Photo Realistic Rendering

 

 

Transmission belt is a machine component used to transmit power from one shatt/ pulley or a rotating component to another. These belts are made mostly of Rubber canvas material having upsides such as low slip, long life and low maintenance costs. The only downside of belt is power lost during transmission.

 

The transmission belt used in the chopper is used to drive the chain shaft driven by the engine flywheel.

• 3 Point arc
• Line
• Sketch offset
• Extrude
• Fillot
• Appearance

• Sketch on Front Plane -Two 3-point orcs of radius 61 mm and 70 mm respectively.
• Give horizontal relation between the centres of both the arcs and use Smart dimension to give a distance value of 350mm between both the centres.
• Drow lines above and below to connect both the arcs.
• Make both the lines tangent at all 4 points with the arc.
• Use sketch offset on the whole sketch of 3.5mm in ouler direction.
• Extrude the sketch region and Blind 88 mm.
• Use fillets of 1mm on shorp edges of the belt.
• Apply appearance of Matte Rubber on the port.
• Save the part using oppropriate name.

2. Kickstand or Side Stand:

Kickstand is a part of bike which helps to keep the bike in up-right position. Its made of a hard metal piece that flips down to touch the ground and provide support to the bike.

Feature and Sketch Tools:

• 2d sketch 
• ellipse
• spline
• pierce
• loft
• cut extrude
• Boss extrudes
• split

Procedure for modelling:

• First draw an ellipse in the front plane using Ellipse tool and align it with the origin.
• Then create a spline from the origin in the midplane using the Spline tool and give dimensions to it.
• Now generate a new plane normal to the spline using Plane tool from Reference Geometry.
• Then create another ellipse on the newly generated plane such that it's centre aligns with the ending of the spline.
• After that using the Lofted Boss/Base tool generate a solid by clicking on the two ellipse and then using Centerline Parameters make the solid allign with the spline.
• Then make 2 domes on either sides of the part using the Dome feature from the Features tab in the given dimensions.
• Now on one side make an extruded cut by drawing a rectangle on the Mid Plane and then extruding it by Through All-Both option.
• After that draw a line on the plane that was created previously using Midpoint Line tool and align it horizontally and vertically withe the origin.
• Then using the Split features from Features tab slice of a small piece of the part.
• Now using Extruded Boss/Base tool extrude a circle which is drawn on the Top plane by selecting Up To Next option for both the directions.
• After that for creating fillets on the parts select the Fillet tool and click on the edges where the fillets have to made.
• Finally a chrome appearance is given to the part using Appearances Scenes and Decals tab.
• Save and close.

3.Front Fender:

         Fender is a part of automobiles that covers the wheel. The fender's function is to contain the various material such as stones, mud, liquids on the roads which otherwise would have sprayed itself on to the inside of the car or the pedestrian behind the car. The front fender is used for the front wheel and rear fender is used for the rear wheel. The fender is also known as a mudguard.

Features & Sketch Tools:

• 2d sketch
• 3-point arc 
• offset
• Extend
• Trim
• Revolve
• spline
• Fillet

Procedure for modelling:

• First Draw a 3-Point arc on the Front Plane using the 3 Point Arc tool from Sketch Tab with the given dimensions.
• Then make another offset arc towards inward using the Offset Entities tool from Sketch Tab.
• Then join the two arcs using the line tool and the Trim Entities tool.
• After that draw line from the center on the same plane and make its one end vertical to one end of the arc.
• Then using the Revolve tool revolve the Shape to create a front fender part.
• For giving an appearance use the appearance tool and then select Bue colour.
• Now draw another arc in the Top plane on either side of a line drawn from the origin using Dynamic Mirror tool and the select the Split tool from featues list and then trim the part that is not needed.
• Similarly draw another arc the on the Front Plane and the using Split tool remove the remaining material.
• Then using the fillet tool round the edges of the part.
• Finally save the part.

4. Rear Fender:

Fender is part of automobiles that frames the wheel. The fender's purpose is to contain the various material such as stones, mud, liquids on the roads which otherwise would have sprayed itself on to the inside of the car or the pedestrian behind the car. The front fender is used for the front wheel and rear fender is used for the rear wheel. The fender is also known as a mudguard.

