Photo Realistic Rendering

Modelling of American chopper in solid works

Introduction

Solid work is most commonly used modeling software in all kind of industries especially mechanical and automotive industries. Primarily used in the R&D Sector to Model 3D parts using 2D sketch. And it have wide verity options to specify Materials and add-in features like photo 360 to render the model in photo realistic. It gives Designers Real- time result in product modeling. In this project we learned about detailed design of American chopper parts, assembling and rendering.

Objective

The Main objectives of this project are:

• To create individual parts of chopper using solid works
• To assemble all the individual parts into a chopper
• To know the application of decals, lights, camera, scenes etc.
• To create photorealistic model and render by using photo view 360 and solid work Visualize.

Design Methodology/Approach

TRANSMISSION BELT

This is used to transmit power from engine to gear box. A belt connects both the pulleys and snugly fits on the grooves of the pulleys. The belt is made up of reinforced rubber with strong synthetic material making the belt durable.

Features used to create Transmission Belt

• Sketch
• Offset
• Extrude boss
• Fillet
• Appearance

Sketch

The sketch is a 2D representation of the Model. These are known as entities in solid works. e.g.: Line, rectangle, spline, circle, arc etc.

Offset

Offset one or more sketch entities, selected model edges or model faces by specified distance. E.g. you can offset sketch entities such as splines or arcs, set of model edges, loops and so on

Extrude Boss/Base

This feature is used to convert a 2D sketch into 3D model.

Fillet

This feature creates a rounded internal or external face on the part. You can fillet all the edges of a face, edges, loop etc.

Procedure to create a model of transmission belt

• Open a new solid work part.
• Then select the Front plane and select the sketch.
• The 2D sketch is created in the Front plane and dimensions and relations are given to make the sketch fully defined. While sketching offset command is used to make duplicate sketch to some distance.
• After this process the sketch is closed. Then the extrude command is used to convert 2D sketch to 3D model.
• Then Fillet is given to the belt as per the given dimensions
• Then finally the model is saved on the name "Transmission Belt".

Kick stand

It is used to support the chopper for parking. It Is also known as side stand.

Features used to create kick stand

• Sketch
• Loft
• Dome
• Extrude boss
• Extrude cut
• Fillet
• Split

Loft

The loft feature allows you to generate geometry. It processing through interpolating surfaces between various cross section of the model .These cross

Sections can be sketches, faces or edges .In the loft interface the cross sections are considered Loft profile.

Dome

This feature is majorly applied to faces. Select one or more planar or non-planar faces. You can apply dome to faces whose centroid lies outside the face. This allows you to apply domes to irregularly shaped contours.

Extrude Cut

This feature is used to remove materials from the 3D model. It is just opposite to extrude boss because it cuts a sketch profile while extruding. You can cut in both directions and mainly used for creating holes, channels, slots etc.

Split

This tool is used to project an entity onto other surface or curved or planar faces. You can also split faces on multiple bodies with one command.

Procedure followed to create a model of Kickstand:

• First open a new Solid works part
• Before creating the sketch change the default planes as follows:

1. Front Plane-Front plane
2. Top Plane- Top Plane
3. Right Plane-Mid Plane

• Then, select mid Plane and start sketch.
• Then 2D sketch is created in the front plane and dimensions are given and sketch is fully defined, while sketching we use spline and trim commands
• There are two new planes created and ellipse is drawn in the new plane as per the requirement.
• Then the loft command is used to create loft for the kickstand the extrude cut is used to cut parts which are not required for the stand.
• Then the dome feature is applied to the smaller face of the kickstand to make the face round and smooth.
• Fillets are applied on the sharper edges for required radius.
• Then finally the part is saved by the name "Kickstand".

Pedal

Pedal is the external part attached to the chassis. And it used to comfort the leg position of the rider.

Feature used to create Pedal

• Sketch
• Extrude
• Fillet
• Linear pattern
• Dome
• Chamfer

Chamfer

A cut on the edge or corner of something that makes it slope slightly rather being perfectly square.

