parked.
2. The kickstand is basically a rod made of steel/iron and it is placed on the chassis
3. It is usually in a curved shape.
4. It can be rotated about 90 degrees

Procedure for modelling kickstand in brief.

1. Open a new part design and draw an ellipse in the front plane with appropriate dimension.
2. In mid-plane, draw a curve for defining the shape of the kickstand.
3. In a plane perpendicular to the curve created in the previous step, draw another ellipse with appropriate dimensions.
4. Use loft boss/base option and loft between 2 ellipse through guideline
5. Create dome on both of the elliptical surface.
6. Create slot on one side of the kickstand for inserting it on the chassis
7. In the smaller ellipse side, remove a portion of kicker stand to make a flat surface.
8. Provide fillet to sharp edges.
9. Change the appearance of the kickstand by applying a suitable material.

5. OIL TANK

Oil tanks are basically storage tank used for storing oil which is used in the chopper. It is placed in between the engine and fuel tank. Capacity and shape of the tank may be different for different types of vehicles. Oil tanks are usually made up of steel.

Procedure for modelling oil tank in brief.

1. The first step for modelling the oil tank to draw the sketch of the top view of the tank.
2. Extrude the sketch up to the required length.
3. Draw the sketch of the front view of the tank and extrude it up to the required length.
4. Combine both the solid by keeping a common portion between them.
5. Apply fillet to all the sharp edges.
6. Apply a suitable colour and material to the oil tank.
7. Three-dimensional view of the oil tank is shown in the figure given below.

6. PEDAL

1. The pedal is a type of lever used for applying torque.
2. This torque is used for brake application, gear changing etc. in the case of motorcycles.
3. In this chopper two pedals are used, one I for application of brake and another used for gear shifting.
4. Pedals are usually made of alloy metals.

Procedure for modelling pedal in brief.

1. The first step for modelling the pedal is to draw the sketch of the pedal and extrude it up to required height.
2. Draw the sketch of the base of pedal rods on the surface of the base and extrude it.
3. Provide fillet to all the sharp edges.
4. Create projected rings on the rod of the pedal for increasing gip and to facilitate insertion of the rubber grip.
5. Apply suitable material to the pedal.
6. Three-dimensional view of the pedal is shown in the figure given below.

7. FRONT WHEEL

FEATURES USED TO CREATE FRONT WHEEL

1. Sketch
2. Revolve
3. Trim
4. Fillet entities
5. Boss/base extrude
6. Revolve cut
7. Linear pattern
8. Chamfer
9. Fillet features
10. Cut extrude
11. Circular pattern
12. Appearances

Circular pattern

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

8. RARE WHEEL

1. 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.
2. The disc and sprocket are attached with a rare wheel
3. The chain connected between the engine and the rare wheel. Chain is a positive drive. Compared to the belt it will be more efficient and losses in the chain will be less comparatively.

Features used to create rare wheel

1. Sketch
2. Revolve
3. Trim
4. Fillet entities
5. Boss/base extrude
6. Planes
7. Revolve cut
8. Linear pattern
9. Chamfer
10. Fillet features
11. Cut extrude
12. Circular pattern
13. Appearances

9. FRONT FORK

Most motorcycles today use telescope forks for the front suspension. The forks can be most easily understood as simply large hydraulic shocks absorbers with internal coil springs.

They allow the front wheel to react to imperfection in the road while isolating the rest of the motorcycle from the motion.

Features used to create front fork

1. Sketch
2. Extrude
3. Trim
4. Revolve
5. Split
6. Plane
7. Convert entities
8. Move/copy body
9. Dome
10. Mirror
11. Combine
12. Curve
13. Sweep
14. Appearances

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 mirror faces with a mid-plane selected only chosen faces within the revolve will be mirrored. Mirroring bodies can a single or multi body part and allows you to select solid geometry instead of 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 is mirrored. Then the parts are manually combined.

Project curve

Project curve is the kind of 3d curve which is projected on the basis of 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

10. CHASSIS

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

Features used to create chassis

1. Sketch
2. Offset
3. Convert entities
4. Project curve
5. Trim
6. Plane
7. Sweep
8. Split
9. Revolve
10. Cut extrude
11. Fillet
12. Combine
13. Appearances

11. ENGINE

1. Engine is the prime mover for the bike. The engine converts a chemical energy into the heat energy and then the heat energy converted into mechanical work.
2. The mechanical work in the engine is rotational motion. This rotational is converted to the wheel with use of the chain and sprocket through the gearbox and clutch.

Features used to create engine

1. Sketch
2. Convert entities
3. Trim
4. Revolve
5. Boss extrude
6. Cut extrude
7. Offset
8. Dome
9. Fillet
10. Project curve
11. Composite curve
12. Sweep
13. Mirror
14. Circular pattern
15. Split

12. GAS TANK

Gas tank are used to store the gas. To give the gas to engine whenever its required.

Features used to create gas tank

1. Sketch
2. Trim
3. project curve
4. Covert entities
5. Sweep surface
6. Loft surface
7. Fill surface
8. Surface trim
9. Surface knit
10. Sweep cut
11. Fillet
12. Appearances

Lost surface

Lost surface 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 free edges/open edges of the surface together. Also it reduces the gap between the two edges of the surface.

13. ASSEMBLY OF CHOPPER:

Intially, 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 cnditions

FEATURES USED TO ASSEMBLY CHOPPER

1. Mates
2. insert part

14. MATES

Mates create geometric relationships between assembly components. As we add mates, we define the allowabledirections of linear or rotational motion of the components we can move a component within its degrees of freedom, visualizing the assemblys behaviour.

15. RENDERING

1. Rendering is the process of creating realistic images of the photorealistic model with the environment.
2. rendering has been done in two ways in solidworks. The following are the two ways,
3. photoview360
4. solidworks visualize
5. in the photorealistic model some of the mate conditions and positions are changed to render realistic models.
6. Then the photorealistic model is rendering into realistic into realistic images with different views.

16. CONCLUSION

1. The parts of the chopper are modeled.
2. The parts are inserted into the assembly environment and the chopper is assembled.
3. The realistic image was rendering with the use of the photoview360 and solidworks visualize