Features & Sketch Tools:

•  2d sketch
• 3-point arc
• Extend
• Trim
• Revolve
• spline
• Fillet
• Shell

Procedure for modelling:

• First Draw a 3-Point arc on the Front Plane using the 3 Point Arc tool from Sketch Tab with the given dimensions.
• Then make another offset arc towards inward using the Offset Entities tool from Sketch Tab.
• Then join the two arcs using the line tool and the Trim Entities tool.
• After that draw line from the center on the same plane and make its one end vertical to one end of the arc.
• Then using the Revolve tool revolve the Shape to create a rear fender part.
• For giving an appearance use the appearance tool and then select Blue Colour.
• ]Now draw another arc in the Top plane and the select the Split tool from featues list and then trim the part that is not needed.
• Then using the fillet tool round the edges of the part.
• Finally save the part.

5. Oil Tank:

Oil tank is a component used to store the oil for lubrication and cooling purposes of engine components. Oil tanks can be of various kinds like engine oil tank, coolant oil tank, radiator oil tank etc. The oil tank used in this American chopper model is used for engine lubrication and cooling. This tank is placed right below the rider seat on top of the gearbox.

Features & Sketch Tools:

• Lines
• 3-point arc
• Boss Extrude
• Combine
• Fillet
• Shell

Procedure for modelling: 

• Rename the Front plane to Mid Plane Oil tank.
• Start a sketch on the Top plane with a horizontal construction line of length 230mm passing through the origin.
• Sketch a line 50mm on one end of the construction line perpendicular to it.
• Sketch an angled line and complete the sketch with an arc.
• Create a reference point vertical to the origin 146mm above.
• Make the angled line collinear to the reference point. Make a tangent relation between the angled line and the arc.
• Mirror the whole sketch about the construction line of oil tank.
• Extrude the sketch blind 170mm.
• Now sketch on the midplane.
• Extrude this sketch through all in both directions.
• Use Combine feature and select operation type as common.
• Fillet all the edges 10mm.
• Create a shell of 3mm to create a hollow tank.
• Apply appearance white on fillet and blue on the oil tank and save the part.

6. Chain:

A chain is a set of several links made of small plates and pin joints, connected in a loop to make a power transmission component. This is mainly used to transmit power from one shaft to another using sprockets as connecting means to the shafts. The main advantage of chain is high power transmission capacity, good flexibility, low cost. The disadvantage of chain is high maintenance.

Features & Sketch Tools:

• 3-Point arc
• Centrepoint slots
• Circle
• Extruded boss
• Make and save block
• Fillet
• Curve driven pattern- tangent to curve
• Mirror
• Appearance

Procedure for modelling: 

• . Rename the Front, Top and Right planes to Mid Plane chain, Centre Plane chain and Front plane chain respectively.
• Sketch the chain path with two 3-point arcs of same dimensions as the rear and front sprocket with diameters of 289mm and 99mm respectively.
• Give 650mm as the horizontal dimension and 147mm as vertical dimension between the 2 arc centres.
• Join the 2 arcs from top and bottom with 3-point arcs of diameter 1500mm and keep tangency at the points.
• Create 2 chain links with pins of diameter 8mm and centre to centre distance of 15.13mm and extrude the pins midplane 25mm.
• Sketch the link plates with appropriate dimensions and extrude the plates of 1 link offset by 9.5mm and value of 2mm.
• Extrude the second link selecting from the inner vertex of the 1st link and  value of 2mm.
• Fillet the sharp edges of pins with value 0.5mm.
• Create a block of both the links and save it as block for future use.
• Make the centre of 1st link coincident to the tangency point of chain path sketch.
• Select Linear Pattern-Curve driven up to the next tangency point of the chain path.
• Import the saved link blocks and repeat the process of pattern separately for all new tangency points for smooth transition of chain links.
• Put all the pins in a new folder and all the plates in a different folder in feature tree.
• Mirror the plates folder across the chain path sketch.
• Apply appearance of chromium plate to the body and save the part.

7. Pedal:

A pedal is a motorcycle component used by the rider to place his/her foot on it while riding the bike. This is also called foot peg and is mounted on both sides of chassis. Its position depends on the type of motorcycle in a chopper type motorcycle, the pedals are placed in forward position such that the legs of the rider are fully extended in a comfortable manner. The pedals also contain protruded sections so as to provide grip to the rider's foot to avoid any kind of slippage. The brakes and the gear shift pedals are mounted on each of the pedals or are nearly placed.

