Photo Realistic Rendering

1. Title: Assembly of American chopper in Solidworks.

The different components of the american chopper model were modelled and they were assembled together in Solidworks. The assembled model was rendered using Photoview and Visualize.

2. Objective:

• To understand the interface of the Solidworks software.
• To understand the 2D sketching process in the solidworks and different options to convert them into 3D bodies.
• To understand the special sketching features available in the Solidworks like projected curves, converting entities, offset entities etc.
• To understand the surface modelling in Solidworks.
• To understand the assembly of components inside Solidworks and editing of assembled components according to need inside the assembly.
• Rendering of models in Solidworks, introduction to photoview 360 and Solidworks Visualize.

3. Introduction:

In this module the modelling of different components of American Chopper and their assembly were carried out using SolidWorks software. After the modelling and the assembly of the chopper were done it was rendered using Photoview 360 and SolidWorks Visualise. A blueprint image as shown below was used to get guidance for sketching and modelling of components.

4. Design Methodology/ Approach:

Flow Chart of the modelling:

Step	Brief Description	Snapshot
1. Modelling of transmission belt	The transmission belt was created using the sketch and extrude fetaures of the SLW modelling. Matte rubber was assigned to it as material.
2. Modelling of Kickstand	The sketch for Kickstand includes two elliptical profile and a spline as the guide curve. A loft was created using the spline as the centreline. An elliptical dome and extrude cut features were used to provide the fillet for outer end and cut for the other end.
3. Modelling of Front and Rear Fenders	Trim and revolve features were used extensively for modelling of the front fender body. Dnamic mirror feature for sketching was used fwhile creating profile used in cutting the pointed shape of the fender using the Split tool available in the SLW.
4. Modelling of Chain	An outline sketch was used to depict the sprockets and path of the chain links. Individual sketch blocks were created for inner and outer links of the chain and were placed along the created outline. After placing the links various profiles were extruded selectively to get pins and two links. A curve driven pattern was created to get the links along the outline. The entire pattern was done in several parts to negotiate the curve properly. Finally the links and pins were sorted into separate folders and the links were mirored to get the cosmetic version of the chain.
5. Modelling of Oil Tank	Two solids were created by using different features and they were combined using the Combine feature to get the solid for the tank. After craeting the solid it was made into shell with 3 mm thickness. Sienna appearance availble under the painted car folder was provide to the body and fillets were provided with white colour to get a good appearance
6. Modelling of Pedal	Single sketch was used initially to extrude the various features of the pedal. The mounting boss was created using the revolve feature with a proper sketch. Linear pattern feature was used to create the other foot rest and the mounting bosses.
7. Modelling of Front and Rear Wheels	Revolve feature was extensively used to create tne tyre and hub sections of the model. Convert entitites and intersection curve features of the sketch tool were used while creatuing the sketches . A revolve cut was used toremove extra material from the rims. After completing the rim, profile for tyre was created and it was revolved to get the tyre. Brake rotor and the calipers were added using extruse and revolve features. Geometry for the tyre treads were sketched and extrude cut option with suitable offset was used to create the treads.
8. Modelling of Front Fork	Most of the parts of front fork were made by the revolve and extrude features.Move body option was used for moving the head light bucket for positioning it. Project curves option was used to create the guideline for handle bar. Area light appearance was used to depict the illumination of the head lamp.
9. Modelling of Chassis	Most of the parts of Chassis are in the form of pipes which can be modelled using the sweep feature of the solid modelling. Some complex guide curves for the sweep needed to be made using the project curve from two curves. Split tool was used extensively for trimming the over projecting parts. Split tool provides the advantage of parametric dimensioning and features update automatically after any changes made to parts.
10. Modelling of Engine	Complete Engine including the mufflers was created as a single component. The modelling started from the gearbox section and various components were added one by one. One of the cylinder along with its fins was created using the extrude and pattern tools and it was mirrrored to get the second cylinder. Project curve was used to draw the guide curves for the mufflers of the cylinders. Chrome was assigned as material for entire Engine.
11. Modelling of Fuel Tank	It was the last component of the model. Most of the features in it were of surface type. Ruled surface and Boundary Surface creation tool were used extensively to create the surfaces. Lofted surface option with proper guide curve was used to create curved surfaces of the underbelly sections of the fuel tank. Knit surface option was used to combine the surfaces together. Sketch for the Seat was created using Projection on the Surfaces option and it was extruded using extrude surface option.
12. Assembly of the Chopper	Chassis was the first component to be imported in the assembly. It was made into a fixed component and all othe componenets were mated to it so as to make everything into a single unit. Mates used for adding the components were coincident, distance, width and limit angle mates. The handle bar was provided with a limit angle mate to allow for the rotation of the handle bar. Similarly the kickstand was also provided with limit angle mate to depict the rotation of the kickstand.
13. Rendering of the Chopper	Primary rendering included appearances like colours, material and lighting for the head lamp and addition of the decals to the parts. Detailed rendering was done using the Photoview 360 and Solidworks Visualize.

