Design, Modelling, Assembly & Photo Realistic Rendering Of American Chopper using Solidworks

By: Gaurav Agarwal

INTRODUCTION

In this project learnt about the Design, Modelling, Assembly & Photo Realistic Rendering of American Chopper with the help of SOLIDWORKS. In this first learnt about different types of commands and how to use them properly to design and model different parts. Blueprint sketch command, it helped in sketching by providing idea about the dimensions and rough geometry of the parts. After designing all the parts, the next step is to assemble the different parts to get our complete product which can done by selecting assembly on the home page of solid works and then providing the proper mates to our parts to get the complete product. After which added decals, lights, camera to improve the final renders. Finally done the rendering of chopper by using SOLIDWORKS visualization.

The components/parts designed and modelled for creating the American chopper are:

1.	Chassis
2.	Engine with exhaust system
3.	Front Wheel & Rear wheel with rims, sprocket, and calipers.
4.	Front fork
5.	Front and Rear fender
6.	Oil tank
7.	Chain and transmission belt
8.	Kickstand and foot pedal

OBJECTIVE:

• To learn the basic commands of SOLIDWORKS.
• To learn how to design and model all the parts of chopper using blueprint sketch.
• Learn to assemble all the parts of chopper with proper mates.
• Acquire the knowledge of different concepts like decals, light, camera angle, render tools etc.
• To create photo realistic view with proper image quality, with the help of photo view 360.
• Rendering of American chopper, with the help of solid works visualization software.

Design Approach:

The design procedure can be approached by using two different approaches.

• Bottom-up Approach: The design approach in which the most primary operations are specified first then combined it later to make larger progressive unit.

• Top-down Approach: Top-down assembly modelling is an assembly-centric modelling method where the assembly design is started at the highest level possible, and individual parts and subassemblies are defined within the context of the overall assembly.

Both the approaches have their individual pros and cons, But for our current project we have chosen the bottom-up approach.

Part Modelling:

In Part Modelling you can create a part from a conceptual sketch through solid feature-based modeling, as well as build and modify parts through direct and intuitive graphical manipulation.

Part Modeling shows you how to draft a 2D conceptual layout, create precise geometry using basic geometric entities, and dimension and constrain your geometry. You can learn how to build a 3D parametric part from a 2D sketch by combining basic and advanced features, such as extrusions, sweeps, cuts, holes, slots, and rounds. Finally, the Part Modeling Help provides procedures for modifying part features and resolving failures.

Assembly:

Assembly modeling is a technology and method used by computer-aided design and product visualization computer software systems to handle multiple files that represent components within a product. The components within an assembly are represented as solid or surface models.

Rendering:

Photorealistic Rendering lets you adjust various visual aspects of your model to improve its appearance and enhance details for better viewing by your employees and customers. Your model updates as you work, and you can move your model in space to see the effects of your rendering from different angles.

Features and properties used:

• Extrude Boss:- The most popular feature from SOLIDWORKS is extrude boss. This feature needs a complete 2D sketch to convert 2D sketch into a solid body. When we exit the fully defined sketch we get boss extrude option and a property manager window pop-up. Into the property manager we see from where the feature begins and where it will end that we need to add dimensions to it. It creates a complete solid body of any shape with closed entities. In this feature we can add dimensions to both the direction (direction 1 and direction 2) according to our need. We can use the direction if it is blind, midplane, from the vertex, etc.

• Fillet:- Solid parts have some sharp edges. To give the roundness to those edges we add fillets. It makes the sharp edges or corners round shape of having different sizes or radius. The material can be added or removed according to conditions whether edges are internal or external. Fillets are used to solid bodies to hide the corners and edges of the part. Various types of fillets are used according to the given condition.

• Extrude cut:- This feature cuts the geometry which we don’t need from the part. This feature also needs a complete 2D sketch, which need to be removed from a solid body. When we draw sketch on the solid part and then we use extrude cut command it removes that part /surface.

• Shell:- It is a very powerful tool in SOLIDWORKS. In this tool we give inside thickness to the geometry and the material gets removed from the body and the part becomes hollow without any hassle.

• Linear pattern:- Linear pattern is used to create multiple identical sketches from a single sketch. The spacing, angles and path can be given in this feature to draw or create pattern. This feature is generally spaced uniformly along one or two linear paths.

