Photo Realistic Rendering

REPORT ON ASSEMBLY OF AMERCAN CHOPPER:

Design of american chopper using Solidworks:

Objective

The objective of the project is to model an american chopper using a CAD software and to render it to create photo realistic view of it.

Introduction

The project explains the designing of American chopper using the CAD software Solidworks from sketching of the parts and modelling them to final rendering of the assembly to give photo realisitic views.

Design Methodology

• Part sketching
• Part modelling
• Assembly
• Rendering

Flowchart:

Part sketching:

All the parts mentioned are sketched as required using the tools in Sketch tab like circle, spline, lines, etc,.

Part modelling:

The sketched 2D parts are converted into 3D parts using features in the features tab like extrude, extrude cut, loft, etc,.

Features used

Boss extrude: This feature is used to expand the object in 3D according to sketch plane.

Extrude cut: Extrude cut is used to cut/remove the 3D object in linear path according to sketch.

Fillet: Fillet is a feature used for making round internal or external edges to avoid sharp edges and make it smooth. This is preferred as it reduces the stress concentration at corners.

Lofted Boss/Base: Lofted boss is a feature used to achieve complex shapes. It does this by interpolating surfaces between various cross-sections of a model. These cross-sections can be sketches, faces, or edges.

Split: Split tool is used to split single solid part into two solid parts. It is used to project an entity onto other surfaces or curved/ planar faces.

Dome: Dome is a feature used to make dome shaped extrude including elliptical dome.

Shell: Shell feature is used to make the solid bodies into hollow parts by selecting outer wall of the solid part and so removes the inner parts. It is also used to reduce the specific thickness.

Combine: Combine tool is used to make integration of two solid parts which intersect each other as same solid part.

Chamfer: Chamfer is used to make a sharp edge or corner slighlt tapered rather than being a perfect square.

Linear pattern: The linear pattern is used to create a different number of instances required to create the pattern linearly.

Curve driven pattern: Curve driven pattern is used to make different number of instances of the modelled part along a sketched curve.

Circular pattern: Circular pattern is used to make 3D feature into circular pattern according to the number of instances.

Revolve boss base: Revolve feature is used to make cylindrical or circular 3D extrude along with a given reference axis as per drawn sketch.

Revolve cut: Revolve cut is used to cut or reduce the extrude of cylindrical round surface.

Move/Copy body: This feature is used to move/copy the 3D body from one place to another place.

Mirror: Mirror is used to mirror a feature or body by reference of the selected plane.

Sweep: This feature is used to sweep any kind of fully detailed sketch along with the plane.

Sweep cut: It is same as sweep but it cuts/removes the body along a sweep path.

Swept surface: It is used to make a surface along with a path which drives the sketch.

Boundary surface: Boundary surface is used to make a surface in between two finished surfaces.

Loft surface: Loft surface is used to make loft in between two profiles along with a guided path.

Knit surface: Knit surface is used to knit the two free edges or open edges of the surfaces together also it reduces the gap between the two edges of the surfaces.

Surface trim: Primarily used to cut away material from a surface.

Projection curve: Projection curve is a 3D curve which is projected on the basis of the two different 2D curves in two different planes.

Trim entities: It is used to trim the unwanted lines or extended entities in the sketch.

Appearances: Appearances define visual properties of the model including colour and texture. Appearances do not effect physical properties which are defined by materials.

Assembly

Assembly is most often referred as putting components together in an assembly line, but more specifically, it refers to creating a complete product that performs an intended function. Changes in the component are automatically reflected in the assembly i.e., the rebuild option will automatically take place or else it will ask the user to rebuild the assembly.

Rendering

Rendering or image synthesis is the automatic process of generating a photo realistic image from a 2D or 3D model using a computer program. The resulting image is referred to as the rendered image.

Components Designed

• Chassis
• Engine
• Front fork
• Front wheel
• Front fender
• Rear wheel
• Rear fender
• Gas tank
• Oil tank
• Chain
• Pedal
• Transmission belt
• Kick stand

Description

Chassis:

Features used:

• Offset Entities
• Convert entities
• Project curve
• Trim entities
• Sweep boss
• Split
• Revolve cut
• Extrude boss
• Fillet
• Combine
• Appearance

The chassis is the part that takes most of the load on the bike. Splines, sweep project curve are used to model the chassis.