Features & Sketch tools:

• 3-Point arc
• Circle
• Spline
• Line
• Sketch fillet
• Extruded boss
• Revolve
• Füllet
• Dome
• Chamfer
• Linear
• pattern
• Appearance

Procedure for modelling:

• First sketch the given shape using the given geometry on the Front plane using various tools like Line,Circle and Spline tools.
• After that extude the shape to a given distance.Then extrude the two smaller circles on one side to a particular distance.
• Now give fillets to the first piece that we have created After that draw a sketch on the top plane using constuction line and normal line.
• Then Revolve that shape with respect to the construction line.
• Now create a dome over that revolved part using the Dome tool from the features list.
• After that give fillets to the dome edges and the small circle extrusions that were previously created.
• Then Extrude the other two circle on the same side as that of the revolved extrusion.
• Now give Chamfer to both the newly created extusions using the Chamfer tool.
• After that draw an offset sketch of the outer edges of the newly created extrusions on the Front Plane and then extrude it with an offset.
• Then give fillet to it and using the Linear Pattern method copy the extrusions across the parts.
• Finally give fillets to whereever necessary.

8. Front Wheel:

Wheel consists of the rims and the tyre which make it the component that makes connection between the motorcycle and the ground. The rim is an important strength component which ensures safe load carrying capacity of the bike. It should have high compressive strength so as to ensure safety while moving. It should be able to absorb shocks and impacts. The tyres are the main contact surface to the ground. It is generally made up of rubber to ensure flexibility and bump absorption. The tyres contain treads which provides grip to the road. The wheel also houses a Disc brake rotor and its calliper.

Front wheels of choppers are always larger than the rear wheel with narrow section as compared to the latter. The front wheel in this American Chopper has a diameter of 604mm which is approximately 23.7 inches. The tyres have a narrow section meaning narrow surface contact.

Features & Sketch tools:

• 3-Point arc
• Lines
• Splines
• Mid-point line
• Circle
• Sketch fillet
• Trim
• Extend
• 3-point centre rectangles
• Revolve boss/base
• Extrude boss/base
• Extrude cut
• Revolve Cut
• Circular Pattern
• Combine
• Fillet
• Chamfer
• Appearance

Procedure for modelling:

• Create a horizontal mid-point line of 110mm on the front plane origin.
• Sketch a 40mm vertical line on both ends of the mid-point line and close the sketch with a line.
• Create a horizontal line of 140mm, 300mm above the origin and make its midpoint vertical to the origin.
• Create a 3-point arc and make its centred with respect to the above line and give it a radius of 230mm. Make sure that the end points of arcs have horizontal relation.
• Close the sketch with lines and give an angle of 75" and sketch fillet of 7.5mm.
• Create a centre line connecting mid-point of above line with mid-point of there and make sure it is vertical Give a vertical distance of 28mm to this line.
• Make sure the sketches are fully defined and revolve the sketch about the line on origin.
• Now create a sketch on Right plane to create spokes.
• Create the stetch using splines,3-point arc and construction lines.
• create relations.
• Extrude bos the sketch using midplane and D1=122mm and do not merge the result.
• Create another sketch on right plane and create 4 splines.
• Extrude cut throught all both and deselect the auto-select option from feature scope and assign only the required body to cut.
• Sketch on right plane 3 circles of Ø215, Ø350 and Ø485 from the orgine.
• Make cob web sketches.
• Offset the spokes 4.5mm inwards and trim the external 3 circles make it construction.
• Use the intersection points of the construction lines and the 3 circles as reference points to create cob web arcs.
• Make 3-point ares at all intersection points.
• Give the dimensions to all arcs.
• Offset all the arcs 8mm below and trim extra.
• Extrude all the arcs up to the spoke vertex on both sides.
• Create new sketch on the Front plane.
• Convert using intersection surface- the inner face of rim on the sketch.
• Create the sketch.
• Revolve cut the sketch about the centre line and deselect auto select in feature scope and select only required body.
• Use circular pattern of the cob web with 3 instances and select the hub as the direction of pattern.
• .Combine the spokes and cob web with the revolved rim.
• Fillet the front and back face of the spokes as required.

Model a Disc brake rotor 

• Sketch a circle on the right plane of 0 345mm.
• Extrude it offset 45mm and blind dl=7mm and don't merge the result.
• Create sketch as shown for the ventilation hales 160mm vertical to the origin on the face of disc.
• Use circular sketch pattern with 14 instances about the disc centre and fully define the sketch Extrude cut the sketches by using up to next.
• Create new sketch on the same disc face for slot cuts.
• Sketch 2 circles about the origin with 0 100mm and 240mm.
• Sketch a line vertical to the origin to connect both circles.
• Sketch another line connecting both the circles 25° apart from the previous line.
• Trim the outer sketches and provide sketch fillets of R5 to 4 corners of the sketch.
• Extrude cut the sketch up to next.
• Use circular pattern with 10 instances about the rotor centre.
• Now sketch a circle of 0 40mm on right plane and extrude cut it through all both to create and axle hole.

