Photo Realistic Rendering

MODELING AND RENDERING OF AMERICAN CHOPPER USING SOLIDWORKS

INTRODUCTION:

• In this Project a model of an American Chopper is created using Solidworks. The parts are individually modelled and then assembled together. The Assembly is then renderred using SOLIDWORKS Photo view 360 and SOLIDWORKS Visualize.

OBJECTIVE:

To understand and practice different tools and features used in the SOLIDWORKS environment by:

• Modelling different parts of an American Chopper.
• Assembling the different parts to form the American Chopper.
• Creating photo-realistic view of the American Chopper by rendering the model using SOLIDWORKS Photo view 360 and SOLIDWORKS Visualize.

DESIGN METHODOLOGY/APPROACH:

PART MODELING:

Parts which are to be assembled to give a 3D prototype model are initially modelled separately by sketching and using some features.

The 3D part is the basic building block of any large-scale design.

Features are the individual shapes that, when combined, make up the part.

DESCRIPTION OF FEATURES:

SKETCH:

• Sketch is the two-dimensional representation of the model with respect to the plane/view from the outside of the model. In solid works there are different sketch options available to create a sketch. These are known as Entities in solid works. The following are some of the entities available in solid works: Line, Arc, Spline, Circle, Rectangle etc.

OFFSET:

• Offset entities take a copy of one’s existing geometry and copies it at an offset. Instead of recreating geometry, one can use this to quickly sketch based on model geometry. Offset entities is a great tool for enlarging or shrinking a sketch geometry.

For example, to offset sketch entities such as splines or arcs, sets of model edges, loops, and so on.

EXTRUDE BOSS/BASS:

• Extrude is a type of feature available in solid works to convert a 2D sketch into the 3D model. Extrude is formed parallel to the sketch plane.

FILLET:

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

LOFTED BOSS/BASS:

• The loft feature is used 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 “Loft Profiles”.

DOME:

• This feature is used to create a Dome on one or more planar or non-planar faces. One can apply domes to faces whose centroid lies outside the face. This allows one to apply domes to irregularly shaped contours.

EXTRUDE CUT:

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

SPLIT:

• The Split tool is used to project an entity (sketch, solid, surface, face, plane, or surface spline) onto other surfaces or curved/planar faces. One is also able to split faces on multiple bodies with one command.

TRIM ENTITIES:

• The Trim Entities tool is mainly used for removing unwanted parts or portions from your design sketch. For trimming, one must have coincident sketch parts with another. The Sketch Trim Entities also consist of “Extend Entities” tool, which helps to extend or adjust the lines.

REVOLVE:

• Revolve adds or removes material by revolving one or more profiles around a centerline. One can create revolved boss/bases, revolved cuts, or revolved surfaces.The revolve feature can be a solid, a thin feature, or a surface.
• The sketch should contain one or more profiles and a centerline, line, or edge to use as the axis around which the feature revolves.

DYNAMIC MIRROR:

• Dynamic mirror is one of the important tools in solidworks. As one sketches the entities, they are mirrored about the pre-selected sketch entity.

APPEARANCES:

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

COMBINE:

• Combine is the type of feature available in solidworks to manually combine the two bodies.

SHELL:

• The shell tool hollows out a part, leaves open the faces one selects, and creates thin-walled features on the remaining faces. If one does not select any face on the model, it shells a solid part, creating a closed, hollow model. One can also shell a model using multiple thicknesses.

CHAMFER:

• It is used to form a cut on the edge or corner of something that makes it slope slightly rather than being perfectly square.

CIRCULAR PATTERN:

• It is used to create multiple instances of one or more features that one can space uniformly around an axis. Pattern instances inherit the feature color of the original feature when the Pattern is based on one feature.

LINEAR PATTERN:

• The linear pattern feature is used to create different number of instances required to create a pattern linearly.

SURFACE MODELING:

• Surface modeling gives the ability to build out a visual representation of an object’s exterior and its contours. In other words, its surface.
• Parts like seat, fuel tank of this chopper are surface modeled.

DESCRIPTION OF FEATURES:

LOFTED SURFACE:

• Lofted Surfaces are surfaces generated by multiple 3D Curves or existing edges, creating a smooth tangency between the selected curves.

SWEPT SURFACES:

• Swept 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:

• It is primarily used to cut away material from a surface, and provides two modes: Standard and Mutual.

EXTEND SURFACE:

• Extend Surface is used to extend the surface which is already created. There are different options available on the extended surface. We can extend the surface as same surface or we can extend the surface tangent to the surface.

SURFACE KNIT:

• Surface knit is used to knit the two free edges/open edges of the surfaces together. Also, it reduces the gap between the two edges of the surface

PARTS MODELED FOR AMERICAN CHOPPER:

The following parts of the American Chopper are modeled in solidworks and assembled together.

• Transmission Belt
• Kickstand
• Front fender
• Rear fender
• Chain
• Oil Tank
• Pedal
• Front Wheel
• Rear Wheel
• Front Fork
• Chassis
• Engine
• Gas Tank

DESCRIPTION OF THE PARTS AND FEATURES USED:

1. Transmission Belt:

It 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.