Linear pattern

The feature or the bodies are patterned linearly.

Chain

Chain is a type of transmission system that is used to transmit power from the engine to rear wheel. A smaller sprocket is connected to the gearbox and a larger one is present on the rear wheel. The gearbox turns the front sprocket which, with the help of the chain drive, turns the rear wheel, putting the motorcycle in motion.

Features used to create Chain

• Sketch
• Trim
• Fillet
• Block
• Extrude
• Patterns
• Appearance

Trim entities

You can make, save, edit and insert blocks for drawing items and sketch entities that you use often, such as standard notes, title blocks, and label positions and so on. You can attach blocks to geometry or to drawing views and you can insert them into sheet formats.

To make Blocks:

1. Create a sketch
2. Click Make Block (tools>block>make block)
3. Select the entity you want to make as a Block for Block entities
4. Click ok and save the first block
5. Repeat steps 2-4 for another block
6. With the sketch in edit mode, add Necessary relations.
7. Finally save the part.

FRONT FENDER

The front fender is the mounted on the front fork. Above the wheel to protect the rider and the chopper other parts from the debris and foreign particles.

Features used to create Front fender:

• Sketch
• Offset entities
• Trim entities
• Revolve
• Dynamic Mirror
• Split
• Appearances

Revolve

Create a sketch that contains one or more profiles and a Centre line or an edge to use as the axis around which the feature revolve tools.

Dynamic Mirror

Dynamic mirror, it is used as you sketch the entities, they are mirrored about the pre sketched sketch entity.

Rear fender

Use of rear fender and front fender are same. The rear fender is mounted on the Chassis of the rear part above the Rear wheel.

Features used to model Rear Fender

• Sketch
• Offset Entities
• Trim Entities
• Revolve
• Appearances

Oil Tank

The oil tank is used to store the oil required to run engine. It is designed as hollow and the thickness of the oil tank is 3 mm in American chopper.

Features used to create oil tank

• Sketch
• Boss Extrude
• Combine
• Fillet
• Shell

Shell

The shell feature is used to define the thickness of thin and thick shell elements.

Combine

Combine feature is used to manually combine two bodies like add, subtract etc.

Front Wheel

The Wheel is an essential part of the vehicle. Wheel is a circular block made of steel/alloy material. On the top of the wheel, The Tire is covered. The tire is made of rubber and it has thin wire with in it.

Features used to create Front Wheel

• Sketch
• Revolve
• Trim
• Fillet sketch
• Boss Extrude
• Revolve Cut
• Linear Pattern
• Chamfer
• Cut Extrude
• Circular pattern

Circular Pattern

Circular pattern is used to create a pattern of spokes and the pattern of groves available in the tire. It is also used to create holes in the discs of the front wheel. The parent bodies/features are used to create number of instances required to create the pattern circularly.

Rear wheel

A circular object that revolves on an axis and is fixed below a vehicle or other object enabling it to move easily over the ground.

The disc and sprocket are attached with rear wheel. The chain is connected between the Engine and rear wheel.

Features used to create rear wheel

• Sketch
• Revolve
• Trim
• Sketch fillet
• Extrude Boss
• Planes
• Revolve cut
• Linear pattern
• Chamfer
• Fillet feature
• Extrude Cut
• Circular pattern

Front fork

Now a day’s most of the motorcycles are using telescopic forks for the front suspension. The forks can be most easily understood as simply large hydraulic shock absorbers with internal coil springs. They allow the front wheel to react to imperfections and undulation in the road while isolating the rest of the motorcycle from that motion.

Features used to create Front Fork

• Sketch
• Extrude
• Trim
• Revolve
• Split
• Move/copy bodies
• Dome
• Mirror
• Combine
• Projected curve
• Sweep

Move/Copy Body:

This feature is used to move/copy the body from one place to another place.

