Photo Realistic Rendering

 

PROJECT REPORT

MODELLING OF AN AMERICAN CHOPPER BIKE USING SOLIDWORKS

BY

VIKAS M

INTRODUCTION

       In the pertaining project, we are going to design, model and render an assembled prototype of an American Chopper Bike. It is to be noted that our project is completely executed in a modelling software called Solidworks and Solidworks Visualize by which we explore several of its operations and privileges to attain the best possible finish.

SKETCH

       Sketching of Design is a basic step in the modelling process as all the pertaining solids are an expansion or extension of the pre-designed entities. Firstly, we need to select a particular plane suitable for the design process. We then use several of the sketch tools such as line, circle, arc, rectangle, etc., based on given observations and calculations. All of it will be available in the 2D-Sketch toolbar. Lastly, we need to check whether the sketches are constrained(or fully defined), as it helps in achieving inflexible parameters without variables and is very significant to achieve a smooth assembly.

MODELLING

       Modelling is a crucial aspect in mechanical design as it converts 2D sketch into 3D entities thereby helping to properly visualize the component. Here there are multiple options and techniques to achieve the above. There are solid metal processes and sheetmetal processes. All of the processes can be manipulated by assigning relevant parameters for suitable designs and henceforth, produce the components. Here we discuss some of the operations used for creating the above design.

Extrude:

A very commonly used mechanical design entity. Mostly involves normally thickening an enclosed 2D sketch.

Revolve:

Another operation which helps in achieving the angular thickening of the 2D entities. It helps in mostly circular or revolved entities through an axis.

Sweep:

This operation involves creating a solid between two separate sketch enclosures with or without a path to follow. This helps in producing sketches with multiple dimensions and non-straight paths.

Fillet:

This operation is used to achieve curved edges for a solid body. This helps in increasing the design speed while avoiding sharp edges with a tangential finish.

Chamfer:

This operation is helpful in getting flat edges or faces by replacing sharp ones. Various   parameters such as distance-distance or angle-distance options are available for design.

Mirror:

This is an operation wherein copies of a selected sketch or a body/bodies w.r.to a plane is created thereby avoiding redesigning and achieve exactly similar dimensions and constraints as the host body.

Multiple entities:

This is an operation similar to mirror but having flexibility to increase the number of bodies w.r.to a path assigned. Various patterns of linear, circular or insert along a path operations will help in achieving the design.

Cut:

This is an operation used to create deep cavities in solid bodies. Similar to extrude, we can vary our options by which manipulation into linear, circular or design based on a path can be created and help in achieving required solids.

Projected curves:

This is a very interesting curve operation by which two different curves in same or different planes is projected to form one curve treading common paths in a separate plane of its own.

FLOWCHART

ASSEMBLY

        This is a very crucial phase in design where two or more models can be related according to the specified limits and tolerances, where the final product is a fully fledged producible or working component. This method also helps in testing and analysing its design compatibility and knowing whether the foregoing equipment is according to its design constraints.

There are multiple operations we can use, but we will discuss the operations only used in this particular project. All the parts have been created undertaking only Bottom Up approach, so mates are really important.

Mates:

This is the operation where a solid body is related to another body or a plane, so as to fix its positions and use multiple dimensions and relations for assigning freedom of movements with the help of an axis or a plane.

APPEARANCE

This is a crucial operation where a body can be assigned real world properties such as metallic or non-metallic, colour of the body, texture on the surface and many more.

We can also assign the environment around the component and lighting effects on the body suitable for various make-ups and arrangements. This can be easily selected and applied in various lists present in the above option.

SOLIDWORKS VISUALIZE

          This is basically an advanced version of appearance and camera options present in the normal SW program. Here we have the advantage of achieving a very high definition rendering by assigning multiple frames with a fine finish. We are provided with a number of body and environment options with freedom of synchronizing the range in various aspects. Provided a good Graphics Processor the images or videos can be achieved to have a real world or an animated feel.

