Photo Realistic Rendering

MODELING & RENDERING OF AMERICAN CHOPPER USING SOLIDWORKS

INTRODUCTION :

A solid modeling computer aided design and computer aided engineering program,is one of the most popular software options for indusrty uses.Solidworks is one of the prominent modeling software available.this software is mainly deal with 3D parts using 2D sketch.The technique is generally to sketch 2D profiles then use methods like extruding and lofting to produce the solid shape.it has other add in features like photoview 360 which helps in rendering of the final model to make it look photo realistic.

in this project we learn about how to design american chopper parts,assemble them and rendering the final chopper after the assembly for realistic look using solidworks.

 OBJECTIVE :

The main objective of this project are :

• To learn and explore the feature and tools available in solidworks 2020 to design and create proto type model 3D American chopper cruiser bike from a 2D concept sketch.
• To convert the 2D concept sketch to 3D model using Solidworks 2020 Software.
• To create individual parts of chopper using solidworks.
• To assemble all the indivisual parts into a chopper.
• Creating a render image using photoview 360 and solid visualize.

Pre-requisite :

2D sketch of cruiser bike,Operating system(window 10),solidworks 2020

DESIGN METHODOLOGY/APPROACH :

Flow Chart :

Name Of Part Modeling :

1. Chassis
2. Transmission belt
3. Kickstand
4. Front Fender
5. Rear fender
6. Oil Tank
7. Transmission Chain
8. Paddle
9. Front wheel
10. Rear wheel
11. Front Fork
12. Gas Tank
13. Engine

FEATURES SPECIFICATION :-

Combine :

Combine feature is used to manually combine two bodies like add,subtract etc..

Chamber : 

A cut on the edge or corner of something that makes it slope slightly rather being perfectly square.

Circular Pattern : 

Circular pattern is used to create a pattern of spokes and the pattern of groves available in the tire.it is also used to create holes in the disc of the front wheel.the parent bodies/feature are used to create number of instances required to create the pattern circularly.

Composite Curve :

this feature is used to join two curves and make them a single curve.Eg combining a projected curve to another curve etc..

Dome : 

This feature is majorly applied to faces.select one or more planar or non planar faces.you can apply dome to faces whose centroid lies outside the face.This allows you to apply domes to irregularly shaped contours.

Dynamic Mirror : 

Dynamic mirror,it is used as you sketch the entities,they are mirrored about the presketched sketch entity.

Extrude boss/Base : 

This feature is used to convert a 2D sketch into 3D model.

Extrude Cut :

This feature is used to remove materials from the 3D model.it is just opposite to extrude boss beacuse it cuts a sketch profile while extruding.you can cut in both directions and mainly used for creating holes,channels,slots etc...

Fillet :

This feature creates a rounded internal or external face on the part.you can fillet all the edges of a face,edges,loops etc..

Fill Surface :

the fill surface feature constructs a surface path with any number of sides with in a boundary defined by existing model edges,sketches or curves including composite curves.

Loft : 

The loft feature allows you to generate complex geometry.it does this by interpolating surfaces between various cross section of the model.These cross sections can be sketches,faces or edges. In the loft interface the cross sections are considered as loft profiles.

Loft Surfaces :

Loft surfaces are surfaces generated by multiple 3D curves or existing edges creating a smooth tangency between the selected curves.

Linear Pattern :

it is also same as circular pattern.the feature or the bodies are patterned linearly.

Move/Copy Body :

this feature is used to move/copy the body from one place to another place.

Mirror : 

by using mirror faces with a midplane selected only the chosen faces within the revolve will be mirrored.mirroring bodies can be used whether in a single or multibody part and allows you to select solid geometry instead of the features and faces in a body.in the fork part the one part is created and the other part is mirrored.then the parts are manually combined.

Mates : 

Mates create geometric relationship between the 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 degree of freedom,visualising the assembly behaviour.

Offset : 

Offset one or more sketch entities,selected model edges or model faces by specified distance.For e.g. you can offset sketch entities such as spline or arcs,set of model edges,loops and so on. you can offset finite lines,arcs and splines.

Patterns :

the curve driven pattern tools allows you to create patterns along a planer or 3D curve.you can base your pattern on a oen curve or on a closed curve such as circle.in the chain part curve driven pattern is used.

 Projected Curve :

projected curve is a kind of 3D curve which is projected based on the two different 2d sketches.

Revolve : 

create a sketch that contains one or more profiles and a centre line or an edge to use as the axis which the feature revolve tools.

Sketch :

the sketch is a 2D representation of mode. These are known as entities in solidworks. e.g, Line, Rectangle, Spline, Circle,  Arc etc...

Split : 

This tool is used to project an entity onto other surface or curved or planar faces.you can also split faces on multiple bodies with one command.

Shell :

The shell feature is used to define the thickness of thin and thick shell elements.

 Sweep :

with the sweep feature we can create a shape by moving a 2D sketch profile along a 2D or 3D sketch path.

Sweep Surfaces :

Sweep surfaces are surfaces that are generated from a section curve positioned along a path.

Surface Trim :

primary used to cut away material from a surface and provides two modes : standard and mutual

Surface Knit :

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

Trim Entities : 

use for make,save,edit and insert blocks for drawing items and sketches entities that you use 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.

TRANSMISSION BELT :

This is used to transmit power from engine to gearbox.

Features used to create transmission belt :

• Sketch
• Offset
• extrude
• Fillet
• Appearances

KICKSTAND :

it is also known as side stand.it is use for support the chopper while it needs to rest on the ground.it has given an angle of 75 degree rotation about boss axis to engage and disengage the side stand.

