Photo Realistic Rendering

American Chopper Design

Objectives-: The objective behind the design of this project is to understand the concept of sketching, modeling & assembly in solid works using sketch tools, features, appearances, defining mates, using relations, creation of reference planes, using curves tool, combine tool, split tool & surfaces tools.

Introduction-:

Understanding & implementing the following tools & features is the primary objective of this project. Implementation of these tools & features gives a vast exposure to the concepts for giving your imagination a proper well-defined sketch & modeling it into a 3D model. The following command & features are-:

1. Boss Extrude.
2. Loft Command.
3. Dome Feature.
4. Split
5. Revolve Command
6. Block
7. Mirror
8. Shell
9. Linear Pattern.
10. Circular Pattern.
11. Composites Curve.’
12. Curve Feature.
13. Projection Curve.
14. Spline Tool.
15. Combine Tool.
16. Extruded Cut.
17. Revolve Cut.
18. Sweep Feature.
19. Move/Copy Body.
20. Reference Planes.
21. Pierce Relations.
22. Insert Sketch Picture.
23. Surface Loft.
24. Surface Sweep.
25. Surface Trim.
26. Surface Knit.
27. Split Line.
28. Assembly of parts/components.
29. Insert Assembly Mates.
30. Mirror Components in Assembly.

The Secondary/Final objective of this project is to give your assembly a realistic view by using Photo-view 360, Rendering tools & Solidworks visualization. The overall conclusion of this project is that it provides exposure & complete understanding of the tools & commands in Solidworks software.

Flow-Chart of Design Process

Features Used in Drawing

1. Boss Extrude-: Boss Extrude feature will project a 2D sketch into a 3D model with reference to a plane or face.
2. Fillet -: The fillet feature is used to make sharp edges, corners, faces, and selected edges round.
3. Loft-: The loft feature is used to make complex 3D shapes using profiles, sketches, points, faces & surfaces. This feature joins the different profiles using the guide path provided by profiles, points, surfaces & faces.
4. Dome-: Dome feature is used to make a curved surface/rounded surface on the face of the sketch.
5. Cut Extrude-: Cut Extrude is the feature that is used to cut/remove a solid area from the 3D extruded model with the reference of the sketch, face/plane.
6. Split -: This feature is used to cut/ split the parts/ components into single entities.
7. Revolve-: The revolving feature is used to make a cylindrical, rounded/revolved model around an axis. This feature is useful in making complex shapes around an axis.
8. Shell-: The shell feature is used to hollow out the 3D model leaving the faces & creating the thin walls by removing the selected area.
9. Curve Pattern -: The Curve pattern is used to make a rounded/ curve pattern of a sketch with a defined increment to a reference of the round axis.
10. Linear Pattern -: The Curve pattern is used to make a linear pattern of a sketch with a defined increment to a reference of the round axis. The pattern can be given a certain spacing/increment & angle too.
11. Mirror-: Mirror feature is used to copy the sketch/face/body with a reference of plane/axis.
12. Combine -: Combine command is used to combine or add the multiple solid bodies into a single body/ entity.
13. Revolve Cut-: This feature is used to cut and add the solid material to form a solid body around an axis/centreline. The revolve cut body can be a solid body, a thin line body.
14. Chamfer-: Chamfer is used to cut the sharp edges/face at a defined angle.
15. Curve-: The curve feature is used to make a complex shape/ entity that cannot be made using straight-line/arcs.
16. Projected Curve-: The projected curve feature is used to project a 3D curve using single/ multiple sketched curves onto a face in a solid body.
17. Composite Curve-: Composite curve is a feature that is used to combine the multiple curves into a single curve.
18. Point-: The point feature is used to create reference points on the planes, and faces. These points are used to construct the sketch/entity on the plane/faces.
19. Reference Plane-: Reference Plane feature is used to create a plane with reference to points/faces/edges on a body. The orientation of the plane can be defined with the angle value and its direction can be chosen. These planes can be used to construct a sketch/entity on a face in a solid body.
20. Sweep -: Sweep feature is used to create a solid body by sweeping a close profile/sketch along an open/closed path.
21. Swept Cut-: Swept Cut is used to cut a solid profile by sweeping a close profile/sketch along an open/closed path.
22. Surface Sweep-: Swept Surface is the feature that is used to create a swept surface with reference to the curve along a defined path.
23. Surface Trim-: Surface trim is used to create a single solid surface by eliminating the unwanted surfaces from two intersecting surfaces.
24. Loft Surface-: Loft surface feature is used to create the complex lofted surface between the two profiles, sketch/entity.
25. Knit Surface-: Surface Knit feature is used to merge/form a single 3d solid body/surface by selecting multiple surfaces. This feature merges multiple surfaces into a single surface/3d body.
26. Boundary Surface-: Boundary surface feature helps you create surfaces that are perpendicular/tangent to the surfaces.
27. Surface Extrude-: Surface extrude helps you to extrude the surface into a direction with reference to the plane/face/edges.
28. Sketch Picture-: This feature helps you to insert the sketch picture into the drawing. The sketch picture can be used as a reference while sketching the geometry.