DESCRIPTION

Here we discuss various parts/components that was made to build the said model. We might have different components having genuine geometry and most of the available operations are applied to get the part.

Transmission Belt:

This the component which transmits energy from the engine motor to the chainlink. A normal extrude with given curvature and distance was applied. An appearance of matt rubber was applied on the surfaces.

Kick Stand:

A kick stand is a very sturdy design used to uphold the vehicle in a particular angle. So, a loft between two ellipse at a specified angle and following a spline gave a part which was balancing the requirements. A dome on each edge  was assigned with the ground edge having a flat surface was created. A metallic silver surface finish gave the final touch.

 

Fenders:

Fenders constitute the quarter arcs at both front and rear ends which protect the wheel and forks from shocks and protect the suspensions. A revolved extrude with a sketch of required dimension along the opposite axis with minimal angle gave the skeletal. And fillets vis-à-vis cut extrudes of pointed edges gave rise to the model. The final coating in metallic sienna finished the model.

 

Chain:

This part helps in transmission of rotatory motion from engine to the rear wheel. This is a continuous setup of smaller chainlinks connected adjacently with metal bolts. The setup attached to the rear wheel gear gives a sturdy and strong transmission.

Oil Tank:

This is a crucial part in the vehicle by which continuous fuel supply is provided to the engine after ignition. The fuel tank is fitted just above piston setup for smooth flow of the fuel inside. Two different solids were adjacently created and later combined to form a complete solid part.

Pedal:

The part which acts both as the footrest and gear changer is the pedal. Given the dimensions mostly extrudes on a number planes gave us the pedal system.

 

Front Wheel:

This is a crucial part where the vehicle can be maneuvered in our desired direction. Apart from the revolve in certain dimension and brake callipers, most of the operation seems to be same. The webbed rim is made using extrusion of splines with patterns of a spider web. The patterns on the tyre is made by cutting particular patterns on the surface and using circular pattern.

Rear Wheel:

This is the part where energy from engine to the road is transferred. Similar to front wheel but a gear to rotate the chain is added in the centre and a broader thickness. Rest is similar to designing the front wheel.

Front Fork:

Here a fork-like object consisting the handle, headlights and suspension is attached to the front wheel. This helps in side manoeuvre of the vehicle. Hence, intersection curves i.e., curve in leu with projected curves is used to gain an exact path for the handle. Then, a circle with certain dimension is swept across the path.

Chassis:

It is the main body where rest of the parts come and sit. This took up several considerations of planes, surfaces, curves(projected) and so and so. But a strong and supportive design was obtained after several hours of sketch-based designing.

Engine:

It has to be the most complex set of machinery designed for most of the operations exclusively for above has been used. Be it synchronized cut for fins or using intersection curves to achieve exhaust gave a thorough idea of why the operations are used. Many sections like the sprocket, air filter and combustion chamber had multiple operations genuinely put.

Gas Tank:

It is the system where seat and a partition from the fork is created. It protects the body from heat of the engine. But since, we need a setup with considerable strength, we use the ‘shell’ option after modelling, so as to give a good thickness for strength. A seat with a comfortable handling and mechanical advantage is also placed accordingly.

ASSEMBLY

The chopper is assembled with a specific set of mates with desired positions and axes. We at first need to take the chassis as the base reference and go on adding parts on a required basis. All are related to certain parameters where allowance such as hole and the shaft or distance from certain axis or plane or face is used.

RENDERING

The most interesting phase in the Solidworks software is giving it a real world or a graphical feel is called ‘rendering’. The most efficient and effective outputs are released mostly by Solidworks Visualize. We can apply decals as per design benefit and colour for some or all the part for ambience or corrosion-resistance. All the operation of Assigning illumination and direction of the lights from headlights and giving a proper environment will have you move the model to the Visualize software, where later multiple background and lighting with intensity will be synchronized. The final render is a fine, elaborate and a high definition finish, which is in a league of its own.

CONCLUSION

The required system for the 2 wheeler is individually created, assembled and rendered for a sleek and comfortable setup for style and transport.