Photo Realistic Rendering

Introduction

This report contains a detailed explanation of

designing an American Chopper starting

from part modelling to final rendering of the

assembly.

Objective

The main objective of this course module is

to learn the basics of part modelling and also

exploring most of the tools that are used in

designing using Solid Works.

The following steps were undertaking while

designing the American Chopper:

1. Design of the individual Components
2. Assembly of the American Chopper
3. Application of decals, setting up the scene,lights and cameras
4. Final rendering of the American Chopper

Methodology

The American Chopper is made up of

following parts:

1. Transmission belt
2. Kick stand
3. Chain
4. Rear fender
5. Rear wheel
6. Pedal
7. Front fender
8. Front wheel
9. Oil tank
10. Front fork
11. Chassis
12. Engine
13. Fuel tank

1.Transmission belt

It is used to transmit power between two

shafts.

Features: Extruded Boss/Base and Fillet.

The profile of the transmission belt is created

as per the dimensions in the front plane, the

belt is given a thickness of 3.5 mm. Once the

sketch is complete the belt is extruded. The

square edges are given fillet. The transmission belt is made out of matte

rubber.

2. Kick stand:

Kick stand is a supporting structure provided

to a bicycle or motorcycle to help it stand in a

vertical position when stationary.

Features: Lofted Boss/Base, Dome, Extruded

Cut, Extruded Boss/Base and Fillet

Mainly loft feature is used to create the kick

stand. Two ellipses are created on the right

plane, one at the top end and one at the

bottom end of the kick stand. A path is

sketched on the front plane which joins the

centre points of the two ellipses created

before using pierce relation between the

centre of the ellipses and the path. Using loft,

the body of the kick stand is created.

Elliptical dome feature is used to create the

rounded end of the kick stand. A slot with an

extruded boss is created at the top end of the

stand using which it is connected to the chassis. At last fillets are provided to the

sharp edges of the stand. Chrome plate

appearance is applied to the kick stand.

3. Chain:

Chain is the connection used to transmit

power from the engine to the rear wheel. It

passes over toothed member known as

sprockets.

Features:

Extruded

Boss/Base,

Linear

pattern, Circular pattern, Fillet, Mirror and

Combine

A main profile of the chain is created using

three point arc and tangent relations between

the arcs using the given dimensions. Create

two throwaway sketches which are used to

create the inside and outside links of the

chain. The plates of the chain links are

extruded using the throwaway sketches and

the connecting pins are created using the

same sketch. Only one side of the plates of

the chain links are created. The created chain

links are pins are then populated on the main

sketch using the linear pattern and circular

pattern features. All the chain link plates are

then mirrored on the front plain. All the

components of the chain are combined as a

single part using combine feature. Chrome

steel appearance is applied to the chain.

4. Rear Fender:

It is the semi cover for the rear wheel.

Features: Revolve Boss/Base, Fillet and Shell

A sketch of created in the front plane using a

three point arc and offset it meet the

thickness of the fender. Create an axis at the

origin. Using revolve boss the required rear

fender is created. Fillets are created on the

sharp of edges. Desired appearance is applied to the fender.

5. Rear wheel:

The circular component of the motorcycle

which helps in the motion of the vehicle and

it receives power from the engine through

chain drive. Rim, Tyre, Rotor, Sprocket and

Calliper are the parts of the rear wheel.

Features:

Revolve

Boss/Base,

Extruded

Boss/Base, Extruded Cut, Revolved Cut,

Circular Pattern, Mirror, Combine, Chamfer

and Fillet.

Initially the rim is created by sketching on the

front plane and the revolved extruded using

an imaginary axis at the origin. A spider web

design of the rim is created on the front

plane and is extruded using mid plane

extrude feature. And this spider web is

circular patterned to required numbers and

the Rim is completed. The spider web spokes

and the rim are combined to form a single

solid body.

For Rotor sketch on the front plane and

extrude it to the required dimensions. Create

the necessary holes using circular pattern.

For Calliper create a profile using lines and

circles and remove the unwanted sketch and

mid plane extrude the calliper profile. Provide

necessary fillets and chamfers to complete

the calliper.

For Sprocket sketch a circle and extrude it to

a required thickness. Apply chamfer to the

outer edges and create a tooth profile on the

extrude and cut it. Apply fillets to the tooth

edges and create the sprocket using circular

pattern feature and required number of teeth.

For Tyre A sketch is created by converting

entities of the Rim. And the Tyre is revolve

extruded. Later profiles are created on the

surface of the Tyre to give the grips to the

tyres.

Separate appearance are applied to each

part of the wheel.

6. Pedal

The part of the motorcycle where the foot of

the rider rests and the place where the gears

and brakes are available easily to the rider.

Features: Extruded Boss/Base,

Revolve

Boss/Base, Dome, Linear Pattern, Chamfer

and Fillet. A sketch is made on the front plane in the

form of the support plate as shown in the

picture above along the a few circles of

required dimensions on either side of the

profile which are later used to produce the

extruded cylinders structures for foot rest

and attachments to the chassis. Provide the

required fillets and linear patterns to produce

the ring structures on the pedal. Appearance

is provided to the pedals with chrome steel.

7. Front Fender

It is the covering plate of the front wheel.

