Photo Realistic Rendering

A REPORT

on

CAD Modelling and Rendering of an AMERICAN CHOPPER and its Components using SolidWorks & PhotoView 360

submitted by:

SAMBHAV DALAL

2020-2021

OBJECTIVE:

The aim is to make a 3D CAD model of an American Chopper- Components and Assembly using SolidWorks and rendering using Photo View 360.

METHODOLOGY:

1. Designing various Components/ Parts
2. Assembly of Components/ Parts
3. Applying Decals, Appearances, Camera, Lights, Scenes
4. Rendering

1. PART MODELLING:

The chopper has following parts to be modelled-

a. Transmission Belt

b. Kick Stand

c. Front Fender

d. Rear Fender

e. Chain

f. Oil Tank

g. Pedal

h. Front Wheel

i. Rear Wheel

j. Front Fork

k. Chassis

l. Engine

m. Gas Tank

a. Transmission Belt:

A belt is a power transmitting component, often used for shafts which are not axially aligned. It is a loop of flexible material that mechanically connects the driving and driven pulleys. Here, it is used to transmit power from engine to gearbox.

Feature Tools: Extruded Boss/ Base, Fillet

Sketch Tools: Line, 3 Point Arc, Offset Entities

Appearance: Matte Rubber

PROCEDURE:

• Sketch the outline of the belt on Front Plane using Line and 3 Point Arc. Apply constraint relations to fully define the sketch.
• Use Offset, inward direction, of 3.5mm (thickness value of the belt).
• Extrude the sketch with a suitable dimension value.
• Apply fillets to avoid corners in the model.
• Apply appearance as required, here, black matte.

Fig 1. Transmission Belt

b. Kick Stand:

A kickstand is a component that helps to keep a two-wheeler upright when it is to be parked or has to be kept stationary somewhere. This piece of metal is connected to the chassis of the vehicle and makes contact with the ground when kicked into a vertical position.

Feature Tools: Lofted Boss/ Base, Dome, Extrude Cut, Split, Fillet

Sketch Tools: Line, 3 Point Arc, Circle, Ellipse.

Appearance: Chrome Steel

PROCEDURE:

• Sketch an ellipse on Front Plane. Add dimensions and constraint relations to fully define it. Use Right Plane to sketch a spline. Give suitable relations to the spline handle and dimension it.
• Create a normal plane at the end of spline and draw an ellipse on that plane. Use pierce relation for spline and mid-point of ellipse.
• Use loft on both sketches.
• Apply dome (elliptical) at the end of spline and remove extra portion using extrude-cut.
• Use fillet and appearance for better and smooth visuals.

Fig 2. Kick Stand

c. & d. Front Fender and Rear Fender:

These components are located over Front and Rear Wheel respectively. The fender is used to restrict the foreign particles like sand, mud, pebbles, liquids, etc. from striking the wheels.

Feature Tools: Revolve Boss/ Base, Split, Fillet

Sketch Tools: Line, 3 Point Arc, Spline, Extended Entities, Trim Entities

Appearance: Painted Siena

Fig 3. Front Fender

Fig 4. Rear Fender

e. Chain:

A chain is a connection of links that mechanically transmits power from engine to the wheel. Here, the power is transmitted to the rear wheel.

Feature Tools: Extrude Boss/ Base, Curve Driven Pattern, Blocks (for links), Fillet

Sketch Tools: Line, 3 Point Arc, Spline, Extended Entities, Trim Entities

Appearance: Chrome Steel

PROCEDURE:

• Sketch two circles on front plane of suitable and different diameter. The circles have to be separated by a distance. Connect them using a 3-point arc. Trim surplus portion of the sketch.
• Create sketches for outside and inside chain links. Make a block of these sketches and save them.
• Use blocks and make coincident relation with larger circle. Select holes and extrude the sketch to create Pins. Extrude again for plates. Apply fillet and repeat the process.
• Use Curve Driven Pattern to create required pins and plates.
• Repeat this method for other curves as well for completing the model.
• Use appearance as required.

Fig 5. Chain

f. Oil Tank:

It is a container for holding or storing fuel. Here, thickness of part is chosen to be 3 mm.

