Photo Realistic Rendering

MODELING OF AMERICAN CHOPPER ON SOLIDWORKS

Introduction: 

In this project, we learn about the design of the American chopper assembly with the help of SOLIDWORKS. Firstly we learn commends and then we draw parts. By using a blueprint sketch, we get an idea about its dimensions and sketch the parts. After designing all the parts we do assembly of the chopper. After that, we add decals, light, camera, and do a rendering of chopper by using SOLIDWORKS visualization.

Components in chopper are:-

1. Chassis
2. Engine with the exhaust system.
3. Front-wheel and rear wheel with rims and sprocket calipers.
4. Front fork
5. Front and rear fender
6. Chain and transmission belt.
7. Kickstand and pedal
8. Oil tank

Objectives:

• To learn the basic command of SOLIDWORKS.
• With the help of a blueprint sketch, we design all the parts of the chopper.
• Assembling all the parts in SOLIDWORK.
• Get the knowledge of concepts like decals, light, and camera angle.
• Proper settings of image quality and getting realistic view with help of photoview 360.
• Rendering of America chopper has been done with help of Solidworks visualization software.

Design approach:-

There are two types of approaches in the design procedure.

1. Bottom-up approach
2. Top-down approach.

Here in this project, we have used the bottom-up approach, we get a clear idea by defining these terms.

• Bottom-up approach: It is the traditional method. Your first design and model parts, then insert them into an assembly and use mate to position the parts. To change the parts, you must edit them individually. These changes are then seen in the assembly.
• Top-down approach: One or more features of a part are defined by something in an assembly, Such as a layout sketch or the geometry of another part. The design intent comes from the top, which is the assembly and moves down to the parts.

 

Let's see what are the features and properties used in the entries model to design different parts:-

1. Extrude boss
2. Fillet
3. Revolve boss feature
4. Extrude cut
5. Shell
6. Linear pattern
7. Mirror
8. Reference geometry
9. Projected curve
10. Knit
11. Mate

Extrude boss:-

Once the Extrude menu appears on the lefthand side of your screen, It will prompt you to select a plane or sketch that will be used to create a 3D model. The Boss extrude/base feature will project a 3D model with the selected sketch or face.

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 loop.

Revolve boss feature:-

This feature works around an axis, by selecting the axis of a sketch it adds around material by revolving around that axis. If there is no axis we can select an edge of a  sketch and it gives us appropriate geometry.

Extrude cut:-

The extruded cut feature removes material from the part. The end condition, Draft, and thin feature options are the same as described in extrude boss/base. To create an extrude cut:

1. Sketch the profile for a cut.
2. Click Extrude cut on the features toolbar or select insert, Cut, extrude on the menu bar.

Shell:-

The shell definition property manager is used to define the thickness of thin and thick shell elements. You can also define a shell as a composite for static, frequency, and buckling studies.

Linear pattern:-

Use linear patterns to create multiple instances of one or more features that you can space uniformly along one or two liner paths. To create a linear pattern:  Create one or more features to replicate.

Mirror:-

The mirror is another way that solid works can create a copy of an existing object. Additionally, you must choose a pane to mirror parts. In most cases, you will have to create your own plan to have the mirror done the way you need.

Reference geometry:-

Reference geometry defines the shape or form of a surface or a solid. Reference geometry includes items such as planes, axes, coordinate systems, and points. You can use reference geometry in the creation of several kinds of features.

Use of reference geometry example:

• Axis: If we want to pattern something and the axis is not available by using a reference geometry axis it gets easier to make a pattern.
• Plane: If we need o sketch and there is a need for the plane by using a reference geometry plane we can draw it and complete the sketch.

Projected curve:-

The curve can be projected by a sketch into a model to create a 3D curve. We can create multiply closed or open contour projected curves from a single sketch. Generally, the curve can be the intersection of two extruding surfaces. The curve which is created can be used as a path for the sketch of the part.

Note: It does not create curves for intersecting curves.

Knit:-

Use of knit surface tool to combine two or more faces and surfaces into one. It creates a solid body when the knit surfaces from a closed volume or leaves as a surface body.

Mate:-

Mate creates a 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 behavior.

This feature includes:-

• Coincident mate: Coincident mate makes two planar faces to become coplanar. This mate can move along with one another but cannot be separate.
• Concentric mate: This feature can be used between a face and plane to make a tangent mate.
• Angular mate: This makes angular relation between flat surface having some angle.

Now we have completed the discussion of how the feature work under solid works. Let us see the application of the features in the chopper that we have built. We are going to discuss part by part as shown in the flowchart.

Transmission Belt:- Transmission belt is located at the round surface of the pulleys to transmit the power. Sketch, Extrude, offset, fillet tools are used. The commonly used material for this is rubber. It is a solid body in which transmission belts are filleted and the appearance given is matte rubber.

Features used to create the transmission belt:

• Sketch
• Extrude
• Offset
• Filler
• Appearance

Kickstand:- First we have created a sketch. And added an additional plane. The loft feature is used here to create the part and the dome has been applied on both sides of the kickstand. the flat surface has been created by using the sketch and a split tool is used. We have used extrude cut for assembly purposes. After the part has been created we applied fillet to the edges. Chrome material is applied to the kickstand.

Features used to create the kickstand:

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

Front Fender:- Here we revolved feature to create the shape of the part. The sketch used an axis and created half curved solid body. Some sharp edges were designed on both sides. The split tool is used to remove the material. The edges of the fender are filleted.

