Photo Realistic Rendering of American chopper

REPORT ON MODELLING OF AMERICAN CHOPPER USING SOLIDWORKS

Objective

• To design the parts of American chopper and assemble them using SOLIDWORK software.
• To add decals, lights, camera and do rendering of the chopper by using SOLIDWORK visualization.
• To set proper image quality and getting realistic view with the help of photoview 360.

Introduction

In this project we learned about the design and assembly of the American chopper using SOLIDWORKS. First, we learnt to use the commands used to sketch and then we draw the parts of the chopper. With the help of blueprint sketch, it became easy to sketch the parts with proper dimensions. After every part is completed, we did the assembly of the chopper. After this we added decals, lights, camera and did the rendering of chopper using SOLIDWORK visualization.

The following components which were designed are

1. Chassis
2. Engine with exhaust system.
3. Front wheel and rear wheel with rims, sprocket and calipers.
4. Front Fork
5. Front and rear fender
6. Oil tank
7. Chain and transmission belt
8. Kickstand and foot pedal
9. Gas tank

Design approach: There are two types of approach in design procedure. 1. Bottom-up approach and 2. Top-down approach. Here in this project, we have used Bottom-up approach, we get a clear idea by defining these terms.

• Bottom-up approach: The design approach in which the most primary operations are specified first then combined it later to make larger progressive unit.

• Top-down approach: Top-down assembly modelling is an assembly-centric modelling method where the assembly design is started at the highest level possible, and individual parts and subassemblies are defined within the context of the overall assembly.

Let’s see what are the features and properties used in the entire model to design different parts:

• Extrude boss
• Fillet
• Revolve boss feature
• Extrude cut
• Shell
• Linear pattern
• Mirror
• Reference geometry
• Projected curve
• Knit
• Mate

Extrude Boss

The most basic feature from SOLIDWORKS is extrude boss. This feature needs a complete 2D sketch to convert 2D sketch into a solid body. When we exit the fully defined sketch we get boss 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 dimensions to it. It creates a complete solid body of any shape with closed entities. In this feature we can add dimensions to both the direction (direction 1 and direction 2) according to our need. We can use the direction if it is blind, midplane, from the vertex, etc. This is how we use this feature.

Fillet

When we draw a solid part, it is having some sharp edges. To give the roundness to those edges we add 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 conditions whether edges are internal or external. Fillets are used to solid bodies to hide the corners and edges and also it gives nice appearance to the part. Various types of fillets are used according to the given condition or it depends upon the part.

Revolve boss feature

This feature works around an axis, by selecting axis of a sketch it adds a round 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:

As the name implies, it cuts the geometry which we don’t need from the part or it can be used to give the desired shape to the sketch or solid part. When we draw sketch on the solid part and then we use extrude cut command it removes that part/surface.

Shell

It is very handy tool in SOLIDWORKS. It gives some sort of idea that how inside geometry of a part will appear. In this tool we give inside thickness to the geometry and material removed from the body and it becomes hollow.

Linear pattern

Linear pattern is used to create single sketch to use multiple times. The spacing, angles and path can be given in this feature to draw or create pattern. This feature spaced uniformly along one or two linear paths.

Projected curve

The curve can be project 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 intersection of two extruding surfaces. The curve which is created can be use as a path for the sketch of the part. Note: It do not create curve of an 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 form a closed volume or leave as a surface body.

Mate

Mate creates 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 make two planar faces to become coplanar. This mate can move along one another but cannot be separated.
• Concentric mate: This makes two circular faces to become concentric and can move along the common axis.
• Tangent: This feature can be use between a face and plane to make tangent mate.
• Angular mate: This makes angular relation between flat surface and the surface having some angle.

Now we have discussed how the features work under SOLIDWORKS. 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 with help of pulleys. The commonly used material for this is rubber. It is a solid body in which transmission belt are filleted and the appearance given is matte rubber.

Features used to create the transmission belt:

• Sketch
• Extrude
• Offset
• Fillet
• Appearance

Kickstand

While designing kickstand first we have created sketch based on an additional plane, the part created by using loft feature and dome has been applied on the both sides of kickstand. Then at the bottom part to rest the kickstand, the flat surface has created by using sketch. We have used extruded cut for an assembly purpose. After the part has been created, we applied fillets to the edges and at the joints of the part. Chrome material is applied to the kickstand.

Features used to create the kickstand:

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

Front Fender

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

Features used to create the Front fender:

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

Rear Fender

Same procedure is used to make rear fender as it was used in front fender. Only the difference between the two are sizes as according to the size of the tire. The front and rear fender are made of metal and appearance given is sienna color which is bright orange texture.

Features 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 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 given to the oil tank is sienna color and the edges filleted are given white paint.

Features used to create the Oil tank:

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

Chain Link

To create chain first we need to draw the sketch using arcs and lines, the line must be tangent to the arc. Then we draw the sketch of blocks and pins and extrude it, then the pins and blocks were pattern along the path and by calculating the number of pins and blocks. When the whole front side chain pattern created. Then front side of blocks can be mirror to the midplane and both side of the blocks has been created. This arrangement has been made according to the sketch. A fine finished chrome metal is used as the appearance of the linked chain.

Features used to create the Chain:

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

Pedal

A pedal is a strong rigid body and used to rest the foot while riding bike. The various features are used to create the pedal are splines, fillets, 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 larger diameter than the rear wheel. To manage impact better than the rear. Front wheel experiences greatest force during braking. First, the rim was created by revolve boss feature and the spider webbed spokes were created by using splines and offsetting them. Then the spider webbed spokes were pattern to the rim. On rim rotor and caliper were modelled. The tire was modelled 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
• 3-point 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 move it forward. It is wider than the front wheel. It gives stability to the vehicle. The steps were followed same like front wheel and appearance given is also 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 front wheel includes parts front fork, handle bars, head lights, break and clutch levers. First the half portion 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 to create the Front fork:

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

Chassis

The chassis is the main frame of the chopper. It holds all the components such as front fork, pedals, kickstand, oil tank, engine, gas tank and rear wheel. It supports all the components and supports to the bike. The modelling of chassis starts with using chopper image for reference. It uses features such as extruded boss, splines, and revolving parts, making mirror and sweep. At the end whole part created by using fillet and it gives nice appearance to the chassis and the sharp edges gets round. The appearance given to the chassis is sienna color i.e. bright orange color.

Features used to create the Chassis:

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

Engine

The main part of the bike is engine. It is also called as heart of the bike. It provides necessary power to drive the bike. A picture is taken for the reference for modelling. The engine consists of parts like crank shaft, transmission pulleys and motor. The upper part of crank shaft 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 feature. The half part of the gas tank 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 shield to prevent the heat from the engine. The seat was modelled 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 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 modelled 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 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 mate feature once the part gets fixed it floats with the main frame. Some parts were modified during assembly to make it perfect according to requirement.

Decals

A decal is something called a “transfer”, and it consists of a picture, image, pattern, or design that’s printed on metal body. We have added decals on Gas tank, Rear fender and Oil tank of chopper. It gives 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 rendering of chopper, we get the idea that how it will look into the environment. This rendering 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 rendering we change color of chopper parts, background images, brightness, rotation and various setting of chopper. Including the resolution and setting number of passes we get more detail visuals of chopper.

Conclusion

Hence, we learnt to design, assemble and render the chopper using SOLIDWORK. We also used several types of tools, decals, lights and camera throughout the project.