Photo Realistic Rendering

Designing and Rendering of American Chopper in Solidworks

Objective:

The purpose of this project is to showcase my knowledge towards the 3D Model and rendering experience in Solidworks. It will be helpful for upcoming students or professionals who are interested in building up a rendering project.

Introduction:

In this project we will learn how to execute a Design project with proper methodology. And I have given a brief detail about the modeling of all components in American chopper assembly. I have used Soliworks Visualize and Photoview 360 software for a series of Photo-realistic renders in a studio setting. We will also see some shortcuts for modeling in the latest version of Solidworks (2019) that I have used. It will reduce the time consumption and increase your productivity.

Design Methodology (or) Action Plan:

I have created the Assembly with “Bottom-Up” approach. This method involves the following steps as,

1. Designing of piece parts of the assembly
2. Assembling the components with proper constraints
3. Applying Decals, Camera setups and scene composition
4. Final Rendering Result

Description:

(1.) Designing of piece parts of the assembly:

The American Chopper assembly consists of the following components,

• Transmission Belt
• Kick stand
• Chain
• Rear fender
• Rear Wheel
• Pedal
• Front Fender
• Front Wheel
• Oil tank
• Front fork
• Chassis
• Engine
• Gas tank

Before starting the modeling, Create a part template with required Units and planes in it and use that for all part models. Here i have used "Millimeter" as Units.

Transmission Belt:

A belt is a Loop of Flexible material used to link two or more rotation shafts mechanically. In this Chopper it is used for transmiision of power from Engine to Gearbox.

Appearence: Matte Rubber

Feature Tools: Extruded Boss and fillets

Sketch Tools: Sketch geometry like Line, 3 point arc & Offet Entities

Procedure:

1. Sketch on front plane by selecting it, draw a horizontal line from Origin and a 3 point arc. Apply relations like tangent

with line, etc., & give dimensions to make it fully defined.

2. Make an offset of 3.5mm of the sketch in inward direction.

3. Extrude the created sketch by giving appropriate dimension.

4. Apply fillets to all sides of extrude sketch for smooth finish.

5. Apply Matte Rubber as appearence.

Kick Stand:

A metal rod attached to a bicycle or motorcycle, lying horizontally when not in use. It can be kicked into vertical position to support the vehicle when it is stationary.

Appearence: Chrome steel

Feature tools: Lofted boss, Dome, Extruded cut, Split and fillet.

Sketch tools: Sketch geometry like Line, Circle, 3 point arc & Ellipse.

Procedure:

1. Sketch on the front plane, by drawing an ellipse which is horizontal to origin and give dimensions and relations to

make it fully defined. Then sketch on the right plane, by drawing a spline from the origin, activate handle and dimension it.

2. Create a new plane at the end of spline, sketch on it by drawing an ellipse and make pierce relation between spline and

ellipse midpoint.

3. Now Loft the sketch and check the desired output path whether it is twisted or correct.

4. Apply elliptical dome to the end of the spline and remove the unnecessary portion using extruded cut.

5. Apply Fillets with required radius and also apply Chrome steel as appearence.

Chain:

Chain acts as a connecting bridge between the engine and rear wheel which helps in transmitting the power.

Appearence: Chrome steel.

Feature tools: Extruded Boss, Curve, driven pattern, Mirror, Blocksand fillet

Sketch tools: Sketch geometry like line, Circle, straight slots and 3 point arc.

Procedure:

1. Sketch on front plane, by drawing two circles of different diameter, separated by a distance and connect them using

3 point arc on both sides, trim the unwanted portion.

2. create a throwaway sketch which is used to create inside and outside chain links. Make a block of these and save it.

3. Insert blocks on the larger end of the drawn circle and make a coinincident relation. Extrude the sketch by selecting holes

in inserted blocks as contours to create pins. Extrude again to create plates by selecting the remaining part in the blocks

and apply fillets. Repeat the Process.

4. Use a curve driven pattern to get required number of pins and plates over the curve.

5. Repeat the process over othercurves to get desired output.

6. Apply Chrome steel as apearence to it and save the part.

Rear Fender:

It is situated over rear wheel which protects the wheel from the foriegn particles like sand, mud and rocks, etc.,

Appearence: Painted Siena

Feature tools: Revolve Boss, Split, fillet and shell.

Sketch tools: Sketch geometry like line, 3 point arc, trim entities and offset entities.

Procedure:

1. Sketch on Front plane, by drawing a 3 point arc above the origin & apply the vertical relation with it.

2. Apply Offset inwards to extrude make it closed sketch using the extended entities and trim entities.

3. Revolve the sketch across the horizontal construction line at origin by giving proper directional angles.

4. Apply Painted siena appearence to it.

Rear Wheel:

A circular Component connected to the rear side of the chassis which recieves power rfom the engine. It Consists of

Rim, Rotor, Caliper, Sprocket and Tyre.