5. Description:

1. Transmission Belt

Used to transmit power from engine to gearbox.

Features used to create it:

• Sketch: A 2D representation of the model expressed with entities like line, rectangle, spline etc.
• Offset: Offset entities by a specified distance, allows to created adjacent parallel entities quickly and accurately.
• Boss Extrude: Creates 3D representation of a 2D sketch.
• Fillet: It is used to create both rounded inward or outward curves on edges.
• Appearances: Apply colors to the model.

2. Kickstand

Kickstand supports the chopper to rest it on the ground.

Features used to create it:

• Sketch: It is the base for making a 3D model which uses entities like line, Splines, ellipse etc to make a 2D representation of the part.
• Extrude boss: It is used to create 3D model out of a 2D sketch.
• Extrude cut: It is used to remove the material from the 3D model. Used for creating holes, paths etc by cutting the material in desired directions. It is basically the opposite of Extrude boss.
• Fillet: It is used to create both rounded inward or outward curves on edges.
• Loft: It is used to create complex geometry along two cross-sections like in here it is used between two ellipse and thus the created way is called lofted profile.
• Dome: The feature allows to create dome like structure on the faces it can be circular or elliptical.
• Split: It is used to project an entity on other surfaces

3. Front Fender/ Rear Fender

Fenders are the protective mountings over the front and rear wheel.

Features used to create it:

• Sketch: It is the base for making a 3D model which uses entities like line, Splines, ellipse etc. to make a 2D representation of the part.
• Offset: Offset entities by a specified distance, allows to created adjacent parallel entities quickly and accurately.
• Trim entities: Allows to remove unwanted lines intersecting.
• Revolve: Taking the center line or axis it revolves the entity.
• Dynamic mirror: Makes the entity identical to the predefined sketch about its center.
• Split: It is used to project an entity on other surfaces.
• Appearances: Apply colors to the model.

4. Chain

Used to transmit power from engine to the rear wheel, which is attached to a sprocket.

Features used to create it:

• Sketch: It is the base for making a 3D model which uses entities like line, Splines, ellipse etc. to make a 2D representation of the part.
• Trim entities: Allows to remove unwanted lines intersecting.
• Fillet: It is used to create both rounded inward or outward curves on edges.
• Block: Created in background to save time and adding blocks from tool and insert.
• Extrude boss: It is used to create 3D model out of a 2D sketch.
• Pattern: A curve driven pattern is used to cut short the time of adding blocks and extruding them one by one. The pattern can be used in open as well as closed loop.
• Appearances: Apply colors to the model.

5. Oil Tank

A hollow container to store oil for chopper to run the engine.

Features used to create it:

• Sketch: It is the base for making a 3D model which uses entities like line, Splines, ellipse etc. to make a 2D representation of the part.
• Extrude boss: It is used to create 3D model out of a 2D sketch.
• Combine: It is used to add or subtract two bodies with each other manually.
• Shell: Feature required to make a part hollow and thus defining the thickness of the shell. In this case the thickness of tank is 3mm.
• Fillet: It is used to create both rounded inward or outward curves on edges.

6. Pedal

Used to rest the foot of the rider attached to the chassis.

Features used to create it:

• Sketch: It is the base for making a 3D model which uses entities like line, Splines, ellipse etc. to make a 2D representation of the part.
• Extrude boss: It is used to create 3D model out of a 2D sketch.
• Fillet: It is used to create both rounded inward or outward curves on edges.
• Linear Pattern: Just like circular pattern it is used to pattern a part in linear direction.
• Dome: The feature allows to create dome like structure on the faces it can be circular or elliptical.
• Chamfer: Feature used to make a perfect square cut on the edges and corners.

7. Front Wheel

Circular alloy block covered with rubber tire.

Features used to create it:

• Sketch: It is the base for making a 3D model which uses entities like line, Splines, ellipse etc. to make a 2D representation of the part.
• Revolve: Taking the center line or axis it revolves the entity.
• Trim entities: Allows to remove unwanted lines intersecting.
• Fillet sketch entity: Giving rounded end to edges and corners.
• Extrude boss: It is used to create 3D model out of a 2D sketch.
• Revolve: Taking the center line or axis it revolves the entity.
• Linear Pattern: Just like circular pattern it is used to pattern a part in linear direction.
• Chamfer: Feature used to make a perfect square cut on the edges and corners.
• Extrude cut: To create cavity in the part.
• Circular pattern: Feature used to create number of identical holes in circular pattern.

8. Rear Wheel

Circular alloy block covered with rubber tire. A disc and sprocket is attached to the rear wheel, the engine transmits the power to the rear wheel.

