Challenge

Photo Realistic Rendering

KKrishna Kumar21 Nov 2021

DESIGN OF AMERICAN CHOPPER BIKE

INTRODUCTION

In this project, we learn about the design of American chopper assembly with help of Solidworks. In this, we first learn to use the command and then we drew parts. by using a blueprint sketch. we get an idea of sketching the parts and its dimension. after designing all the parts we do assembly of the chopper. after assembly, we add decals, light, camera and do a rendering of chopper by using Solidworks Visualization.

The following chopper components are,

Transmission belt
Kickstand
Front fender
Rear fender
Chainlink
Oil tank
Foot pedal
Front-wheel
Rear-wheel
Front fork
Chassis
Engine
Gas tank

OBJECTIVE

To learn the basic commands of solid work.
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 setting of image quality and getting realistic view with the help of photo view 360.
Rendering of American chopper has been done with help of SolidWorks visualization software.

DESIGN APPROACH

There are two types,1. Bottom-up approach 2. Top-down approach. here in this project, we have to use a bottom-up approach.

Bottom down approach: The design approach in which the most primary operation is specified first then combined later to make a larger progressive unit.

DESIGN METHODOLOGY

COMMANDS USED

SKETCH COMMANDS

Smart dimension- Create a dimension of one or more selected entities
Line- Line is one of the first sketching tools in SolidWorks sketch command manager which can be drawn horizontally, vertically or at any angle. it plays a very important role to complete a 2D drawing of the product or part and is very easy to utilize its features.
circle- The circle is another important sketching tool that enables to creation of the circular drawing on the graphics area. there are two circle tools are available and they are the center circle and perimeter circle.
rectangle- sketches rectangles or squares with a center point at a selected angle. parallelogram sketches a standard parallelogram.
spline- A two or three-dimensional defined by a set control point. points with a spline can be added or deleted.
ellipse- sketches a complete ellipse.
tangent arc- An incomplete circle defined by its tangency to the sketch entity.
sketch fillet- A tangent arc in between two sketch entities can be created.
point- Insert a point or vertex into a sketch entity. this cannot be deleted if it is part of the sketch endpoint or center point.
sketch picture - Insert an image file into the background of a sketch. this allows the user to do 2D sketches based on the image uses the sketch picture property manager to alter the inserted image.
offset entities- Copy a sketch entity to a specified distance from the original entity.must have a sketch entity already drawn and selected to use this tool.
mirror entities-Created reflected copy of the desired entity about a centerline or axis.
move entities-Move the component within the degrees of freedom.
linear sketch pattern- pattern a sketch entity horizontally, vertically, or angled.under the property manager the user can specifythe distance between the original sketch entity and the patterned copy, the number of instances, and the angle at the pattern will appear. sketch entities can be skipped by selecting the drop-down arrow in instances to skip, selecting the text box, and then left-clicking the patterned entities to skip.
convert entities- solid Model edges entity to convert to 2D sketch entity.
trim- sketch entities can be trimmed shorter using the trim entities tool.
extend- you can add on the length of a sketch entity. extend entities to extend a sketch entity to meet another sketch entity.
intersection curve
sketch contours

FEATURE COMMANDS

Extrude boss- The most basic feature from Solidworks is extrude boss. this feature needs to complete.2D sketch to convert 2D sketch into a solid body. whenwe exit the fully defined sketch we get boss to extrude option and a property manager window pop up. into the property manager, we see from where the feature begins and where it will end that we need to add dimension to it. it creates a completely solid body of any shape with closed entities. in this feature, we can add dimension to both direction. according to our need. we can use the direction if it is blind, midplane, from the vertex, this is how to use this direction.
Fillet- When we drew a solid part it is having some sharp edges. to give the roundness to those edges we and fillets. it makes the sharp edges or corners round shape of having different sizes or radius.the material can be added or removed according to the conditions whether edges are internal and external. fillet is used to solid bodies to hide the corners and edges and also gives a nice appearance to the part. various types of fillets are used according to the given condition.
Revolve boss base- this feature work 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 the edges of a sketch and it gives us appropriate geometry.
Extrude cut- As the name implies, it cuts the geometry which we don't need from the part of it can be used to give the desired shape to the sketch on the solid part and we use extrude cut command it removes that part/surface.
Shell- It is a very handy tool in Solidworks. it gives some sort of idea that how the inside geometry of a part will appear. in this tool we give inside thickness to the geometry and material from the body and it becomes hollow.
Linear pattern- The linear pattern is used to create a single sketch to use multiple times. the spacing, angles and path can be given in this feature to drew or create pattern. this feature spaced uniformly along or two linear paths.
Mirror- this feature creates a copy of the solid part. when this feature is applied it needs a plane or axis to, mirror. select the body which is to be mirror, select an axis or plane then apply feature and the mirrored part will get. multibody parts: apply the feature to one or more multibody parts by selecting geometry patterns and using feature scope to choose which bodies should include the feature.
Reference geometry- It defines the shape or form of a surface or a solid.this includes feature such as planes, axes, coordinate system, and points. this can be used according to need in a sketch.
Projected curve- The curve can be projected by a sketch into a model to create a 3D curve. we can create multiple closed or open contour projected curves from a single sketch. generally, the curve can be an intersection of two extruding surfaces. the curve which is created can be used as a path for the sketch of the part.
Knit- Use of knit surface tool to combine two or more faces and surfaces into one. it create a solid body when the knit surfaces form a closed volume or leave 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 degreeof freedom, visualizing the assembly behavior.

