Photo Realistic Rendering

Title: Design of American Chopper.

Objective:

The objective of this project is to learn and understand the different tools and commands in SolidWorks by creating a Model of the American Chopper with all the different parts and to assemble the different parts in the assembly. Finally to Render and make a photorealistic view in the SolidWorks Visualize and PhotoView 360.

Introduction:

In this project we use Solidworks 2020 software to design an American Chopper Motorcycle and the complete procedure of creating parts and the assembly is explained in this report.

Features of Solidworks used in this project are:

BASIC FEATURES:

• Sketch: A collection of lines and other 2D objects/entities on a plane or face that forms the basis for a feature such as a base or a boss. A 3D sketch is non-planar and can be used to guide a sweep or loft.
• Offset: It is a feature in sketching features, wherein an entity can be placed away from the original entity at a certain distance.
• Extrude: A feature that projects a sketch to either add material to a part (in a base or boss) or remove material from a part (in a cut or hole).
• Fillet: Fillet creates a rounded internal or external face on the part. You can fillet all edges of a face, selected sets of faces, selected edges, or edge loops. Fillet can have single radius throughout or it can have multiple radii.
• Chamfer: A cut on the edge or corner of something that makes it slope slightly rather than being perfectly square. It can either be symmetric or asymmetric.
• Loft: Loft creates a feature by making transitions between profiles. A loft can be a base, boss, cut, or surface. You create a loft using two or more profiles. Only the first, last, or first and last profiles can be points. All sketch entities, including guide curves and profiles, can be contained in a single 3D sketch.
• Dome: Select one or more faces. You can apply domes to faces whose centroid lies outside the face. This allows you to apply domes to irregularly shaped contours. Dome can be elliptical or spherical.
• 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. You are also able to split faces on multiple bodies with one command.
• Trim Entities: Select the trim type based on the entities you want to trim or extend. All trim types are available with 2D sketches and 2D sketches on 3D planes.
• Revolve: This feature makes a solid body or surface which has circular symmetry around an axis.
• Dynamic Mirror: Dynamic mirror is an important tool in solid works. As you sketch the entities, they can be mirrored about the pre-selected sketch entity with this tool.
• 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.
• Combine: Combine is the type of feature available in solid works to manually combine the two bodies which intersect each other.
• Shell: The shell feature helps create thick, thin, or composite shells from solid bodies. This feature can also create shell which is offset from the solid body.
• Circular Pattern: The circular parent bodies/ features are used to create a different number of instances of the required feature to create the pattern circularly.
• Linear Pattern: In linear pattern parent bodies/ features are used to create a different number of instances required to create the pattern linearly along a pre-selected direction.

SURFACE MODELING:

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

Features Description:

• Lofted Surface: Loft Surfaces are surfaces generated by multiple 3D Curves or existing edges creating a smooth tangency between the selected curves.
• Swept Surfaces: Swept Surfaces are surfacing 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: 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 knitis 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 parts of the American Chopper are modeled in Solidworks and assembled together are as follows:

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

Transmission Belt

The Transmission Belt is used to transmit the Power from the Engine to Gear Box.

Procedure to create a model of Transmission Belt:

• Open the SolidWorks, click on the new part.

• Then, select the front plane to start the sketch.
• The 2D sketch is created in the front plane by giving it appropriate dimensions, relations to fully define a sketch. While sketching, the offset command is used to duplicate the sketch at some distance.
• After this process, the sketch is closed. Then, the extrude command is used to convert a 2D sketch into a 3D model.
• Then, the fillet is given to the belt as per the requirements. The model of the transmission belt is created.
• The model is saved and named Transmission Belt.

Kick Stand:

The Kick Stand is used to support the chopper. It is also known as Side Stand.
Procedure to create a model of KickStand:

• Open the SolidWorks, click on the new part.
• Change the names of the planes.

• Front Plane - Front Plane
• Top Plane - Top Plane
• Right Plane - Mid Plane
• Then, the mid-plane is selected to start the sketch.
• The 2D sketch is created in the front plane by giving it dimensions, relations to fully define a sketch. While sketching we used the spline and trim commands.
• There are two new planes created and the ellipse are drawn in the new plane as per the requirement.
• Then the loft command is used to create a loft for the Kickstand.
• Dome command is used to make dome at one of the ends.
• The extrude cut command is used to cut the parts which are not required for the stand.

Front Fender :

The Front Fender is a part mounted on the fork above the wheel to protect the rider and the chopper other parts from debris and foreign particles.

Procedure to create front fender

• First, the sketch was created based on the dimension acquired from the video lectures.

• The sketch was made on the front plane , along with a referance axis was drawn about which the profile was to be revolved.
• The components was not fully revolved ,as it is a front fender we have to provide the direction of revolving in both left and right direction i.e, 5 degree and 130 degree.
• On the center plane we have to create a sketch as shown in the image , the dimensions are given, here we used dynamic mirror option to create similar spline on both side .using this sketch we had to make / split the upper end of front fender.
• Using split tool, split the revolve geometry.
• Again we create the spline sketch on front/ vertical plane for extrude cut the lower part of fender.
• Then using fillet command we provide a 10mm fillet on the side edges.