Apearence: Rim - Chrome steel

Rotor - Carbon steel

Caliper - Painted Siena

Sprocket - Chrome steel

Tyre - Matte Rubber

Feature tools: Revolved Boss & Cut, Extruded Boss & Cut, Circular pattern, Combine, Mirror, Chamfers and fillets.

Sketch Tools: Sketch geometry like Line, 3 point arc, circle, spline, rectangle, trim & Extended entities, Convert & Offset

entities.

Procedure:

1. Select front plane and sketch the outer part of wheel and dimension it to make fully defined.

2. Revolve the sketch across the temporary axis.

3. Sketch on the right plane, by drawing a vertical construction line from the origin and one more line at angle.

Draw a spline and mirror all the three entities across vertical construction line and extrude them.

4. For spider webbed design, offset all the drawn three entities and remove the unwanted portion using cut extrude.

5. Connect the spokes using 3 point arc, offset them and make it closed sketch by using line. Extrude the sketch.

6. Select front plane and draw a spline from the origin to remove unwanted area using extrude cut.

7. Select spokes and use circular pattern. Combine them to make a single solid body.

8. Rotor - Sketch on front plane, by drawing a circle and extruding it, trim others. Pattern circularly to create holes over the

rotor.

9. Caliper - Draw circles and lines as per desing of the body. Trim unwanted area and extrude it and apply the chamfers.

10. Sprocket - Draw a circle and extrude it. Apply chamfer to the outside and create teeth by cut extrude. Cut extrude the

unwanted areas and apply fillets.

11. Tyre - Use Rim as convert entities and revolver. Draw rectangle and apply dimensions, relations to make it fully defined.

Extrude it and apply fillets.

12. Apply the above mentioned appearences for respective bodies in the part.

Pedal:

The external part attached to chassis which is used for foot resting and gear changing.

Appearence: Chrome Steel

Feature tools: Revolve Boss, Extrude Boss, Dome, Linear pattern, Chamfer & fillets.

Sketch tools: Sketch geometry like Line, circle and spline.

Procedure:

1. Draw a sketch on the front plane, line and spline from the origin and give dimension to make it fully defined. Extrude it

and apply fillet. Slect the front surface of the extruded part and sketch on it by drawing two circles. use a dome circular

feature on it.

2. Apply linear pattern across the boss extrude and chamfer the corners.

3. Apply Chrome steel as part appearence.

Front fender:

It is situated over the front wheel to protect the wheel from mud and dust, etc.,

Apearence: Painted siena.

Feature tools: Revolved boss, split, fillet.

Sketch tools: Sketch geometry like line, spline, 3 point arc, extend and trim entities.

Front Wheel:

A circular object connected at front end on the vehicle helps in movement.

Apearence: Rim - Chrome steel

Rotor - Carbon steel

Caliper - Painted Siena

Tyre - Matte Rubber

Feature tools: Revolver Boss & Cut, Extruded Boss & Cut, Circular pattern, combine, Mirror, chamfer, fillet.

Sketch tools: Sketch geometry like line, 3 point arc, circle, spline, rectangle, Trim & extended entities, convert & Offset

entities.

Oil Tank:

A hollow part which stores oil to run the engine with minimum thickness of 3mm.

Apearence: Painted Siena

Feature Tools: Extruded boss, combine, shell, fillet.

Sketch tools: Sketch geometry like line, spline and cirlce.

Procedure:

1. Sketch on the top plane by drawing line, 3 point arc and give relation, dimension them for fully defined, extrude it.

2. Sketch on the front plane by drawing a spline and line, dimension them and extrude it by midplane through all and

combine two separate bodies.

3. Apply fillet and Painted Siena to it.

Front Fork:

It is a part of Chopper that hold the front wheel. It consists of two blades which are joined at top by the triple clamp.

It acts as a shock absrober which allows just the front wheel to react to the tracks by reducing the impact of it in other

parts.

Appearence: Fork - Chrome steel

Handle grip and brake wires - Matte Rubber

Head Lamp - Light glass

Feature Tools: Extruded Boss & Cut, revolved Cut, Dome, Project Curve, Swept Boss, Combine, Mirror and fillets.

Sketch Tools: Sketch geometry like line, spline, cirlce, convert entities and trim entities.

Procedure:

1. Fork Tube - Sketch on the front plane, draw cylinderical shape by using line and give dimensions and relations and then

revolve it.

2. Triple Clamp - Select top plane and draw a concentric circle to the fork tube and draw another circle left and upward.

Connect the circle and make it fully defined and extrude it.

3. Bulb - Select the front plane, draw a horizontal construction line, spline and revolve it. Move the bulb in z direction then

give filet.

4. Handle and brake wire - Select the top plane and draw the handle using spline, make it fully defined. draw a circle at the

end of the spline and sweep along the path. Here the projected curve is used to obtain the exact curvature.

5. Select the Bodies, miiror it and combine.

6. Apply the above mentioned appearence to the respective bodies of the part.

Chassis:

The most essential part of a vehicle on which all the components of a motorcycle, like the suspension, wheel, fuel tank,

seats, handlebars, etc., are attached to this base structure which leads strength to the vehicle operation.

