Challenge

Photo Realistic Rendering

VVamsikrishna Bathala21 Apr 2022

title:

desiging, modelling ,assembly and photo realistic rendering of american chopper

objective :

objective of this project is to get an understanding of basic solidworks tools for designing ,modelling and assembling of the parts

introduction:

this report consists of basic explantion of the designing and modelling of the chopper parts and assembling these parts inorder to get an american chopper along with the rendering of the parts

flow chart:

description:

1.transmission belt:

select the front plane and draw two lines closed
close the two lines with the two arcs in tangent with the size line with 350mm length
the diameters of the circles are d1-140mm d2 - 160mm
use offset option and select the the sketch drawn to offset of 6mm thick
now exit the sketch and extrude it with a thickness of 88mm
select the appereance tool in order to apply the colour
pick a rubber matt black and apply to the belt

2.side kick stand

select the front plane
draw a ellipse of length 40mm, width 18mm in the front plane
select the right plane use spline with a length of 225 mm as mentioned
now on the other end of the spline create a plane perpendicular to it and draw an another ellipse of length 30mm and width 12mm
use loft base tool select the ellipse and centerline thus creates asolid
create dome of 10mm in bigger face and domes of 5mm on smaller face
now select the mid plane and draw a rectangle of length 28mm and height 8mm cut the part from solid using extrude cut
draw a circle of diameter 8mm on the center of the ellipse and extend upto next surface
select the front plane and draw a line on stand to height of 4.5mm from bottom of the stand
use split option select the line ,select the part to cut and press ok
provide fillet to the edges
use appereance tool and select the colour
apply metallic sillver to the solid

3. front fender:

select the front plane and draw an arc
radius of the arc is 125mm and also the select to two edges select the horizontally equal
length of the arc is considered as 160mm , provide center height of 280mm
use offset tool and select the object offset inside provide a thickness of 6mm
draw vertical lines from the corners, use trim extend to extend the offset curve to lines and trim the remaining lines
create a center line and revolve it using revolve command with 5 degrees at direction 1 and 130 degrees at direction 2
select the mid plane , use spline to provide a curve such that it is point 1 is 50mm horizontal and 45mm vertical ,point 2 is 200mm vetical from origin
use split tool select the line and cutpart select the part to be cut and done
repeat the same procedure to the other end
use fillet of 6mm radius on to top face
use apperance option to provise colour of sieana

4. rear fender:

select the front plane
draw an arc of radius of 290mm and also select the two edges of curve and then select horizontally equal
provide a length of 364 mm and a center height of 90mm
now offset the arc to 6mm
draw vertical lines from the corners, use trim extend to extend the offset curve to lines and trim the remaining lines
create a center line and revolve it using revolve command with 10 degrees at direction 1 and 140 degrees at direction 2
select the mid plane
use arc with both corner of either of the fender and make sure the are horizontal
and also make them horizontal to origin and provide a length of center height of 227mm
select the fillet and select the corners and provide a radius of 45mm
and also give 4mm on top of th face
use appereance tool to colour to sieana

5.oil tank

a 2d sketch is created as per the given dimensions in the top plane
then the sketch is extruded on both directions 170mm on one side and 10mm on other side
a new sketch is created on the midplane and extruded into both sides using through all option
combine the feature is used to build a commam part using both the models
fillets are used at the edges
shell feature is applied with a thickness of 3mm and previewed with the help of sectional view
appearance of oil tank is changed to siena with white at the edges
then saved

6.chain

rename the planes as per the construction required mentioned
select the midplane and sketch is created as per the given dimensions
a run away sketch is created at the midplane and blocks are created as chainlink1 and chainlink2 inorder to save them as a seperate part and use them to create links
these blocks are inserted on to the 2d sketch created o the midplane and applied certain relations to make coincident with curve
these blocks are then extruded and fillets are applied at the faces of the pin'
curve driven pattern is applied along the curve and some extrudes are drawn manually to perfectly allign with chain path
then chain bodies are classified into chain plates and pins in seperate folders to keep them more organised
these chain plates are mirrored uding mirror entities
chrome appearance is applied to the chain
part then saved