Engine:

Features used:

• Trim entities
• Revolve boss
• Extrude cut
• Offset entities
• Dome
• Fillet
• Projected curve
• Composite curve
• Sweep boss
• Mirror
• Circular pattern
• Split
• Appearance

The engine incorporates the cooling fins, spark plug representation, intake and exhaust manifolds, transmission unit with transmission belt, and pulleys.

Front Fork:

Features used:

• Extrude boss
• Trim entities
• Revolve boss
• Split
• Copy/Move bodies
• Dome
• Mirror
• Combine
• Projected curve
• Sweep boss
• Appearance

It is the modelled using the revolve feature mainly and the headlights are also fused into the front fork.

Front wheel:

Features used:

• Revolve boss
• Trim entities
• Fillet
• Extrude boss
• Revolve cut
• Linear pattern
• Chamfer
• Cut extrude
• Circular pattern
• Appearance

The front wheel is thinner than the rear wheel. It is designed to be multibody part to consisting of the rotor, tyre, rim, sprocket, calliper.

Front fender:

Features used:

• Offset entities
• Trim entities
• Revolve boss
• Split
• Appearances

The front fender for the front wheel is designed by revolving the cross section and removing materials from the end to give it shape.

Rear wheel:

Features used:

• Revolve boss
• Trim entities
• Fillet
• Extrude boss
• Revolve cut
• Linear pattern
• Chamfer
• Extrude cut
• Circular pattern
• Appearance

The rear wheel is designed similar to the front wheel but is a bit wider than the front wheel. It is also designed as a multi-body part.

Rear fender:

Features used:

• Offset entities
• Trim entities
• Revolve boss
• Appearances

The rear fender is also modelled similar to front fender by revolving a sketched cross section.

Gas tank:

Features used:

• Projected curve
• Trim entities
• Sweep boss
• Loft surface
• Knit surface
• Sweep cut
• Fillet
• Appearance

The fuel tank is designed as per the info sketch. It is hollowed out to make a tank for the fuel inside. The mostly applied features include extrude surface, boundary surface, shell, and knit surface.

Oil tank:

Features used:

• Boss extrude
• Combine
• Fillet
• Shell
• Appearance

The oil tank is placed above the engine block which is also made hollow inside. Extrude and shell are the major features used in this part.

Chain:

Features used:

• Trim entities
• Fillet
• Blocks
• Extrude boss
• Linear patterns
• Appearances

The chain was more complex to model. The inner plate, outer plate, pins were modelled and then curve driven pattern was used to replicate the parts for the whole chain along the sketched path for the chain. It is necessary to keep all the parts as individual body as they need to rotate around the path which will not be possible if the whole chain is modelled as a single body.

Pedal:

Features used:

• Extrude boss
• Fillet
• Linear pattern
• Dome
• Chamfer
• Appearance

There are two pedals one on each side. One pedal was sketched and modelled using extrude and revolve features while the other was replicated using the in-context mirror feature in assembly.

Transmission belt:

Feartures used:

• Extrude boss
• Fillet
• Offset entities
• Appearances

This transmission belt is designed to adapt to the two pulleys modelled on one side of the engine block.

Kick stand:

Features used:

• Loft boss
• Extrude boss
• Extrude cut
• Dome
• Fillets
• Split
• Appearance

The sketch for the model was created and then using the sweep feature the extrude was done. At one end it is kept opened to mate it with the chassis.

ASSEMBLED AMERICAN CHOPPER:

Assembly is most often referred to putting components together in an assembly line, but more specifically, it refers to creating a complete product that performs an intended function. Changes in the component are automatically reflected in the assembly or the user is asked to rebuild the document.

The American chopper is an assembled using the feature called mates. Each and every part is mated with the other or the base part with specific relation. Some reations used are,

• Concentric
• coincident
• parallel
• Tangent
• Width
• Angle

Final renders of American chopper created using PhotoView360:

Below are some final rendered images of the above modelled American chopper using Solidworks PhotoView360.

Conclusion:

Thus, the parts of the American chopper are designed and assembled using Solidworks and are rendered to photo realistic images using PhotoView360.

Link to Assembly zip file: https://drive.google.com/file/d/1KFJMfH0tLPYhHrC7yj0hQqm7RqZWYiDQ/view?usp=sharing