The feature used to create the Front fender:

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

Rear Fender:-The method used to create a rear fender is the same as the front fender. The main difference is the dimensions are changed, it's because of the size of the tire. The front and rear fender are made of metal and the appearance given is sienna color which is a bright orange texture.

The feature used to create the Rear fender:

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

Oil Tank:- The base of the oil tank is sketched on the top plane and extruded above to attain the structure of the oil tank and another sketch is added on the midplane it is then extruded and then combined together and at the end, a shell function is used to make part hollow from inside. Fillet is applied on the outer edges to make it round. The appearance is given to the white paint.

Features used to create the Oil tank:

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

Chain link:- First we need to draw the sketch using arcs and lines, Check the lines are tangent to the arc. Then we draw the sketch of blocks and pins and extrude it, then the pins and blocks were patterned along the path and by calculating the number of pins and blocks. When the whole front side of blocks can be a mirror to the midplane and both side of the blocks has been created. This arrangement has been made according to the sketch. Finely finished chrome metal is used as the appearance of the linked chain.

The feature used to create the Chain:

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

Pedal:- A pedal is a strong rigid body and used to rest the foot while riding a bike. The various features are used to create the pedal are splines, fillet, 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

Front Wheel:- Front-wheel is having a larger diameter than the rear wheel. To manage impact better than the rear. Front-wheel experiences the greatest force during braking. The rim was created by revolve boss feature and the spider-webbed spokes were created by using splines and offsetting tools. Then the spider-webbed spokes were patterned to the rim. On rim rotor and caliper were modeled. The tire was created using revolve and threads were applied. The appearance given to the tire is matte rubber and rotor and spokes are chrome metal and caliper is sienna color.

Features used to create the Front wheel:

• Sketch
• Lines
• 3point arc
• Sketch fillet
• Revolve
• Spline
• Extend
• Trim
• Cut extrude
• Offset
• Revolve cut
• Circular pattern
• Chamfer
• Fillet

Rear Wheel:- The rear tire is primarily used for accelerating the vehicle and moving it forward. It gives stability to the vehicle. The steps are the same as the front wheel and the appearance given is also the same only the component added here sprocket to link the chain.

Features used to create the Rear wheel:

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

Front Fork:- Front fork attaches the whole chassis and the front wheel. It is typically made with triple clamps. It is also used to give suspension to the whole bike and the front wheel includes parts front fork, handlebars, headlights, brake, and clutch levers. The handlebar and cables are sketched using a projected curve tool. First, the half portion of the front fork creating. And the second half portion is mirrored. The handles of the front fork were given grips.

Features used to create the Front fork:

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

Chassis:- The chassis is the main part of the chopper. It holds all the components such as the front fork, pedals, kickstand, oil tank, engine, gas tank, and rear wheel. It supports all the components and supports the bike. Using chopper image for reference for modeling of chassis. Features such as an extruded boss, splines, and revolving parts, making mirrors and sweeps. Fillet tool used to remove the sharp edges. The appearance given to the chassis is sienna color.

Features used to create the Chassis:

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

 

Engine:- Engine is the main part of the bike. It is also called the heart of the bike. It provides the necessary power to drive the bike. Chopper sketch is used as a reference to the modeling. The engine consists of parts like a crankshaft, transmission pulleys, and motor. In the upper part of the crankshaft, 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. The edges of the engine were filleted and the appearance given is chrome metal.

Features used to create the Engine:

• Sketch
• Blueprint sketch
• Lines
• Circles
• Boss extrude
• Fillet
• Revolve
• Dome
• Circular pattern
• Chamfer
• Linear pattern
• Mirror
• Cut extrude
• Combine
• Mirror
• Curve
• Composite curve
• Split

 

Gas Tank:- This part is mainly made with splines and sweep features. The half part of the gas tank is first created and then it is then mirrored about the plane. The two separated parts were made single part by using the knit feature. The gas tank covers the oil tank and engine, and also it acts as a shield to prevent the heat from the engine. The seat was modeled on the top of the gas tank. The fillets were added to the edges of the gas tank. The last shell feature was added to make it hollow from the inside.

Features used to create the Gas tank:

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

 

Assembly of the Chopper:- All the parts were modeled and were imported to assemble them. In assembly, the mating feature is most commonly used to locate and relate the parts with one another. Chassis is the main component that is inserted first and then fixed. The other components were inserted one by one and by using planes for reference and giving the mating feature once the part gets fixed it floats with the mainframe. Some parts were modified during assembly to make it perfect according to requirements.

Decals:- A decal is something called a “transfer”, and it consists of a picture, image, pattern, or design that’s printed on a metal body. We have added decals on the Gas tank, Rear fender, and Oil tank of the chopper. It gives a nice appearance to the chopper.

Rendering:- The term rendering comes from the graphic world where a rendering is an artistic drawing of what a new structure would look like. In Computer-Aided Design (CAD), a rendering is a particular view of a realistic image. By doing a rendering of the chopper we get the idea that how it will look into the environment. This rendering is done in the SOLIDWORKS Visualize software. By using PHOTOVIEW 360  we can add various camera views to the model, we can set various angles, directions, and can set appropriate distances to get the perfect camera view. In rendering, we change the color of chopper parts, background images, brightness, rotation, and various setting of the chopper. Including the resolution and a set number of passes, we get more detailed visuals of the chopper.