7. pedal

a 2d sketch is created at the front plane as per the given dimensions and then extruded using extruded boss/base upto 8mm
a new sketch is created on the front face of the model and extruded upto 20mm
and another sketch is created on the other side of the face and is revolved using revolved boss/base feature
dome feature is applied at the end of teh revoved part
unsymmetrical chamfer is applied to the other two parts
a new sketch is created by using offset entites option at the base of the three parts and is extruded from the faces at an offset of 20mm of 2.5mm
fillets are applied to all newly created edges with 1mm radius
an linear pattern is applied to create four instances of the same at a spacing of 20mm
fillets are then applied to the reamining formed edges
part then saved

8. Front Wheel

the front wheel here designed having mainly four parts

rim
rotor
caliper
tire

rim:

select the rightplane and sketch the geometry as per the given dimensions
now use revolve command in order to get complete curvature of the rim
use right plane and sketch the spokes as per the dimensions mentioned and use extrude cut feature inorder to get the spokes
connect the ribs of spokes to the rim by using combine geometry option and add and then use circular pattern in order to get two more ribs od spoke
now go to combine feature add hub ,rim and ribs as a single body

rotor and caliper:

take front plane of hub as the referance plane and sketch the rotor as per the given dimensions
extrude the geometry by offset away from the hub
sketch a circle of dimeter of 8mm and use linear pattern and select circles with an angle of 142 degrees
use a circular pattern to mirrors the holes to a no of 14 sets
on the same plane sketch the caliper as per the given dimesions
extrude the sketch on the both directions and use camfer the front face using distance to distance option of 8mm and 20mm
and then apply fillet of 4mm to all the edges of the caliper

tire:

select the front plane and thenclick on the convert entities to get a referance line on the front plane and then change it to construction line
now use revolve feature to the sketch by taking and referance of centre line to create the outer pheripery of the wheel
selct the front plane to create threads on tire
use rectangle sketch to sketch the enties as per the given dimensions atotal of 4 rectangle are sketches with an realtion to the origin
use extrude to rectangles by an offset extrude cut 4mm from the surface
use circular pattern to get a total of 14 sets of threaded sets on the tire

appearances:

apply a matte rubber appearance to the tire
apply a carbon stell to the rotor
apply siena to the caliper
apply chromium plate to the rim

9.rear wheel:

rear wheel modelled here consists of five parts

rim
brake rotor
calliper
sprocket
tyre

rim:

by sketching on the right plane and using revolve command and then created two rough body referances ,also there is a need for the further adding and removal of materials
then create spokes by using a constraints drawn sketch and the boss extruding
then remove the curved shaped material by extrude cut on the centre plane by taking the referance geometry as roughly extruded spoke elements
then draw ribs geometry to connect the extruded spokes of rim
after then the spokes and the outer periphery was ready so i used circular pattern to get spokes
use combine feature to add all the parts

rotor and calliper:

consider the front face of the hub as the referance sketch plane then sketch the rotor dimensions and offset and extrude from the hub
draw acircle on the front face ,extrude the circle and use linear pattern
use circular pattern to create multiple combinations of linear pattern over the circumferance
a caliper is created as aconstrained sketchon the pervius face and extrude that
a camfer is given to the face of the calliper
fillet is applied to the edes of the calliper of different radius

sprocket:

sketch the dimentional entities by taking referance of rotor front face also offset the entities with out merging the results
then provide an fillet to the extruded part
use circular pattern around the circumferance od the sprocket

tyre:

use convert entities option take a referance of the rim curve and sketching the geometry of the tyre
crate a sketch make the revolve option to create outer periphery
then threads geometry are sketched on the tyre and the extrude cut to cut the material from the tyre
use circular pattern over the revolved tyre to get the complete thread over the tyre

