Photo Realistic Rendering

Modelling and Rendering of American Chopper in SolidWorks

Objective:

The main objective of this project is to learn the basics of SOLIDWORKS, including - part modelling,assembly modelling,photo-realistic rendering and to model different parts of a custom-designed American chopper.

Introduction:

The following steps were undertaken while designing the American chopper:

• Design of the individual components.
• Assembly of the American chopper.
• Application of decals,setting up the scene,lights and cameras.
• Rendering of the American chopper using SolidWorks Photo view 360 and SolidWorks Visualize.

Part Modelling:

The process of creating a virtual prototype of something by modeling each individual part separately,which can then all be assembled together to create the model of the final product.

Parts Modeled for American Chopper:

Parts are Modeled and assembled in the following sequence:

• Transmission Belt

• Kick Stand

• Front Fender

• Rear Fender

• Oil Tank

• Chain

• Pedal

• Front Wheel

• Rear Wheel

• Front Fork

• Chassis

• Engine

• Gas Tank

1.Transmission Belt:

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

Features used:

• Sketch
• Offset
• Extrude
• Fillet
• Appearances

Sketch:

The sketch is a two-dimensional representation of the model. There are different sketch options in SolidWorks like Line, Arc, Circle, Rectangle, Spline. These are known as Entities.

Offset:

Offset one or more sketch entities, selected model edges, or model faces by a specified distance. For example, you can offset sketch entities such as splines or arcs, sets of model edges, loops,etc.

Extrude:

Extrude is a type of feature to convert a 2D sketch into 3D model.

Fillet:

Fillet/Round 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.

2.Kick Stand:

The Kick Stand is used to support the chopper. It is also known as Side Stand.

Features used to create KickStand:

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

Loft:

The loft feature in SOLIDWORKS allows you to generate complex geometry in a single feature. It does this by interpolating surfaces between various cross-sections of a model. These cross-sections can be sketches, faces or edges. In the loft-interface, these cross-sections are considered as "Loft Profiles

Dome:

Select one or more planar or non-planar faces. You can apply domes to faces whose centroid lies outside the face. This allows you to apply domes to irregularly shaped contours.

Extrude cut:

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

Split:

The SOLIDWORKS Split Line 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.

3.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.

Features used to create Front Fender:

• Sketch
• Offset Entities
• Trim entities
• Revolve
• Dynamic mirror
• Split
• Appearances

Trim entities:

Trim is used to remove the objects, which meet the edges of other objects. It is used to remove extra lines or extra parts of an object. We can also perform trim using different selection methods.

Revolve:

Revolves add or remove material by revolving one or more profiles around a centerline. You can create revolved boss/bases, revolved cuts, or revolved surfaces. The revolve feature can be a solid, a thin feature, or a surface.To create a revolve feature: Create a sketch that contains one or more profiles and a centerline, line, or edge to use as the axis around which the feature revalve can be used.

Dynamic mirror:

Dynamic mirror is an important tool in SolidWorks. As you sketch the entities, they can be mirrored about the pre-selected sketch entity.

4.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.

Features used to create Rear Fender:

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

Appearances:

An Appearance defines the visual properties of a model, including colour and texture. Appearances do not affect physical properties, which are defined by materials. Every material is assigned to a default appearance that emulates the look of the material.

5.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.

Features used to create Oil Tank:

• Sketch
• Boss Extrude
• Combine
• Fillet
• Shell
• Appearances

Combine:

Combine feature is used to manually combine the two bodies into the one body.

Shell:

The Shell Definition Property-Manager is used to define the thickness of thin and thick shell elements.

6.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.

Features used to create the Chain:

• Sketch
• Trim
• Fillet
• Blocks
• Extrude
• Patterns
• Appearances

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.

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.

7.Pedal:

Pedal is the external part attached to the chassis.Pedal is to use your foot or leg power to power something, or to press on something that provides power.

Features used to create Pedal:

• Sketch
• Extrude
• Fillet
• Linear pattern
• Dome
• Chamfer
• Appearances

Chamfer:

Chamfer is used to cut on the edge or corner of something that makes it slightly slope or rounded rather than being perfectly square or straight.

Linear Pattern:

linear patterns is used to create multiple instances of one or more features that you can space uniformly along one or two linear paths. To create a linear pattern: Create one or more features to replicate. Click Linear Pattern (Features toolbar) or Insert > Pattern/Mirror > Linear Pattern.

8.Front Wheel:

A wheel is a circular block 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. Wheel rotates to move the vehicle.

Features used to create the Front Wheel:

• Sketch
• Revolve
• Trim Entities
• Fillet
  
• 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 sporks and the patterns 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 partem circularity.

9.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
• Fillet Entities
• Boss/Base Extrude
• Planes
  
• Revolve Cut
• Linear pattern
  
• Chamfer
• Fillet Features
• Cut Extrude
• Circular Pattern.
• Appearances

10.Front Fork:

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
  

Move/copy Body:

Move/ Copy body is used to move/copy the body from one place to other places in the fork.

Mirror:

By using the mirror feature we can mirror the body or part to the other side. Mirroring bodies can be used whether in a single or multi-body part and allows you to select solid geometry instead of the features and faces in a body. In the fork part, one part of the fork is created and the other part is mirrored.Then the parts are manually combined.

Project Curve:

A tool you are going to use to form 3D curves from two 2D curves from two different planes.To project a curve: Click Project Curve on the Curves toolbar, or Insert > Curve > Projected.Use this selection to project a sketched curve onto a model face. Under Sketch to Project , select the curve in the graphics area or from the flyout FeatureManager design tree.

Sweep:

With the Sweep feature, we can create a shape by moving a 2D sketch Profile along a 2D or 3D sketch Path.

11.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

12. 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

12.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

Loft Surface:

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

Sweep Surfaces:

Sweep surfaces are surfaces 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.

Surface knit:

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

Assembly of the American Chopper:

• All the designed components are taken into the assembly section in Solid Works and using different mating features such as concentric, coincident, parallel, etc.Here the assembly of the American Chopper is created.
• After assembly the Decals are applied to the Chopper and various aspects such as camera,external lightnings,background scenes,etc. are created before rendering.

Features used to assemble the Chopper:

• Mates
• Insert part

Mates:

Mates create geometric relationships between 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 degrees of freedom, visualizing the assembly's behaviour.

Insert Parts:

We can insert the other components which need to be mated with the prime fixed component.

Rendering:

Rendering is the process of creating realistic images of the Photorealistic model with the environment.The rendered image incorporates the appearances, lighting, scene, and decals included with the model.

Rendering has been done in the following two ways in SolidWorks

• Photoview 360
• Solidworks Visualize

Rendered images in SolidWorks PhotoView 360:

Rendered images in SolidWorks Visualize:

Conclusion:

• The parts of the American Chopper are sketched and modelled.
• The parts are inserted into the assembly environment and American Chopper is assembled.
• The photo-realistic image was rendered with Photo-view 360 and Solidworks Visualise.

Here I like to thank my mentor Mr.Soundar Rajan for guiding me to complete this project successfully.

Link to view the model:

https://drive.google.com/drive/folders/1qBhfa6_sTyhhvtrQSJxg4jNnMyuK-W9H?usp=sharing