Parts used in Assembly

1. Transmission Belt-: This part is modeled using the Boss Extrude feature & fillet command. The part is given a Leather-look black appearance.

2. Kickstand -: This part is modeled using the features & commands such as Boss Extrude, fillet, Cut extrude, split, dome & Loft command. The part is given a chrome appearance. This part is assembled to the chassis of the chopper.

3. Front Fender-: This part is modeled using Revolve, fillet & split commands. The part is given a chrome appearance.

4. Rear Fender-: The part is modeled using the commands such as Revolve, fillet, split & shell. The part is given a chrome appearance.

5. Transmission Chain-: The part is modeled using commands and features such as Chain Blocks, Boss extrude, Curve Pattern, fillet & mirror. The part is given a Copper appearance.

6. Front Wheel-: The part is modeled using commands such as revolve, boss extrude, Cut Revolve, Extruded cut, Curve pattern, Combine, Chamfer & Filler. The part is given a Black rubber appearance.

7. Rear Wheel-: The part is modeled using the commands such as revolve, boss extrude, cut extrude, curve pattern, fillet, combine, cut revolve & chamfer. The part is given a black rubber appearance.

8. Chassis-: The part is modeled using the commands/ features such as curve, sweep, mirror, boss extrude, cut extrude, chamfer, fillet, dome, split, revolve, mirror, and combine. The part is given a Siena appearance.

9. Chopper Engine-: The part is modeled using the commands such as -: Boss Extrude, Fillet, Revolve, Curve Pattern, Dome, Cut extrude, chamfer, Linear Pattern, Mirror, Split, Sweep, Combine, Revolve, Composite Curve, Project Curve. The Part is given a chrome appearance.

10. Front Fork-: The part is modeled using the commands such as -: Revolve, boss extrude, fillet, linear pattern, Dome, Body/Move/copy, Sweep, Project Curve, Mirror, Combine. The part is given a different appearance such as Light for the headlamps, rubber for the handles, Metal for the lever & rubber for the wire.

11. Gas Tank-: The part is modeled using commands such as -: Surface Sweep, Surface Loft, Surface Knit, Boundary Surface, Surface Extrude, Surface Trim, Curve, Mirror, Split Line, Fillet, Cut Sweep & shell. The part is given the Siena appearance.

12. Oil Tank-: The part is modeled using the commands such as -: Boss Extrude, Combine, fillet & shell. The part is given a metal appearance.

13. Pedal-: The part is modeled using commands such as -: boss extrude, fillet, revolve, dome, chamfer & linear Pattern. The part is given a chrome appearance.

American Chopper Assembly

The assembly of American Chopper design is performed on the old traditional technique of the Bottom to Top approach. In this type of Assembly process, each part/component is sketched and modeled individually. Then the mates are used to position and align the parts in the assembly.

This project gives insights on Bottom to up approach and how you can put all the designed parts into assembly and assembled them. In defining, mates users have to be very specific in defining the relations to the individual parts so that the assembled components function properly.

The types of mates used in the assembly of the chopper are-:

1. Coincident Mate.
2. Distance Mate.
3. Concentric Mate.
4. Limit Angle Mate.
5. Width Mate.
6. Parallel Mate.
7. Position Mate.
8. Tangent Mate.

The different views of the Assembly are-:

Rendering of Assembly using Photo-View 360 & Solidworks Visualization

Rendering of Assembly includes the rendering of parts, assembled body, setting up of scenes, setting up of the environment, setting up of camera, insertion of decals on to the parts, and setting up of lights. The rendering process provides a realistic view and feeling of the 3D object placed in a suitable environment.

The rendering process in this project provides us an understanding on what is the importance of setting up scenes, and how to play with the environment to provide the 3D assembled body a realistic view. The camera setup such as change of focal point, different camera views & perspective view of the camera. The Environment setup gives us instances of how to play with brightness, contrast, and other settings to enhance the appearance of the object. The rendering process in visualization taught us how we can play with the appearance of each component, apply the material to each component and play with them to get a perfect realistic experience of the assembled body.

Some of the rendered assembly views are attached below-:

Conclusion-: This Project provides us with brief learning on how to sketch & model your ideas into 3D sketches using the features & tools in Solidworks. The assembly tasks provide us a glimpse on Bottom to Top approach the traditional method used for the assembly of parts & components.

The Rendering tasks provide us instances on how to play with scenes, lights, camera & environment to provide a realistic experience of your object. Overall learning from this project can be concluded that it provides you the exposure to the industrial projects as well as a deep understanding & stronghold on the basic concepts of Solidworks.