FEATURES USED:

• Boss Extrude
• Fillet

2. KICKSTAND:

A kickstand is a device on a 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:

• Loft
• Dome
• Cut Extrude
• Split
• Boss Extrude
• Fillet

3. FRONT 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 road spray from being thrown into the air by the rotating tire. Front fender is placed above front tyre.

FEATURES USED:

• Revolved Boss
• Split
• Fillet

4. REAR 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 road spray from being thrown into the air by the rotating tire. Rear fender is placed above rear tyre.

  FEATURES USED:

  • Revolved Boss
  • Split
  • Fillet
  • Shell

  

  

  5. CHAIN:

  The chain on the bike is responsible for transferring the mechanical power from the engine to the rear wheel of the bike.

  FEATURES USED:

  • Extruded Boss
  • Fillet
  • Projected Curves
  • Curve Pattern
  • Mirror

• 6. OIL TANK:

  An oil tank has the purpose of storing lube oil to lubricate the engine parts so as to avoid wear and tear due to extreme heat.

  FEATURES USED

  • Extruded Boss
  • Fillet
  • Shell
  • Combine

• 7. PEDAL:

  A pedal has the function of shifting the gears to get the desired speed from the engine and also apply the breaking force.

  FEATURES USED:

  • Extruded Boss
  • Fillet
  • Revolved Boss
  • Dome
  • Chamfer
  • Linear pattern

• 8. FRONT WHEEL:

  A wheel is a circular block of a hard and durable material where the center has been bored with a circular hole through an axle bearing about which the wheel rotates.

  FEATURES USED:

  • Extruded Boss
  • Cut Extrude
  • Revolved Cut
  • Circular Pattern
  • Combine
  • Fillet
  • Chamfer

• 9. REAR WHEEL:

  A wheel is a circular block of a hard and durable material where the center has been bored with a circular hole through an axle bearing about which the wheel rotates.

  FEATURES USED:

  • Extruded Boss
  • Cut Extrude
  • Revolved Cut
  • Circular Pattern
  • Combine
  • Fillet
  • Chamfer

• 10. FRONT FORK:

  A bicycle fork is the part of a bike that holds the front wheel. A fork typically consists of two blades which are joined at the top by a fork crown.

  FEATURES USED:

  • Extruded Boss
  • Revolved Boss
  • Fillet
  • Extruded Cut
  • Dome
  • Revolved Cut
  • Swept Boss
  • Project Curve
  • Mirror
  • Combine

• 11. CHASSIS:

  The chassis mostly consists of hollow tube which serves as a skeleton for the gearbox, engine, front fork and rear wheel of a bike to be mounted.

  FEATURES USED:

  • Swept Boss
  • Project Curve
  • Mirror
  • Extruded Boss
  • Fillet
  • Extruded Cut
  • Dome
  • Combine
  • Chamfer
  • Split
  • Revolved Boss

• 12. ENGINE:

  An engine or motor is a machine designed to convert one form of energy into mechanical energy. Heat engines, like the internal combustion engine, burn a fuel to create heat which is then used to do work.

  FEATURES USED:

  • Swept Boss
  • Project Curve
  • Mirror
  • Extruded Boss
  • Fillet
  • Extruded Cut
  • Dome
  • Chamfer
  • Split
  • Revolved Boss
  • Linear pattern
  • Circular Pattern
  • Composite Curve

• 13. GAS TANK:

  A gas tank (or petrol 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:

  • Surface Loft
  • Surface Knit
  • Project Curve
  • Fillet
  • Swept Surface
  • Split
  • Mirror
  • Swept Cut
  • Plane

  

  ASSEMBLY OF AMERICAN CHOPPER:

  MAIN ASSEMBLY:
• Initially, the Chassis part is inserted in the assembly by using insert parts in the option.After that, the part gets inserted in the assembly environment and is fixed when we click OK.
• Similarly the other parts of the chopper are inserted into the assembly and given possible mate conditions.

FEATURES USED TO ASSEMBLE AMERICAN CHOPPER:

• Mates
• Insert part

  Insert Parts

  We can insert the other components which need to be mated with the prime fixed component.

• 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 behavior.

  

  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 this project. The following are the two ways,
  • Photo view 360
  • Solid-works Visualize

  3.In the photo-realistic model some of the mate conditions and positions are changed to render-realistic models.

  4.Then the photo-realistic model is rendered into realistic images with different views.

  5.Here I have used both the photo-view 360 and Visualise for rendering the assembled model.

  

  CONCLUSION:

  • The parts of the American Chopper are modeled.
  • The parts are inserted into the assembly environment and American Chopper is assembled.
  • The photo-realistic image was rendered with the use of the Photo-view 360 and Solidworks Visualise.
  • I would like to thank my mentor Mr. Soundar Rajan for helping me with the challenges I faced at various stages in completing the project.