Photo Realistic Rendering

Modelling of American chopper on Solidworks

Introduction:

In this course, we learned about the complete designing of American Chopper using solidworks, from the initial sketching to the final assembling. Initially we learned about the customization of menus and all the commands that we are using frequently in the solidworks while sketching. With the help of appropriate dimensions, sketching of all the parts were done and created separately. Once every part is created, then we are ready to assemble the parts into a complete model. After assembling the parts, we are ready to add decals, lights and camera etc. to do the rendering of the American chopper using Solidworks visualization.

The parts or the components we created to make the American chopper are:

1. Chassis.
2. Engine with exhaust and air filter.
3. Front Wheel including Disc brakes and calipers.
4. Rear wheel including disc brakes, calipers and chain sprockets.
5. Front fender.
6. Rear fender.
7. Front fork including handle bar and headlights.
8. Gas tank.
9. Chain.
10. Transmission belt.
11. Kickstand and foot pedal.

Objectives:

• To learn the basics interface of solidworks.
• To Sketch the parts of American chopper using solidworks.
• To Assemble all the parts to make a complete model in solidworks.
• To know the application of photoview 360 and to add decals and to set camera and lights to get a realistic view of our model.
• To know the various features available in the Solidworks visualize and to render the model.

Design Approach:

There are two types of design approach we follow in designing.

• Bottom-up approach
• Top-down approach

Bottom-up approach: In the bottom-up approach, the most primitive operation is done first followed by the complex operations.

Top-down approach: The approach in which the design is started at highest possible level and the sublevels are followed by it.

Fig. 01: Design approach flow chart.

Features / tools used to sketch and design in solidworks:

We have,

• Extruded Boss/Base
• Revolved Boss/Base
• Swept Boss/Base
• Lofted Boss/Base
• Extruded Cut
• Revolved Cut
• Swept Cut
• Lofted Cut
• Fillet
• Chamfer
• Linear pattern
• Circular pattern
• Mirror
• Shell
• Combine and so on.

Fig. 02: Features Tab

a. Extruded Boss/Base:

With the fully defined sketch, we can extrude it by using the extruded base/boss feature to make it complete solid model or part. This feature contains option such as “From to Direction” to select the direction in which we want to extrude our part. “Dimension” column to get the required the length of our model.

Fig. 03: Extrude Boss/Base Interface

b. Revolved Boss/Base:

To get a cylindrical object, we use Revolved Boss/Base feature in our fully defined sketch. As in Extruded Boss/Base feature we got “Axis of Revolution” to give the axis or plane in which we wish our model to revolve. We also got the direction tab to give the direction for our model.

Fig. 04: Revolved Boss/Base

c. Extruded Cut:

If we want a hollow space in our model, we can do it by using the Extruded cut feature. This feature requires a proper fully defined sketch with closed entities. When we click on this feature, the property manager window will pop-up with an option similar to Extruded boss/base feature. It got “From and To” to give the feature from where it has to cut our model. And the direction in which it has to cut is given in the “Direction” section available.

Fig. 05: Extruded Cut feature while applying.

Fig. 06: Model after applying extruded cut.

d. Fillet:

Fillets are the most important and frequently used features as it has got many advantages. Once we made a solid part, it will have sharp corners and edges which we do not like to have. So, to make the sharp edges/corners to look smooth and have nice finish, we use this “Fillet” feature. The thickness of the fillet can be adjusted in the property manager window pop-up.

Fig. 07: Fillet feature while applying

Fig. 08: Model after applying fillet feature.

e. Linear Pattern:

Linear pattern is used make a copies/duplicates of the feature which we want in our model, in the linear direction. It is an easy feature which let us do same the process for n number of times, without adding any extra sketches.

Fig 09: Linear pattern is being applied.

Fig. 10: Model after linear pattern is applied.

f. Mirror:

Mirror feature is used to mirror/copy the object, features in our model. When the feature is applied the property manager window will pop-up asking you the axis or plane in which you want your feature or object to get mirrored or copied. You can also select multiple features.

Fig. 11: Mirror feature is being applied.

Fig. 12: Model after Mirror feature is applied.

g. Reference Geometry:

It is used to define a sketch or feature in an appropriate plane or axis. It is also used create a plane of our desired requirement to create a sketch on that plane and then get our model in desired position.

Fig. 13: Reference Geometry

h. Knit:

Knit is a feature which is used to bind/combine two or more faces and surfaces into a single body. It creates a closed body.

i. Mates:

Mates is the feature which you can see and use during the assembly of our parts into complete model. It creates a geometric relationship between two parts. When we apply mate, it defines linear or rotational motion to the parts to get it fixed at the right position with the other part. There are many mates which we can apply to the models, they are:

Coincident mate: Coincident mate allows us to make two planes into coplanar. When we apply this mate, the part cannot be removed separate from the plane.

Tangent mate: Tangent mate is used to place the part and the plane in a tangent relation.

Concentric mate: Concentric mate is used to make the circular faces to be concentric and allow them to move along the axis.

Angular mate: Angular mate is allowed to make the part to be fixed at a certain angle with the flat surface.