Features used to create kickstand :

• Sketch
• Loft
• Dome
• Extrude cut
• Fillet
• Split

FRONT FENDER :

The front fender is the mounted on the front fork above the wheel to protect the rider and the chopper other parts from the debris and foreign particles.

Features used to create Front fender :

• Sketch
• Offset Entities
• Trim Entities
• Revolve
• Dynamic Mirror
• Split
• Appearances

REAR FENDER :

The use of rear fender is the same as front fender.The rear fender is mounted on the chassis of the rear part above the rear wheel.

Features used to create rear Fender :

• Sketch
• Offset Entities
• Trim entities
• Revolve
• Appearances

CHAIN :

Chain is a type of transmission system that is used to transmit a power from the engine to the rear wheel.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 :

• Sketch
• Trim
• Fillet
• Blocks 
• Extrude
• Pattern
• Appearances

OIL TANK:

The Oil Tank is used to store the oil required to run the engine.it is a hollow one.the thickness of the oil tank is given by 3mm in our chopper model.

Features used to create Oil tank :

• Sketch
• Boss Extrude
• Combine
• Fillet 
• Shell

PEDAL :

Pedal is the external part attached to the chassis.The pedal is used to place the leg on top of that to give comfort to the rider.

Features used to create Pedal :

• Sketch
• Extrude
• Fillet
• Linear Pattern
• Dome
• Chamber

FRONT WHEEL :

A wheel is a circular block made of steel/alloy material.on the top of wheel,the tire is covered.the tire is made of rubber and it has thin wires within it.

Features used to create Front wheel :

• Sketch
• Revolve
• trim
• Fillet Sketch
• Boss Extrude
• Revolve Cut
• Linear Pattern
• Chamber
• Cut Extrude
• Circular Pattern

REAR WHEEL :

A circular object that revolves on an axis and is fixed below a vehicle or other object enabling it to move easily over the ground the disc and sprocket are attached with rear wheel.

The chain is connected between the engine and rear wheel.

Features used to create Rear wheel :

• Sketch
• Revolve
• Trim
• Sketch fillet
• Extrude Boss
• Planes
• Revolve Cut
• Linear Pattern
• Chamber 
• Fillet Feature
• Extrude Cut
• Circular Pattern

FRONT FORK :

Most motorcycles today use telescopic forks for the front suspension.The forks can be most easily understood as simply large hydraulic shock absorbers with internal coil springs. They allow the front wheel to react to imperfections in the road while isolating the rest of the motorcycle from that motion.

Features used to create Front Fork :

• Sketch
• Extrude
• Trim
• Revolve
• split
• move/copy bodies
• dome
• Mirror
• Combine
• projected Curve
• Sweep

CHASSIS :

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

Features used to create Chassis :

• Sketch
• Offset
• convert Entities
• projected Curve
• Trim
• Sweep
• Split
• Revolve
• Cut Extrude
• Fillet
• Combine

ENGINE :

Engine is the prime mover for the bike.The engine converts a chemical energy into heat energy and then the heat energy is converted to mechanical work.

The mechanical work in the engine is a rotation motion.This rotation is transmitted to wheel with the help of chain and sprocket through the gear box and clutch.

here twin cylinder engine with twin exhaust pipe setup is considered,this is just outer body and no internal parts of engine are designed.

Features used to create Engine :

• Sketch
• Trim
• Revolve
• Boss Extrude
• Extrude Cut
• Offset
• Dome
• Fillet
• Projected Curve
• Composite Curve
• Sweep
• Mirror
• Circular Pattern
• Split

GAS TANK :

Gastanks are used to store gas and its gives gas to the engine when required.

Features used to create Gas Tank :

• Trim
• Projected Curve
• Sweep Surface
• Loft Surface
• Fill Surface
• Surface Trim
• Surface Knit
• Sweep Cut
• Fillet

ASSEMBLY OF THE CHOPPER :

• In the assembly,all individual parts inserted into assembly workbench of solidworks.Assembled the parts of chopper using standard mates (coincident,Parallel,Tangent,Perpendicular etc..),Advanced mates (symmetry,width,angle etc) and mirroring.
• some parts like kickstand and front fork needed a limiting angle which was set while applying the mates.some parts had to be edited to avoid any bad geometry for showing up in the assembly.
• while doing assembly keeps remembering that + sign indicates that parts are over defined and - sign under defined.

 

Feature used to assemble chopper :

• Inserting Parts
• Mates

RENDERING :

• Rendering is a process of creating realistic images of the photorealistic model with the environment.
• rendering has been done in two ways in solidworks : Solidworks Visualize & photoview 360

  In the photorealistic model some of the mate conditions and positions are changed to render realistic models.then,the photorealistic model is rendered into realistic images with different views.

Photoview 360 :

photoview 360 is a visualization and rendering solution includes with Solidworks.Providing a highly interactive environment for viewing designs as well as for creating photo realstic rendering it can be used to showcase our designs as well.

Solidworks Visualize :

Solidworks visualise provides a suite of stand alone software tools that combine industry leading rendering capabilities with visual design oriented features and workflows,allowing easy and fast creation of visual content that communicates a designs vision,passion and emotion.

CONCLUSION :

• Learn to use diffrent tools to convert 2D Concept drawing to 3D CAD model using Solidworks 2020.
• Learn how to draw defined sketch and create parts also modify same in assembly by checking the physical parameter.
• Learn to apply material and trying different appearances option to export into rendered images.
• Learn how to render an model by use of photoview 360 and solidworks visualize and diff types of camera angle,views & background images.