Apearence: Painted Siena

Feature Tools: Extruded Boss & Cut, Dome, split, project curve, swept Boss, combine, Revoled Boss, Chamfer, Mirrors and

Fillets.

Sketch Tools: Sketch geometry like line, spline, 3 point arc, circle, convert & Offset entities.

Procedure:

1. Insert Blueprintof chopper in the front plane, adjust the location, transparency and sketch on it. Draw two concentric

circles with an offset of 4mm.

2. Draw a horizontal and vertical line from origin. Then a spline connects the circle center and tangent to the horizontal

line and gets a projected sketch.

3. Sketch on top plane, draw a horizontal line parallel to the line and draw on the front plane connected with the spline to

make it fully defined.

4. Next Sketch on the right plane, draw a spline from the top to bottom with relation to origin.

5. Cut extrude the unwanted and mirror the bodies and combine.

6. Apply fillet & Chamfer and Painted Siena as Appearence to the part.

Engine:

Apearence: Chrome steel

Feature Tools: Extruded Boss & Cut, Revolved Boss, Dome, Split, Project curve, composite curve, Swet boss,

Circular pattern, chamfer, mirror and fillets.

Sketch tools: Sketch geometry like line, spline, 3 point arc, circle, convert & Offset entities.

Procedure:

1. Insert the picture according to X, Y, Z reference, select front plane draw a diagram of base of engine by using line and

3 point arc, extrude it. Then again extrude it on the larger circle and small one.

2. Sketch on the front plane by line entities then extrude it and give fillet to the base of the engine.

3. Select top plane, draw the pulley by line and turn on a temperary axis to revolve it.

4. Sketch on the pulley by selecting the edge then draw rectangle and extrude towards outside to next surface and select

sketch and make circular pattern.

5. Slect the outer face of the pulley and sketch on it, draw a circle inward then draw a small cicle vertical to origin, use the

circular pattern feature, select the center point respectively and coincident. Then use Extrude cut feature to remove the

material.

6. Select the front plane to create the cylindrical part of the engine. Draw aline from the origin again draw a line which

will be collinear to line. Generate the new plane by selecting the line and end point on the line. Sketch in a new plane,

draw arectangle and extrude it upward. Use fillet as well. Create an angle rectangle to the new plane and use Cut

extrude.

7. Draw a curve, sketch 2D diagram in two different plane by ensuring the end point shold be same, use convert entities,

Construction line, Spline after projected curve, draw two concentric circles, make use of pierce relation to curve then

sweep it.

Gas Tank:

Apearence: Tank - Paint Siena

Seat - Fabric

Feature tools: Swept surface, Loft surface, Boundary surface, projected curves, knit surface, Sweep cut, combine,

Sheel, mirron, and fillet.

Sketch tools: Sketch geometry like line, spline, circle, convert & Offset entities.

Procedure:

1. Insert Blueprint in the front plane and give proper dimensions for locating and rename it. Sketch on front plane by

Construction line, spline roughly as per sketch picture and give dimensions to make it fully defined.

2. Create a plane at the end point of the spline and sketch on it, by drawing another spline & make a pierce relation

with sketch 1, then sweep the surface.

3. Sketch on top plane by drawing splines & lines. Trim outside portion using trim surface.

4. Create one more plane using the front plane and end point of surface 2 as reference. Sketch on it, by drawing a spline

and a vertical construction line to dimension it.

5. Draw tow sketches on front plane and Midplane, using Spline, line and project curve and use lofted surface along the

projected curve.

6. Repeat the procedure for sketching the remaining surface, mirror and apply kint surface.

7. Seat - Selct the outer edges and offset it and extrude it and apply fillet.

8. Remove the unwanted suface using Swept Cut and apply shell to the body.

9. Apply the above mentioned appearence to the respective solid bodies of the part.

(2.) Assembling the components with proper constraints:

1. All parts which are designed in part file are to inserted in this assembly.

2. Insert the components one by one as per requirement.

3. Apply mates to each and every parts for proper alignment.

4. Apply Mate condition to wheels and kick stand with top plane to snap it the floor.

Rendered Assembly:

(3.) Applying Decals, Camera setups and scene composition:

In this section, Decals (a Design prepared on special paper) are applied to Gas tank, Oil tank and Rear Fender as

Shown below.

Camera Setups and Scenes and lights:

Camera set-up is essential for the final rendering of chopper which helps in showcasing the realistic image.

Check appropriate scenes and proper light set-up also.

(4.) Final Rendering Result:

I have used Solidworks photo Visualize to make it realistic in looking.

1. Import the assembly file into the visualize application.

2. Change the appearence of parts as per requirement.

3. Add Scenes (Environment) and Cameras for proper background and location.

4. Select the Rendering speed and resolution and check the output. Once everything is ok, then do final rendering and

save the file.

Conclusion:

Now the Designing and rendering of the Amreican chopper is completed as per the design methodology.

I hope you have understood it clearly and made easier for you to give realistic rendering and background scenes.

This would help you to handle any rendering in a quick and organized way.