• Mirror:- This feature creates a mirror part for the selected part. It requires a plane or axis to mirror and most importantly the part to be mirrored.

• Reference geometry:- It defines the shape or form of a surface or a solid. This includes features such as planes, axes, co-ordinate system and points. This can be used according to need in a sketch.

• Projected curve:- This feature helps in projecting a curve from a sketch into a model to create a 3D curve. We can create multiple closed or open contour projected curves from a single sketch. Generally, the curve can be intersection of two extruding surfaces. The curve which is created can be used as a path for the sketch of the part.

• Knit:- It can be used to knit or to combine two or more faces and surfaces into one. It creates a solid body when the knit surfaces form a closed volume or leave as a surface body.

• Mate:- Mate creates geometric relationship between assembly and component. When we add mates, it defines the allowable direction of linear or rotational motion of component within its degree of freedom, visualizing the assembly’s behaviour.

This feature include

• Coincident mate: Coincident mate make two planar faces to become coplanar. This mate can move along one another but cannot be separated.
• Concentric mate: This makes two circular faces to become concentric and can move along the common axis.
• Tangent mate: This feature can be use between a face and plane to make tangent mate.
• Angular mate: This makes angular relation between flat surface and the surface having some angle

Features used in modelling of components/parts for American chopper part by part:

Transmission Belt: Transmission belt is a sub component of the engine, it is installed at the round surface of the pulleys. It is used to transmit power from the engine to the transmission. The commonly used material for this is rubber. Features used to create the transmission belt are:

• Sketch
• Extrude
• Offset
• Fillet
• Appearance

Kickstand: Firstly, created a sketch of cross section of the side stand on a plane than created a curve on plane perpendicular to this plane using spline tool which will become our guide curve for the loft feature. The curve should pierce the center of the cross section of the cross-section sketch. On the other end of the curve create a plane and draw the other cross section sketch on this plane and use loft feature. Then using dome, split, fillet, extrude cut completed the part as required. Features used to create the kickstand:

• Sketch
• Ellipse
• Pierce
• Loft
• Cut extrude
• Boss extrude
• Split

Front fender: Here we revolved the sketch using an axis and created half curved solid body. Created some sharp edges on both sides of fender by using the split tool and removed the unwanted material. The edges of the fender are filleted. Features used to create the Front fender:

• Sketch
• 3-point arc
• Offset
• Extend
• Trim
• Revolve
• Spline
• Fillet

Rear fender: Almost identical procedure as of front fender only difference between the two is the sizes as according to the size of the wheel. Features used to create the rear fender:

• Sketch
• 3-point arc
• Extend
• Trim
• Revolve
• Spline
• Fillet
• Shell

Oil Tank: Sketched the base of the oil tank on the top plane and extrude the 2-D sketch. Now create another sketch on the midplane, extrude the sketch and then combine both the sketches. Apply the shell feature to make the oil tank hollow, also apply fillets to improve the aesthetics of the oil tank. Features used to create the oil tank are:

• Sketch
• Boss extrude
• Combine
• Shell
• Fillet
• Appearance

Chain link: It is one of the most complex component in the whole project but can be simply created by sketching the sub component of the chain link i.e. a link and a guide curve using different sketching command and finally applying a curve pattern. Then add mirror feature to the whole component to complete the part. Features used to create the chain link are:

• Sketch
• Circle
• 3point arc
• Slot
• Sketch block
• Fillet
• Curve pattern
• Mirror

Pedal: A pedal is a strong rigid body and used to rest the foot while riding bike. The various features are used to create the pedal are splines, fillets, dome, chamfer, and linear pattern. The appearance given to the pedal is chrome metal. Features used to create the Pedal:

• Sketch
• Lines
• Circles
• Fillet
• Revolve
• Dome
• Chamfer
• Linear pattern
• Extrude boss
• Appearance

Front wheel: First, the rim was created by revolve boss feature and the spider webbed spokes were created by using splines and offsetting them. Then the spider webbed spokes were pattern to the rim. On rim rotor and caliper were modelled. The tire was modelled using revolve and threads were applied. Then different appearances are applied to the rim, tire, caliper, and the rotor disc. Features used to create the Front wheel:

• Sketch
• Lines
• 3-point arc
• Sketch fillet
• Revolve
• Extend
• Trim
• Extrude cut
• Offset
• Revolve cut
• Circular pattern
• Chamfer
• Fillet

Rear wheel: The rear wheel is mostly responsible for power delivery form chain to road surface to push the vehicle forward. It is wider than the front wheel. The steps were followed same as front wheel except the sprocket to link the chain. Features used to create the Rear wheel:

• Sketch
• Lines
• 3-point arc
• Fillet (sketch)
• Revolve
• Spline
• Extrude cut
• Offset
• Revolve cut
• Circular pattern
• Chamfer
• Fillet
• Appearances

Front Fork: The Front fork attach the whole chassis and the front wheel. The front fork is a suspension component for bikes First the half portion of the front fork has been created and the rest is mirrored about the plane. Projected curves were used to model the handles and the cables. The handles of the front fork were given grips. Features used to create the Front fork:

• Sketch
• Lines
• Revolve
• Circle
• Fillets
• Linear pattern
• Spline
• Extrude cut
• Dome
• Curve
• Sweep
• Plane
• Mirror
• Combine
• Appearance

Chassis: The chassis is the main frame for all vehicles. It holds all the components such as front fork, pedals, kickstand, oil tank, engine, gas tank and rear wheel. It supports all the components and supports to the bike. Firstly, chopper image is added for reference purposes. Then using it as reference a sketch is created using different sketching tools. Finally, appearances are added to the part. Features used to create the chassis are:

• Blueprint sketch
• Splines
• Curves
• Mirror
• Boss extrude
• Extrude cut
• Chamfer
• Dome
• Split
• Revolve
• Combine
• Sweep

Engine: The main part of the bike is engine. It provides necessary power to drive the bike. A picture is taken for the reference for modelling. The engine consists of parts like crank shaft, transmission pulleys and motor. The upper part of crank shaft the cooling fins were located. The air filters were drawn using spline and the exhaust system is also made with splines and projected curves and sweep feature. Features used to create the Engine:

• Sketch
• Blueprint sketch
• Lines
• Circles
• Boss extrude
• Fillet
• Revolve
• Dome
• Pattern
• Chamfer
• Mirror
• Curves
• Composite curves
• Split

Gas Tank: It is mainly made with splines and sweep feature. Only half part of the gas tank is created, the other half is created using the mirror feature about the correct plane. Both parts are then combined using knit feature. A seat is also created on the gas tank using extrude surface and fillet feature. Lastly, shell feature is used to make the tank hollow. Features used to create the gas tank are:

• Blueprint sketch
• Spline
• Surface sweep
• Surface trim
• Surface boundary
• Surface loft
• Curve
• Mirror
• Surface knit
• Surface extrudes
• Fillet
• Extrude cut
• Shell

Assembly

• Assembly modeling is a technology and method used by computer-aided designand product visualization computer software systems to handle multiple files that represent components within a product. The components within an assembly are represented as solid or surface models.
• Firstly, import all modelled part document file into SOLIDWORKS assembly window one at a time. Then with the use of mate assign proper relationships between the parts as they get imported. Also assign proper positions to the parts relative to each other.
• Lastly, modify any part document according to the need of the assembly.

Decals

• A decal is a 2D image applied to a model. You can use decals to apply warning or instruction labels to models. You can use decals to create model details that you can represent with an image instead of with the model geometry, such as a car grill or a picture frame.
• Now, add decals to the oil tank, gas tank, and the rear fender using edit decal feature which comes under render tools, it improves the overall aesthetics of the chopper.

Rendering

• Photorealistic Rendering lets you adjust various visual aspects of your model to improve its appearance and enhance details for better viewing by your employees and customers. Your model updates as you work, and you can move your model in space to see the effects of your rendering from different angles.
• In SOLIDWORKS rendering can done using solidworks visualize, under new project import the model to be modelled. Now in rendering we can change colour of chopper parts, background images, brightness, rotation and various setting of chopper.

Conclusion:

• Acquired knowledge about the sketching and modelling basics of solidworks and about their application in part and surface modelling.
• Successfully created, modelled, and assembled all parts of American chopper using solidworks.
• Rendered the assembled chopper using solidworks visualize and photoview 360.