This feature includes:-

Coincident mate- coincident mate makes two planner faces to become coplanar. this mate can move along with one another but be separated.
Concentric mate- This makes two circular faces become concentric and can move along the common axis.
Tangent - 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.

COMPONENTS OF AMERICAN CHOPPER

1. TRANSMISSION BELT

A transmission belt is used to transmit power from one end to another end of pulleys. Its located from the power output pulley to the gear drive pulley. the commonly used material for this is rubber. and the appearance given is matte rubber.

Using line and arc constraints making a sketch with given dimensions offset, and offset the sketch with offset entities after making a extrude using boss extrude. after making extrude create 1mm fillet edges of transmission belt.

Features used

sketch
Extrude
offset
fillet
appearance

2. KICKSTAND

The kickstand is a supporting mechanism and is used to prop up the vehicle when it is not in use.

while designing the kickstand first we have created a sketch based on an additional plane. the part was created by using a loft feature and dome has been applied on both sides of kickstand. the surface has created by using the sketch. and used extrude cut for an assembly purpose. after applying fillets to the edges. after chrome material is applied to the kickstand.

Features used

sketch
Ellipse
splines
loft
pierce
cut extrude
boss extrude
split

3. FRONT FENDER

A guard over the wheel of a chopper vehicle. it is used shaped and positioned so as to block the splashing of water or mud. Also, it's used on the front&back wheels of the vehicle.

Here we revolved the sketch using an axis and created half curved solid body. some sharp edges are designed on both sides of the fender by using the split tool the material is removed. the edges of the fender are filleted.

Features used

sketch
Extend
offset
3-point arc
revolve
trim
spline
fillet

4. REAR FENDER

A guard over the wheel of a chopper vehicle. it is used shaped and positioned so as to block the splashing of water or mud. Also, it's used on the front&back wheels of the vehicle.

the same procedure is used to make the rear fender as it was used in the front fender. only the difference between the two is the sizes according to the size of the tire. the fender made of metal and the appearance given is sienna color.

Features used

sketch
Extend
offset
3-point arc
revolve
trim
spline
fillet
shell

5. OIL TANK

The oil tank is used to store cooling and lubricating oil which flow over the moving parts, reducing friction and heat generated.

In an oil tank start with top plane making line and make a tangent arc coincident with construction line make a straight line coincident with sketching point to get a fully defined sketch and make a dynamic mirror after that make a extrude. then make a line with midplane to make an oil tank and extrude after that make combine both shapes to obtain an oil tank make a fillet with all edges. after, applying the shell feature command get the hollow tank made.

Features used

3-Point arc
line
boss extrude
combine
fillet
shell

6. CHAINLINK

chain is used to transmit power from the engine to sprocket at rear wheel for an acceleration of the vehicle.

started with a two circle which located as construction line reference after that drew a 3 point curve which is tangent with two circles with specific radius then trim additional liner after that create a chain pin block. by using that block to make coincident and concentric relation which the chain block make path with the curve which is drawn.after fixing block with extrude the pin and chain plate at offset then make a curve driven pattern by curve as a reference by following the same procedure to create a complete chain model. chrome metal is used as the appearance of the linked chain.

Features used

sketch
circle
3-point arc
block
slot
fillet
curve pattern
mirror

7. PEDAL

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

Making a fully defined sketch filled with lots of relation and sketch ended with the fully defined sketch as like to get an exact dimension a pedal. the extrude a fixing pin using a contour selection make pedal frame same as that after that make a revolving of leg rest from the same sketch to get a rest to finish making a fillet and chamfer at end of the rest and make a dome an end. finally, a pattern in leg support at a pedal is extruded by using linear pattern command.