Features: Revolve Boss/Base, Split and Shell

A sketch of created in the front plane using a

three point arc and offset it meet the

thickness of the fender. Create an axis at the

origin. Using revolve boss the required front

fender is created. Two different sketches are

created in the top plane and the right plane to

cut the front fender in to required shape.

Fillets are created on the sharp edges of the

fender. Desired appearance is applied to the

fender.

8. Front wheel

It is rolling part situated on the front of the

motorcycle. This wheel helps to guide the

vehicle according to the movement of the

front fork as desired by the rider.

Features:

Revolve

Boss/Base,

Extruded

Boss/Base, Extruded

Cut,

Revolved Cut,

Circular Pattern, Mirror, Combine, Chamfer

and Fillet.

Initially the rim is created by sketching on the

front plane and the revolved extruded using

an imaginary axis at the origin. A spider web

design of the rim is created on the front

plane and is extruded using mid plane

extrude feature. And this spider web is

circular patterned to required numbers and

the Rim is completed. The spider web spokes

and the rim are combined to form a single

solid body.

For Rotor sketch on the front plane and

extrude it to the required dimensions. Create

the necessary holes using circular pattern.

For Calliper create a profile using lines and

circles and remove the unwanted sketch and

mid plane extrude the calliper profile. Provide

necessary fillets and chamfers to complete

the calliper. For Tyre A sketch is created by converting

entities of the Rim. And the Tyre is revolve

extruded. Later profiles are created on the

surface of the Tyre to give the grips to the

tyres. Separate appearance are applied to each

part of the wheel.

9. Oil Tank

Engine oil storage unit of the motorcycle,

which ensures it's smooth running.

Features: Extruded Boss/Base, Combine, Shell

and Fillet On the top plane create a sketch by creating

a 3 point arc and few line and apply tangent

relations. Then extrude the profile to obtain a

structure. On the front plane, create another

sketch and extrude it using mid plane

extrude. Now split the bodies and remove the

unwanted part to obtain the oil tank. Apply

necessary fillets. Now using shell feature

make the oil tank hollow of required

thickness. And apply the desired appearance

10. Front Fork

It is used to guide the entire vehicle. It holds

the front wheel and other control device

operated by rider. It consists of two columns

along with shock absorber which is held

together by triple clamp.

Features: Extruded

Boss/Base, Revolved

Boss/Base,

Extruded

Cut, Revolved Cut,

Project Curves,

Swept Boss/Base, Dome,

Combine, Mirror, Chamfer and Fillet

Create the long tube on the front plane by

creating the sketches and with appropriate

dimensions and then revolve extrude it. Then

create the half of the triple clamp using

appropriate dimension sketch. On the same

plane create the headlight by revolve

extrusion. On the top plane and draw sketch

for creating the handle using spline and

sweep patterns. Select all the created bodies

and mirror them along the front plane and

combine the entire object. Select an

appropriate appearance to the front fork.

11. Chassis

It is the skeleton of the vehicle to which all

the components of the motorcycle are

attached to. It also provides the required

support to the vehicle.

Features: Extruded

Boss/Base, Revolved

Boss/Base, Linear pattern,

Extruded Cut,

Revolved

Cut, Project

Curves,

Swept

Boss/Base, Dome, Combine, Mirror, Chamfer

and Fillet

The blueprint of the motorcycle is imported

to the part design, by adjusting the location,

transparency and the sketch of the chassis is

carried on this blueprint. This chassis is

made of 4 mm thickness tubes bent and

joined using splines and created/projected

curves. At the end all the tubes are

connected to a plate and further this chassis

is extended till the rear wheel hub.

12. Engine

Engine is the main component of the vehicle

where the power is generated by burning fuel

and later transmitted to wheel to create the

required motion.

Features:

Extruded

Boss/Base, Revolved

Boss/Base, Extruded Cut,

Revolved Cut,

Circular pattern,

Project Curves,

Swept

Boss/Base, Dome, Combine, Mirror, Chamfer

and Fillet

Again using the inserted picture and

choosing the front plane, the base of the

engine is created using three point circle and

lines (using tangency properties) and extrude

to required dimensions. Again using the

same sketch extrude the two circles. Again

on the front plane create the twin engines in

the V-shape. Create the sketch for pulley and

create the pulley using revolved extrusion.

Create the cylindrical part in the front of the

engine on the front plane. Using the curves

created and projected curves, create the

profile of the exhaust pipes and create the

swept boss feature. Then the spark plugs are

created at the end. Apply the appropriate

material to the engine.

13. Fuel / Gas Tank

Fuel storage component of the American

Chopper and it supplies the required fuel to

the engine.

Features:

Swept Surface,

Loft Surface,

Boundary

Surface,

Project

Curves,

Knit

Surfaces, Sweep Cut, Combine, Shell, Mirror

and Fillet

In the front plane using splines, construction

lines and projected curves create a surface

sweep to create half of the tank. Create

another surface extrude to create the seat.

Now mirror the created part of the tank and

knit the entire surface together. Now apply

appropriate materials to the gas tank and the

seat.

Assembly of the American Chopper

All the designed components are taken into

the assembly section in Solid Works and

using different mating features such as

concentric, coincident, parallel, etc., the

entire assembly of the American Chopper is

created. After assembly the Decals are

applied to the Chopper.