Parts and its Design Procedure:

1. Chassis:

Chassis is the main component of the chopper. Chassis is created by using the splines, lines and curves. Then it gets extruded by using the extruded boss/base feature. Then the appearance is added to the part. Features used to create the chassis model are:

• Sketch
• Splines
• Curves
• Extruded boss/base
• Mirror
• Fillet
• Chamfer
• Split
• Dome
• Revolve boss/base
• Combine

Fig. 14: Chassis

2. Engine with Exhaust and air filter:

Engine, the most important part of a bike is created by sketching it using appropriate features. Here we designed a two-cylinder engine with air filter in it. Features that are used in modelling the engine are:

• Sketch
• Line
• 3-point arc
• Circle
• Extruded Boss/Base
• Fillet
• Revolved Boss/Base
• Dome
• Circular pattern
• Chamfer
• Linear Pattern
• Mirror
• Curve
• Split
• Composite curve
• Combine

Fig. 15: Engine

3. Front Wheel including disc and caliper:

Front Wheel of our chopper model is designed by sketching many sketches on several planes. Rim is created first and then the spider-web design spokes are created following by the disc and the caliper. Finally, Tire is created following by the threads. Finally, appearances are added to each part based on our requirement. The features used to create the entire model are:

• Sketch
• Line
• 3-point arc
• Sketch fillet
• Revolve
• Spline
• Trim
• Extend
• Mirror
• Cut extrude
• Offset
• circle
• Revolve cut
• Circular pattern
• Fillet
• chamfer

Fig. 16: Front Wheel

4. Rear Wheel including disc, caliper and chain sprocket.

Rear Wheel is wider than the front Wheel. Hence the steps followed are similar to that of the front wheel but with different dimensions. Finally, appearance was added to each part based on our requirement. The features used to create the entire model are:

• Sketch
• Line
• 3-point arc
• Sketch fillet
• Revolve
• Spline
• Trim
• Extend
• Mirror
• Cut extrude
• Offset
• circle
• Revolve cut
• Circular pattern
• Fillet
• chamfer

Fig. 17: Rear Wheel

5. Front Fender:

Front Fender is created as a half curved solid body by using revolved sketch. Fillets are added to the edges. And finally, appearances are added. Features used to create the fender are:

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

Fig. 18: Front Fender

6. Rear Fender:

Rear fender also follows the same procedure as the front fender. Only difference between the two fenders are the size, because of their tyre size. Then the appearance is given to the rear fender as same as the front fender.

Features used to create the rear fender are:

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

Fig. 19: Rear Fender

7. Front fork including handle bar and headlights:

Front fork has many parts including suspension, handle bars, headlights, brake and clutch levers, brake and clutch cables. Initially one half of the model is created and then the entire model part is mirrored about the plane. Here, we use a new feature, Projected curve, very helpful feature used to create 3D curves. Then the appearances for each is part is applied. The features that are used to create the front fork are:

• Sketch
• Line
• Revolve
• Circle
• Fillets
• Linear pattern
• Spline
• Extruded cut
• Dome
• Curve
• Sweep
• Mirror
• Combine
• Plane
• Projected Curve

Fig. 20: Front Fork

8. Gas tank:

The Gas tank is made by creating the half part of it by using lot of splines and sweep feature. Then the other part is mirrored using mirror feature. Then the two parts are made into single part by using the knit feature. Features used to create the tank are:

• Sketch
• Spline
• Surface sweep
• Trim
• Surface boundary
• Surface loft
• Curve
• Mirror
• Knit
• Extruded Boss/Base
• Fillet
• Extruded cut
• Planes
• Shell

Fig. 21: Gas Tank

9. Oil Tank:

Oil tank is a small and easy part to design. And in here, we use a new feature called Shell, which is a very helpful feature in creating closed containers. When the design is done and the model is created, appearance is added to the oil tank. Features used in creating the oil tank are:

• Sketch
• Lines
• 3-point arc
• Boss-extrude
• Fillet
• Shell
• Combine

Fig. 22: Oil Tank

10. Chain:

The Chain contains a very long process to design a model. We have to create the link and its pair first. And then we have to add them into the blocks. Later, we can use the blocks to create the chain by making them tangent to the curve. This is followed for the entire chain model process. Once the chain model is created, then the appearance is given to the model.

Features used to create the chain are:

• Sketch
• Circle
• 3-point arc
• Slot
• Block
• Fillet
• Curve pattern
• Mirror

Fig. 23: Chain

11. Transmission belt:

Transmission belt is a part that is created by using the sketch and extrude feature. Once the model is created then the appearance is added to it.

Features used to create the transmission belt are:

• Sketch
• Line
• 3-point arc
• Extrude
• Offset
• Fillet

Fig. 24: Transmission belt

12. Kickstand and Foot pedal:

Kick stand is created by creating the ellipse on a plane and extruding it using loft feature and the end part is closed. Features used to create the kick stand are:

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

Fig. 25: Kick stand

Foot Pedal:

Foot pedal consists of various features to create. Features used to create the pedal are:

• Sketch
• Lines
• Circles
• Fillet
• Revolve
• Dome
• Chamfer
• Linear pattern

Fig. 26: Foot pedal

Assembly of the Chopper:

All the parts that are modelled using Solidworks, has been imported to assembly window in solidworks to assemble them. In assembly, mate is the feature which is most commonly used to locate and relate the parts with one another.

Chassis is acts as the main component which is inserted and then fixed, at first. The other components are brought in and then inserted one by one by using planes for reference and giving them proper definition using mate feature once the parts are placed, it floats with the main frame and then it is fixed. Some parts are modified during assembly to make it perfect according to requirement.

Decals:

A decal consists of a picture, image, pattern, or design that’s printed on a metal body. We have added decals on Gas tank, Rear fender and Oil tank of chopper. It gives nice appearance to the chopper.

Rendering:

Rendering is the term used to refer the artistic drawing, how it will look in the future or how the output will look like. Rendering of our American chopper model is done in the SOLIDWORK Visualize software. By using PHOTOVIEW 360, we can add various camera views to the model, we can set various angles, direction, and can set appropriate distance to get the perfect camera view. In SOLIDWORK Visualize software, we can change the color of chopper parts, background, brightness, rotation and various setting of chopper. By adjusting the resolution and setting number of passes we get more detail visuals of chopper. Rendering is done to check how our chopper model will look in the environment.