Rear Fender:

The use of the rear fender is the same as the front fender. The rear fender is mounted on the chassis of the rear part above the Rear Wheel to protect the body from mud.

Procedure to create the Rear Fender

The procedure to make rear fender is same as that of creating the front fender.

Oil-Tank:

The Oil-tank is another part of the Chopper. Oil tank is used to store the oil required to run the Engine. Oil tank is the Hollow one. The thickness of the oil tank is given as 3mm in our chopper.

Chain:

Chain is used to transmit the power from the engine to the Rear Wheel. Chain is made of steel. The Sprocket is used to transmit the power to the chain. The sprocket is connected with the Shaft with the help of a key.

Blocks:

We can make, save, edit, and insert blocks for drawing items and sketch entities that we use often, such as standard notes, title blocks, label positions, and many more. We can attach blocks to geometry or drawing views, and we can insert them into sheet formats.

To create blocks:

1. Create a sketch.
2. Click Make Block. (Blocks toolbar) or Tools > Block > Make.
3. Select the sketch entities you want to make as a block for BlockEntities.
4. Repeat steps 2-4 for each of the remaining sketch entities.
5. With the sketch in edit mode, add the necessary relations.
6. Save the part.

Make block is used to make a block of chain which is repeated throughout the length of the chain using curve driven pattern.

Patterns:

The Curve Driven Pattern tool allows us to create patterns along a planar or 3D curve. We can base our pattern on an open curve, or a closed curve, like a circle. In the chain part Curve Driven Pattern is used.

Pedal:

Pedal is the external part attached to the chassis. The pedal is used to rest the leg of the driver on its top for the comfort of the rider.

Procedure to make Pedal

• Create a sketch on the front plane, then provided the necessary dimension to sketch along with the contours.
• Then by using same sketch create different 3d structure, such as plate and pins.
• Then extrude the right hand side hole which was created. Also by sketching on the top plane a used revolve command to create a mounting pin like structure.
• Then provide a dome at the end of previously created pin. Without selecting merge ellptical option.
• By sketching on a front extruded face off-set the circular entities, on all the pins created previously.
• Then create an offset extrude of those sketches, and used a linear pattern by specifying the center distance and number of pattern as 4.
• Then using fillet option, apply a fillet on the sharp edged surfaces.

Front Wheel:

A wheel is a circular element made of the Steel/Alloy material. On the top of the wheel, the tyre is attached. The tyre is made of Rubber and it has thin wires within it.

Features used to create the Front Wheel:

• Sketch
• Revolve
• Trim
• Fillet Entities
• Boss/Base Extrude
• Revolve Cut
• Linear pattern
• Chamfer
• Fillet Features
• Cut Extrude
• Circular Pattern
• Appearances

Circular Pattern:

Circular pattern is used to create a pattern of the spokes and the treads (Grooves) available in the tyre. Also, it is used to create holes in the brake discs of the front wheel. The parent bodies/ features are used to create a different number of instances required to create the pattern circularly.

Rear Wheel:

• A circular object that revolves on an axle and is fixed below a vehicle or other object to move it easily over the ground.
• The disc and sprocket are attached with a rear wheel.
• The chain is connected between the Engine and the Rear Wheel. Chain is a positive drive. Compared to the belt it will be more efficient and losses in the chain drive are comparatively less.

Features used to create the Rear Wheel:

• Sketch
• Revolve
• Trim
• Fillet Entities
• Boss/Base Extrude
• Planes
• Revolve Cut
• Linear pattern
• Chamfer
• Fillet Features
• Cut Extrude
• Circular Pattern
• Appearances

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. It filters the bums to give comfort to the rider.
Features used to create the Front Fork:

• Sketch
• Extrude
• Trim
• Revolve
• Split
• Plane
• Convert entities
• Move/copy Body
• Dome
• Mirror
• Combine
• Curve (Project Curve)
• Sweep
• Appearance

Chassis:

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

Features used to create the Chassis

• Sketch
• Offset
• Convert entities
• Project Curve
• Trim
• Plane
• Sweep
• Split
• Revolve
• Cut Extrude
• Fillet
• Combine
• Appearance

Engine:

• Engine is the prime mover for the Bike. The engine converts a Chemical energy into the Heat energy and then the heat energy is converted into mechanical work.
• The mechanical work in the engine is rotational motion. This rotation is converted to the wheel with the use of the chain and sprocket through the gearbox and clutch.

Features used to create the Engine:

• Sketch
• Convert entities
• Trim
• Revolve
• Boss extrude
• Cut extrude
• Offset
• Dome
• Fillet
• Project curve
• Composite curve
• Sweep
• Mirror
• Circular Pattern
• Split

Gas Tank:

Gas tank is used to store the fuel gas. Fuel gas is required to drive the engine.

Features used to create the Gas Tank:

• Sketch
• Trim
• Project curve
• Convert entities
• Sweep Surface
• Loft Surface
• Fill surface
• Surface trim
• Surface knit
• Sweep cut
• Fillet
• Appearances

Assembly of American Chopper components in their prescribed position.

• While making Assembly i used various constraints options,Such as Coinsident,Concentric,Tangents ,And distance.
• I further applied the above listed constraints By considering the geometry modeling features (plane surfaces and vertices)

Renders:-