10.front frok:

sketch the fork and revolve the sketch geometry
then model the supporting memeber by selecting the prescribed plane
then model the head light by using the feature of spline and revolve
to model the handle use the projection of two curves and use the intersection curve to model
then using the handle bar, crate a referance plane on the sweep axis using the revolve command
use the same projection of curves to get the brake wire axis line
then mirror the all the bodies, then combine the necesary components
apply suitable appearances to the components of the front fork

11.chassis:

add the ble print sketch to mid plane
sketch a curve on both bottom plane and the mid plane using projected curve option
draw an another sketch on the right plane using the projected curve to draw a curve
use aswept boss tool sweep abody through the curve
mirror the solid sketch created
skectch on the right plane and extrude it
use a extrude cut option to remove portion from the extruded part
create a referance plane parrale to mid plane and sketch on face ahown draw to concentric circles to sweep
using the split tool cut the part atthe end
after an another tol about the bottom plane and draw another sketch on it and also draw a curve on the mid plane
after that combine all parts
sketch on the midplane and then extrude with the merge option turned on
fillets are given to the to all the edges with suitable radius
draw an another sketch on the midplane and themn extrude the part
now draw an another sketch on the right plane and then extrude and various fillets are given
given an apperance of sieana to the combined part

12. engine part:

the blue print of the chopper is added gto the front plane
various sketches are given on the front plane and then extruded
sketch on the right plane and is revoved to make a part
a new plane with respect to the right plane and draw a sketch on the plane and revolve
draw a sketch on the front plane and extrude
use a circular pattern option make the teetch of the chain
repeat the same pattern to the other sprocket
provide domes to the created parts
a sketch is drawn on the front plane and is cut extruded to make holes on the sprocket
certian fillets and camfers are given to the parts
another sketch is drawn on the front placne and is extruded after that one more sketch id drawn on the same plane
a new sketch is drwan on the front plane and a new plane is created with respect to the sketch
now sketch is drawn on the newly created plane and are then extruded
two more sketch are drawn on the newly created plane
camfers and fillets are provided to the edges
then sketch is drawn an the same plane and is then extruded to create a shape
to copy this sketch linear pattern optio is used
fillets are applied
then sketch is drawn on the cylinder that is created and is then extruded outward and dome is given
shape is mirrored on the both sides of cylinder
a sketch is drawn on the front plane and is then extruded and fillets are applied
use split option some parts are removed
entire cylinder is then mirroed to back side
fillets are given to the edges
then somes sketch are drawn on the top plane and are extruded and certain fillets are given
sketches drawn on th efront plane and are extruded and camfered
now a small sketch is drawn on the sprocket created and is then extrude cut and fillet is given
then use circular pattern option to copythe cut throughoutthe sprocket
camfers are provided
another sketch id drawn on the front plane and another on right plane
then it is swept using the sweep tool to make the exhaust tube
all the parts are then combined
then a plane is created with respect to the top plane
another sketch is drawn on the front plane a curve is drawn on that is previously created this sketch is used to swept part
again a sketch is drawn on the front plane and is revoved to make the air intake
various fillets are applied
then a sketch is drawn on the top plane and then it is extruded and using a circular pattern tool the cuts is copied throughout the part
then make the exhuast tube 4 curves are drawn differnet planes and using projected curves options to make curve and using the swept option make a sweeping part
follw the same procedure to other exhaust pipe
then sketch tha face of the spark plug and another curve on the front planes so that it can be used to make the wire of the spark plug follow the same procedur eto other plug

13.gas tank:

start a sketch on the midplane and draw a spline and surface extrude it
thyen draw a sketch on the top plane and cut the excess sheet
then draw a spline on the right plane and mid plane and project then curve
then mirror the solid and knit it and create the solid
then sweep cut the tue hole
complete the drawing by giving the fillets and the appearances

14. assembly of chopper:

at first assemble the chassis by giving the plane relations
then assemble the parts by giving the mate option
thyen check the assembly and rectify it
then assemble the front wheel and front fender with the front fork plane relation
then complete the assembly by checking whether there are any insection of the parts

rendering:

1. camera view( photo view 360)