Features used

sketch
circle
lines
fillet
revolve
dome
chamfer
linear pattern

8. FRONT WHEEL

The wheel is used as a locomotive component of every vehicle. the wheel is generally rotated based on the axis fixed with the vehicle. it's built with hard rim cover with a nylon tire. It also include sprockets, caliper, rotor, tire.

first, the rim was created by revolve feature and the spider-webbed spokes were created by using splines and offsetting them. then the spider-webbed spokes were modeled spokes were a pattern to the rim. on rim rotor and caliper were modeled. the tire was modeled 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

sketch
lines
3-point arc
revolve
sketch fillet
spline
extend
trim
cut extrude
offset
revolve cut
circular pattern
fillet
chamfer

9. REAR WHEEL

The output power of the gearbox is transmitted to the rear wheel. it holds the entire part of the chopper and it provides the movement of the vehicle.

its primarily used for accelerating the vehicle and moving it forward. it is wider than the front wheel. it gives stability to the vehicle. the steps were followed same like front wheel and the appearance given is also the same only the component added here sprocket to link the chain.

Features used

sketch
3-point arc
lines
sketch fillet
spline
revolve
trim
extrude cut
extend
revolve cut
offset
circular pattern
fillet
chamfer

10. FRONT FORK

The 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. first, the half position of the front fork has been created and the whole body is mirrored about the plane. projected curves were used to model the handles and the cables. the handles of the front fork were given grips.

Features used

sketch
lines
circle
revolve
fillets
linear pattern
spline
dome
extrude cut
sweep
curve

11. CHASSIS

Chassis is a skeleton of the bike which is a mainframe that is used to hold everything like the engine, gas tank, pedal, and every part. its s support all the components and support to the bike. the modeling of the chassis starts with using a chopper image for reference. it uses features such as extrude boss, spline and revolving parts, making mirror and sweep. at the end whole part was created by using a fillet and it gives a nice appearance to the chassis and the sharp edges get round. the appearance is given to the chassis sienna.

Features used

Blueprint sketch
sketch
splines
mirror
curves
boss extrude
extrude cut
chamfer
dome
split
combine
revolve

12. ENGINE

The engine is the powerhouse of the chopper. it device is used to convert chemical energy into mechanical energy and provides power for the movement of vehicles.

The main part of the bike is engine. it also called as heart of the bike. it provides the necessary power to drive the bike.a picture is taken for reference for modeling. the engine consists of parts like crankshaft, transmission pulleys, and motor. the upper part of crankshaft the cooling fins were located. the air filters were drawn using spline and projected curves and sweep feature. the edges of the engine were filleted and the appearance given is chrome metal.

Features used

sketch
Blueprint sketch
circle
lines
boss extrude
fillet
revolve
dome
circular pater
chamfer
linear pattern
mirror
combine
cut extrude
curve
split
composite curve

13. GAS TANK

The gas tank is used to store the fuel which is needed for making a powerful engine in the combustion process.

This part is mainly made with spline 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 knit feature. the gas tank covers the oil tank and engine and also it acts 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. at the last shell feature were added to make it hollow from inside.

Features used

Blueprint sketch
sketch
surface sweep
spline
surface loft
surface trim
curve
mirror
surface extrude
surface boundary
surface knit
fillet
shell
extrude cut

ASSEMBLY OF THE CHOPPER

All the parts were modeled and were imported to assemble them. In assembly mate feature is most commonly used to locate and relate the parts with one another. chassis is the main component which is inserted first and then fixed. the other components were inserted one by one and by using planes for reference and giving the mainframe. some parts were modified during assembly to make it perfect according to requirements.

FEATURES USED

MATE

Advanced mate
mechanical mate

Constraints

concentric
coincident with planes
tangent with planes
parallel
perpendicular

DECALS

A decal is something called a transfer and it consists of a picture, image, pattern or design that's printed o 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

In computer-aided design (CAD), a rendering is a particular view of a realistic image. by doing a rendering of chopper we get the idea that hoe it will look into the environment. this rendering is done with Solidworks visualize software. and, by using PHOTO VIEW 360 we can add various angles, directions, and can set appropriate distances to get the perfect camera view. in rendering we change color of chopper parts, background images, brightness, rotation, and various setting of the chopper. including the resolution and set number of passes we get more detailed visuals of the chopper.

1. PHOTO VIEW 360 IMAGE