Feature Tools: Extrude Boss/ Base, 3-point arc, Combine, Shell, Fillet

Sketch Tools: Line, Spline, Circle

Appearance: Painted Siena

Fig 6. Oil Tank

g. Pedal:

The part where the rider can rest his foot and also can change gear.

Feature Tools: Extrude Boss/ Base, Revolve Boss/ Base, Dome, Linear Pattern, Chamfer, Fillet

Sketch Tools: Line, Spline, Circle

Appearance: Chrome Steel

Fig 7. Pedal

h. & i. Front and Rear Wheel:

A wheel is a circular object which helps the vehicle in its movement. It comprises of various parts such as- Rim, Caliper, Rotor, Tire, Sprocket (rear wheel only). The rear wheel is generally wider to achieve better traction.

Feature Tools: Extrude Boss/ Base, Revolve Boss/ Base, Extrude-cut, Revolve cut, Circular Pattern, Combine, Mirror, Chamfer, Fillet

Sketch Tools: Line, Spline, Circle, Rectangle, Trim Entities, Extend Entities, Convert Entities, Offset Entities

Appearance: Chrome Steel- Rim, Sprocket

Carbon Steel- Rotor

Painted Siena- Caliper

Matte Rubber- Tire

Fig 8. Front Wheel

Fig 9. Rear Wheel

j. Front Fork:

The part of the chopper that holds the front wheel. It also acts as the shock absorber. Due to this, only front wheel bounces or reacts during non-smooth roads and isolates rest of the parts from that movement.

Feature Tools: Extrude Boss/ Base, Revolve Boss/ Base, Extrude-cut, Project Curve, Swept Boss, Mirror, Fillet

Sketch Tools: Line, Spline, Circle, Trim Entities, Convert Entities

Appearance: Chrome Steel- Fork

Matte Rubber- Handle Grip and Brake Wires

Fig 10. Front Fork

k. Chassis

The most important part of a vehicle on which all other parts are mounted or attached which provides strength and ability to be stable. A blueprint of the chopper shall be needed to model the chassis.

Feature Tools: Extrude Boss/ Base, Extrude-cut, Project Curve, Swept Boss, Combine, Mirror, Fillet

Sketch Tools: Line, Spline, 3-point arc, Circle, Offset Entities, Convert Entities

Appearance: Painted Siena

Fig 11. Chassis

k. Engine:

The component that is responsible for providing energy to run the vehicle. It converts chemical energy to heat energy of the fuel. Here, the engine drives the rear wheel via chain and sprocket.

Feature Tools: Extrude Boss/ Base, Extrude-cut, Project Curve, Swept Boss, Combine, Mirror, Fillet, Dome, Split, Composite Curves, Revolve Base/ Boss

Sketch Tools: Line, Spline, 3-point arc, Circle, Offset Entities, Convert Entities

Appearance: Chromium Plate

Render Image: Photo View 360

Fig 12. Engine

Fig 13. Render Engine

m. Gas Tank:

The storage tank through which engine gets the fuel supply.

Feature Tools: Swept Surface, Loft Surface, Boundary Surface, Project Curve, Knit Surface, Combine, Mirror, Fillet

Sketch Tools: Line, Spline, 3-point arc, Circle, Offset Entities, Convert Entities

Appearance: Painted Siena- Gas Tank

Fabric- Driver Seat

Fig 14. Gas Tank

2. ASSEMBLY, DECALS & RENDERING OF THE CHOPPER PARTS:

Procedure:

• Open new assembly and starting from chassis. Insert all the components as and when required.
• While inserting the parts in assembly window, work on the mates simultaneously to keep the assembly fully defined.
• Observe the geometrical errors in the assembly and edit the part models as required. No part should overlap the geometry of other part.
• Use of planes to align all the parts with respect to chassis planes is very crucial while using mates.
• Set wheels and kick stand tangent to the Top plane so that the chopper seems to be grounded and rendering becomes more effective.
• Once, assembly is completed, apply various decals on parts like gas tank & rear fender.
• Now, chopper is ready for rendering. Setup the camera and lights as required and render the model using Photo View 360.

Render Images: Photo View 360

Fig 15. Chopper View 1

Fig 16. Chopper View 2

Fig 17. Chopper View 3

Fig 18. Chopper View 4

Fig 19. Chopper View 5