Mirror

By using mirror faces with a mid-plane selected only the chosen faces within the revolve will be mirrored Mirroring bodies can be used whether in a single or multi body part and allows you to select solid geometry instead of the features and faces in a body In the fork part the one part is created and the other part is mirrored. Then the parts are manually combined.

Projected curve

Projected curve is a kind of 3D curve which is projected based on the two different 2D sketches

Sweep

With the sweep feature we can create a shape by moving a 2D sketch profile along a 2D or 3D sketch path.

Chassis

Much like a human spine and the supporting skeleton, a motorcycle chassis holds everything together - from the engine, suspension, wheels, fuel tank, handlebars, seat, etc. All the component attached to this base structure which lends a motorcycle its strength and ability to handle well.

Features used to create Chassis

• Sketch
• Offset
• Convert Entities.
• Project Curve
• Trim
• Sweep
• Split
• Revolve
• Cut Extrude
• Fillet
• Combine

Engine

A motorcycle engine is a prime mover that powers a motorcycle. The engine converts a chemical energy into the heat energy and then the heat energy is converted to mechanical work. The mechanical work in the engine is a rotational motion. This rotation is transmitted to wheel with the help of chain and sprocket through the gear box and clutch.

Features used to create engine

• Sketch
• Trim
• Revolve
• Boss Extrude
• Extrude Cut
• Offset
• Dome
• Fillet
• Projected Curve
• Composite Curve
• Sweep
• Mirror
• Circular pattern
• Split

Composite curve

This feature is used to join two curves and make them a single curve. E.g. combining a projected curve to another curve etc.

Gas Tank

Gas tanks are used to store fuels and deliver the fuel to engine.

Features used to create Gas tank

• Trim
• Projected curve
• Sweep surface
• Loft surface
• Fill surface
• Surface Trim
• Surface Knit
• Sweep Cut.
• Fillet

Loft surfaces

Loft surfaces are surfaces generated by multiple 3D curves or existing edges creating a smooth tangency between the selected curves.

Sweep surfaces

Sweep surfaces are surfaces that are generated from a section curve positioned along a path.

Fill surface

The fill surface feature constructs a surface path with any number of sides with in a boundary defined by existing model edges, sketches or curves including composite curves.

Surface Trim

Primarily used to cut away material from a surface and provides two modes: standard and mutual.

Surface Knit

Surface knit is used to knit two free edges/open edges of the surface together. Also it reduces the gap between two edges of the surfaces.

ASSEMBLY OF THE CHOPPER

Assembly is a process of mating many parts with respect to geometrical relations.

• Initially the Chassis part is inserted in the assembly by using insert parts in the option. After that the part is inserted in the assembly environment and click ok to fix the Chassis.
• After that other parts of the chopper are inserted into the assembly and given possible mate conditions.

FRONT VIEW

SIDE VIEW

TOP VIEW

ISOMETRIC VIEW

CAMERA VIEW

CAMERA SETUP VIEW

Features used to assemble chopper

• Inserting parts
• Mates

Mates

Mates create geometric relationship between the assembly components. As we add mates, we define the allowable directions of linear or rotational motion of the components.

RENDERING

• Rendering is a process of creating realistic images of the photorealistic model with the environment.
• Rendering has been done in two ways in Solid works
• Photo view 360
• Solid works Visualize

In the photorealistic model some of the mate conditions and positions are changed to render realistic models.

Then, the photorealistic model is rendered into realistic images with different views.

Photo view 360

Photo view 360 is a visualization and rendering solution includes with Solid works. Providing a highly interactive environment for viewing designs as well as for creating photo-realistic rendering it can be used to showcase our designs as well.

Solid work visualize

Visualize allows you to leverage your 3D CAD data to create photo-quality content in the fastest and easiest way you can-from images to animations, interactive web content, and immersive Virtual Reality. It have industry leading rendering capabilities with visual design oriented features and workflows.it makes easy creation of visual content.

CONCLUSION

• Learned about converting a sketch into solid modeling.
• Understood assembling of parts.
• Learn how to render an image by adding different types of materials, camera views, and background images.