Photo Realistic Rendering

Title: Design of an American chopper and Photo Realistic Rendering Using Solidworks.

Objective:

• The objective of this project to create part models of the American Chopper and assembly the parts using Solidworks. 
• To add Decal, Camera view, and Environment Scene of the assembly.
• To create the photo-realistic Model of this American chopper assembly and rendering the assembly using Solidworks Phtotview 360.

Introduction:

This project explains designing different parts of the chopper and assembling them to get a complete chopper model using Solidworks. It also tells about the rendering of the model using Solidworks Visualize to make the chopper more natural and realistic.

Design methodology/approach:

 

MODELLING & ASSEMBLING FEATURES:

The various modeling features used for modeling the American Chopper are discussed as follows:

• EXTRUDE BOSS/BASE:

Extrude Boss/Base is one of the important and very useful tools in Solidworks CAD software to create solid 3D models. It 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 add materials to that contour and convert it into a 3D model.

• EXTRUDE CUT:

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

•  REVOLVE BOSS/BASE:

Revolved Boss or 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. You can access revolved boss/base from both command manager and menubar.

• REVOLVE CUT:

Revolved cut feature is one of the very useful Solidworks feature tools, which helps to remove materials from 3D models that possess axis symmetry. Revolved cut removes materials by revolving a closed profile along an axis. You can access this Solidworks feature from both the command manager and menubar.

• SWEEP:

SWEEP is the one feature in Solidworks that helps sweep a closed profile along a closed or open path. In this session, we are going to use a simple 3D object as an exercise to demonstrate the use of the SWEEP command in Solidworks.

•  FILLET:

 A fillet is a tool used to round an edge, vertex, or face on both inside and outside of a 2D or 3D model. The fillet type, location, and radius of the fillet are defined.

•  CHAMFER:

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

• MIRROR:

 The mirror tool in Solidworks is used to copy a 2D or 3D object about a reference line or plane. Creates a copy of a feature, (or multiple features), mirrored about a face or a plane.

•   SHELL:

In Solidworks, Shell feature having their own property manager which controls the application of shelling process on designed models. Here, both uniform thickness and multi-thickness shelling can be easily done by using this feature tool.

• LINEAR & CIRCULAR PATTERN:

 The Linear Pattern Command is used to drive features, faces, or bodies in a linear direction. The Circular Pattern Command is an excellent tool used to replicate features, faces, or bodies in a rotational manner about an axis.

  

• PROJECTED CURVES:

 A projected curve is a 3D curve that represents the intersection of two extruded surfaces of two sketches on intersecting planes.

• Mates:

Mate operation is the basic tool for assembling the parts. Mates are used in SOLIDWORKS to constrain and connect different parts in an assembly. There are various mate operations such as coincident, parallel, perpendicular, tangent, concentric, lock, etc. 

Modeling of the American Chopper:

• TRANSMISSION BELT:

 Belts may be used as a source of motion, to transmit power efficiently, or to track relative movement. It was modeled by using basic tools like extrude and fillets. Finally, appearance was given to the belt.

•  KICKSTAND:

A kickstand is a device 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. The body of the kickstand was created by using a loft tool and the dome was applied at the ends. Then split tool was used to create a flat bottom end. Extrude and fillets were used to model the remaining part.

• FRONT & REAR FENDERS:

 A Fender is the part of a car, truck, or motorcycle that surrounds the wheel well. The primary function of a Fender is to prevent dirt and debris from being thrown into the air by the tire. It was very easy to model these fenders. Both fenders are modeled by using features like revolve, split, and other features with different dimensions.

  

• CHAIN:

 The chain is used to transmit mechanical power from the engine to the rear wheel. The Roller chain is the commonly used type. Though the chain is a complicated model, it was easily modeled by using mirrors, curves, and curve-driven patterns. The links were modeled as blocks and later imported. The curve-driven pattern was done multiple times to get an accurate result.

• OIL TANK:

 Whether it is a car or a bike, a vehicle's engine is dependent on the fuel tank for continuous fuel supply. In the future, it may be replaced by batteries in electric vehicles. The oil tank was modeled by using a dynamic mirror entity and combine features. Shell feature was used to make it hollow. It was a simple model.

• PEDAL:

A pedal is a strong rigid body and used to rest the foot while riding bikes. Splines, fillets, dome, and linear patterns were some of the features used to model the pedal.

• FRONT-WHEEL:

 Front-wheel has a larger diameter to take and manage impact better than the rear. The front tire experiences the greatest forces during braking. First, the rim was created using revolve feature and spider-webbed spokes were created by using arcs and offsets. Then rotor and caliper were modeled. Finally, the tire was modeled using revolve and treads were applied.

• REAR-WHEEL:

 The rear tire is primarily used for acceleration and propelling the motorcycle forward. It is wider than the front wheel to improve the stability of the bike. The steps followed for the front wheel were used here. But this wheel has a rear sprocket as an additional component. It has varying dimensions.

• FRONT FORK:

 A front fork connects a motorcycle's front wheel and axle to its frame, typically via triple clamps. Most forks incorporate the front suspension and front brake and allow the front wheel to rotate about the steering axis so that the bike may be steered. This was modeled by using features like extrude and mirror. Projected curves were used to model the handles and cables. A special appearance was given to the headlights that show them glowing.

• CHASSIS:

 Chassis is the main body of the chopper. It is the skeletal frame of the bike and holds other components like the front fork, pedals, kickstand, oil tank, gas tank, and engine. It provides strength and support to the bike. Its modeling was started by using a picture as a reference for sketching. It involved features like splines, projected curves, and split. It took more time to model.

•  ENGINE:

  The engine is the heart of the bike. It provides the power necessary to drive the vehicle. A picture is imported for reference before modeling. First, the bottom part of the engine, consisting of the crankshaft, motor, and transmission pulleys, was modeled. Then the upper part of the engine with cooling fins is drawn. Then rear sprocket and air filter were modeled. Finally, the exhaust system and spark plug were modeled using splines, projected curves, and sweep features.

• GAS TANK:

 The gas tank covers the oil tank and engine and also acts as a shield that prevents the heat from the engine. The seat and opening for the fuel tank are located on the top of the gas tank. This also involved using a reference picture for sketching. One half of the tank was created and the mirrored. Then seat was modeled on the top of it and fillets were applied. Finally, the tank was shelled to make it hollow.

ASSEMBLY OF THE CHOPPER:

All the parts modeled were imported to assemble them. In assembly, the mating feature was often used to locate and relate the parts with one another. Chassis was inserted initially and fixed. The other components were inserted and set with a reference to the chassis. Some parts were modified during assembly to make it perfect.

 

RENDERING OF THE CHOPPER:

In rendering, the chopper was made to set up in such a way to look natural and unique. Decals were added to the body parts. Views and light directions were changed. Using Solidworks to visualize, the appearances, background scenes, and camera views were changed. Then final rendering was done to make the chopper, a cool and realistic one.

RENDERING IMAGES:

SIDE VIEW:

FRONT VIEW:

LEFT VIEW:

CAMERA VIEW:

CONCLUSION:

1. Design all the parts of the chopper with fully defined sketch.
2. Assembly of the chopper in Solidworks 2020.
3. Rendering of the chopper in Solidworks Photo-View 360.

 Note: These are the Rendering images of Photo-view 360. (I was unable to take the rendering images in Solidworks Visualize software because the software was continuously crashing. Thanks.)