Features used to create it:

• Sketch: It is the base for making a 3D model which uses entities like line, Splines, ellipse etc. to make a 2D representation of the part.
• Revolve: Taking the center line or axis it revolves the entity.
• Trim entities: Allows to remove unwanted lines intersecting.
• Fillet sketch entity: Giving rounded end to edges and corners.
• Extrude boss: It is used to create 3D model out of a 2D sketch.
• Linear Pattern: Just like circular pattern it is used to pattern a part in linear direction.
• Chamfer: Feature used to make a perfect square cut on the edges and corners.
• Extrude cut: To create cavity in the part.
• Circular pattern: Feature used to create number of identical holes in circular pattern.

9. Front Fork

Used to steer the bike.

Features used to create it:

• Sketch: It is the base for making a 3D model which uses entities like line, Splines, ellipse etc. to make a 2D representation of the part.
• Trim entities: Allows to remove unwanted lines intersecting.
• Extrude boss: It is used to create 3D model out of a 2D sketch.
• Split: It is used to project an entity on other surfaces.
• Dome: The feature allows to create dome like structure on the faces it can be circular or elliptical.
• Mirror: Allows to create exact part quickly wrt the center reference plane.
• Projected curve: It allows to make complicated 2D curve by two different 2D curves its reference.
• Sweep: Allows to create 2D profile along with path given by 2D sketch.

10. Chassis

The chassis is the frame of the chopper, all other components like engine, oil tank etc.

Features used to create it:

• Sketch: It is the base for making a 3D model which uses entities like line, Splines, ellipse etc. to make a 2D representation of the part.
• Trim entities: Allows to remove unwanted lines intersecting.
• Revolve: Taking the center line or axis it revolves the entity.
• Extrude boss: It is used to create 3D model out of a 2D sketch
• Extrude cut: To create cavity in the part.
• Dome: The feature allows to create dome like structure on the faces it can be circular or elliptical.
• Offset: Offset entities by a specified distance, allows to created adjacent parallel entities quickly and accurately.
• Fillet sketch entity: Giving rounded end to edges and corners.
• Mirror: Allows to create exact part quickly wrt the center reference plane.
• Projected curve: It allows to make complicated 2D curve by two different 2D curves its reference.
• Sweep: Allows to create 2D profile along with path given by 2D sketch.
• Circular pattern: Feature used to create number of identical holes in circular pattern.
• Split: It is used to project an entity on other surfaces.
• Composite curve: This feature combines two curves and make a single curve.
• Appearances: Apply colors to the model.

11. Engine

Engine generates power to move the bike by converting chemical energy to heat and heat energy to rotational energy. This rotational energy of engine is transmitted to the rear wheel.

Feature used to create it:

• Sketch: It is the base for making a 3D model which uses entities like line, Splines, ellipse etc. to make a 2D representation of the part.
• Trim entities: Allows to remove unwanted lines intersecting.
• Revolve: Taking the center line or axis it revolves the entity.
• Extrude boss: It is used to create 3D model out of a 2D sketch
• Extrude cut: To create cavity in the part.
• Dome: The feature allows to create dome like structure on the faces it can be circular or elliptical.
• Offset: Offset entities by a specified distance, allows to created adjacent parallel entities quickly and accurately.
• Fillet sketch entity: Giving rounded end to edges and corners.
• Mirror: Allows to create exact part quickly wrt the center reference plane.
• Projected curve: It allows to make complicated 2D curve by two different 2D curves its reference.
• Sweep: Allows to create 2D profile along with path given by 2D sketch.
• Circular pattern: Feature used to create number of identical holes in circular pattern.
• Split: It is used to project an entity on other surfaces.
• Composite curve: This feature combines two curves and make a single curve.
• Appearances: Apply colors to the model.

12. Gas tank

Used to store gas.

6. ASSEMBLY OF AMERICAN CHOPPER:

Assembly requires establishing mates between different parts appropriately.

• First, the chassis is inserted and fixed. Now all other parts will be mated with respect to the chassis.
• Mates are applied to set all the parts on the bike.

The following pictures denotes the sequences of adding the parts and applying mates to the American chopper assembly.

The following picture is the assembly pictures of American chopper in different view orientation.

Camera view

Featured used for assembly:

• Inserting parts
• Mates: Mates give the relation between two parts, their orientation positioning and movement as required by the parts.

7. RENDERING:

Rendering allows to give a photo-realistic perspective to the model created by Photoview 360.

Photoview 360 is a rendering tool inside the Solidworks to create photo-realistic model.

The following are some rendered photos created by photoview 360.

• American_Chopper_Render_Sumit_Yadav

8. Conclusion:

Working on this project was a wonderful tour to the resources available in the Solidworks software. This project enabled me to explore the variours designing options, methodologies and difference between varoius methods of solid and surface modelling. A good amount of exposure was made to the rendering part of modelling. Making projected curves was one of the interesting things that one can get hands on experience while working on this project. It enables the designer to get intended shape of a sweep path during modelling.