Model the colliper for the disc brake

• Sketch on the rotor face 2 circles of 200mm and 380mm.
• Sketch a vertical construction line from the centre of rotor above.
• Sketch 2 lines intersecting both circles keeping the lines 54° apart.
• Dimension an angle of 63° between the construction line and the solid line and trim the extras.
• Extrude the calliper sketch 19.5mm in d1 and 10.5mm in d2 and do not merge results.
• Chamfer both faces of calliper (distanco-distance with dl-6mm and d2=20mm).
• Fillet the edges with appropriate dimensions.

Model the tyre of front wheel:

• Sketch on the Front plane and convert entities with intersection curve and delete the bottom instance that is converted.
• Sketch a 3-point arc of Ø226mm keeping the end points of arc horizontal and at a distance of 154mm.
• Centre of the arc should be horizontal to the origin and at a distance of 7mm.
• Sketch lines to connect the end points of arc to the converted entity on top of the rim.
• Use sketch fillet of 7mm at corner points.
• Revolve the sketch about the Right plane centre axis line and do not morge results.
• Sketch 2 more rectangles of dimension 90mm x 8mm.

Tyre treads sketch:

• Sketch on Front plane 2x 3-point centre rectangle of dimension138mm x 8mm.
• Convert the rim edge in to the sketch and make it construction and place it.
• Extrude cut the entire sketch offset 450mm and use offset from surface of tyre face 4mm.
• Reverse the feature and see the preview for appropriate cuts.
• Keep the feature scope to the tyre only.
• Use Round fillets on the tread edges to make it look smooth.
• Use circular pattern for the tread cuts around the centre of tyre/hub with 14 instances.

Apply the following appearances:

• Candy red apple car paint for calliper.
• Chromium plate for rims and spokes with cob web design.
• Chromium plate for Disc brake rotor.
• Matte rubber for the tyre.
• Save the part as Front wheel

9. Rear Wheel:

Wheel consists of the rims and the tyre which make it the component that makes connection between the motorcycle and the ground. The rim is an important strength component which ensures safe load carrying capacity of the bike. It should have high compressive strength so as to ensure safety while moving it should be able to absorb shocks and impacts. The tyres are the main contact surface to the ground. It is generally made up of rubber to ensure flexibility and bump absorption. The tyres contain treads which provides grip to the road. The rear wheel also houses a Disc brake rotor and its calliper and specifically a Chain sprocket to drive the wheel using power transmitted from engine.

Rear wheels of choppers are generally smaller in diameter than the front wheel having a broad section as compared to the latter. The rear wheel in this American Chopper has a diameter of 484.5mm which is 19 inches. The tyres have a broad section meaning broader surface contact heavy load carrying capacity and greater grip.

Features & Sketch tools:

• 3-Point arc
• Lines
• Splines
• Mid-point line
• Circle
• Sketch fillet
• Trim
• Extend
• 3-point centre rectangles
• Revolve boss/base
• Extrude boss/base
• Extrude cut
• Revolve Cut
• Circular Pattern
• Combine
• Fillet
• Chamfer
• Appearance

Procedure for modelling:

• First, draw a shape on the front plane so that it can be revolved at a particular axis to form the rim of the rear wheel and the shaft of the rear wheel.
• After that on the right plane draw an arc using the 3 Point arc tool and make a shape and then it is extruded at a particular distance from the middle towards either side of the plane.
• Again draw certain shapes on the right plane using drawing tools and then using the Extruded cut option make spokes for the rim.
• Then draw arcs that connect the spokes on the same plane and extrude them.
• Now using the Circular Pattern tool select the spoke that was made previously and then by selecting an axis to make more of the same spoke throughout the rim.
• After that combine all the parts(rim, spokes and the shaft).
• Then start a new sketch on the front plane after selecting the intersection curve option on the rim for that plane. Now draw a shape so that it can be used to extrude cut a certain amount of materials from the spokes and the shaft.
• Now give fillets to the spokes and other parts that are created till now.
• After that to generate a hole at the center of the rim draw a small circle on the right plane and then use the extrude cut option.
• Then draw another sketch on the front plane and is then revolved to create the part that forms the shaft.
• Now draw another circle on the right plane and then extrude it with an offset. And this forms the disc of for the brakes and to make holes another shape is drawn on the plane of the disc. Then using the linear pattern option make 4 of them at a particular angle. Now extrude cut all 4 of them.
• After that using the circular pattern tool create the same holes throughout the disc.
• Then draw a sketch on the same disc plane and using the circular pattern tool make copies of it throughout the disc.
• After that fillets are given to the parts that are created above.
• Now on the right plane draw a sketch of the caliper and is extruded.
• Then Chamfers are given to either side of the chamfer.
• Then fillets are given certain edges of the caliper.
• After that, to make the sprocket for the chain a circle is drawn on the right plane and is extruded and is given chamfers on the edges.
• Now another sketch is drawn on the plane of the to create the cut for the gear and each of the cuts are copied throughout the part using circular pattern option.
• After that, another pattern is drawn and extruded on the same plane to create a design on the sprocket.
• Again the fillets are given to the sprocket.
• Then to create the tire for the rear wheel, a sketch is drawn on the front plane and is then revolved using the revolved boss tool.
• After that for giving the threads to the tire shapes are drawn on the front plane and are then extruded and the fillet is applied.
• Using the circular pattern tool the thread is mode to spread throughout the tire.
• Finally, appearance are given to each part using the appearance tool.

Model a Disc brake rotor 

• Sketch a circle on the right plane of 0 345mm.
• Extrude it offset 45mm and blind dl=7mm and don't merge the result.
• Create sketch as shown for the ventilation hales 160mm vertical to the origin on the face of disc.
• Use circular sketch pattern with 14 instances about the disc centre and fully define the sketch Extrude cut the sketches by using up to next.
• Create new sketch on the same disc face for slot cuts.
• Sketch 2 circles about the origin with 0 100mm and 240mm.
• Sketch a line vertical to the origin to connect both circles.
• Sketch another line connecting both the circles 25° apart from the previous line.
• Trim the outer sketches and provide sketch fillets of R5 to 4 corners of the sketch.
• Extrude cut the sketch up to next.
• Use circular pattern with 10 instances about the rotor centre.
• Now sketch a circle of 0 40mm on right plane and extrude cut it through all both to create and axle hole.

Apply the following appearances:

• Candy red apple car paint for calliper.
• Chromium plate for rims and spokes with cob web design.
• Chromium plate for Disc brake rotor.
• Matte rubber for the tyre.
• Save the part as Front wheel

10.Front Fork:

The element which connects the front wheel and axle to the rest of the frame is known as o front fork. The tripe clamp or yoke is one of the main parts of the front fork. The front fork contains a front brake and front suspension.

Features & Sketch tools:

• 3-Point arc
• Lines
• Splines
• Circle
• Trim
• Revolve boss/base
• Extrude boss/base
• Linear Pattern
• Extrude cut
• Revolve cut
• Dome
• Body move/copy
• Sweep
• Curves-Projected
• Reference geometry- planes
• Mirror
• Combine
• Fillet
• Chamfer
• Appearance

Procedure for modelling:

• Sketch the following on front plane.
• Revolve it about the 1330mm line.
• Sketch on top face of R30mm of fork and sketch a circle of Ø75mm.
• Create the sketch to create triple clamp.
• Extrude boss/base the sketch from offset toward the fork 20mm and d=40mm and do not merge results.
• Fillets all edges 5mm.
• Show temporary axis and use linear pattern for the triple clamp with 2 instances at 240mm distance.
• Create following sketch for the axle and extrude (up to surfacd select triple clamp flat surface ).
• Merge only with fork.
• Create a connection between triple clamps.
• Extrude it up to the upper triple clamp surface .

Headlight Bucket Sketch:

• Sketch on Front plane.
• Revolve it about the line and do not merge.
• Move the bucket in Z direction-48mm.
• Make headlight detailing by extrude cut 5mm on face and using sketches and use revolve cut.
• Create a dome on headlight lens of 7mm.

Handle bar sketch:

• Sketch a 035mm circle on face of triple clamp.
• Sketch on top plane.
• Sketch on Front plane.
• Use curves- Projected curves and create a curve from above 2 sketches.
• Sweep the circle on the curve path.
• Create handle grip on reference plane at handle bar end by sketch.
• Revolve the sketch about the 154mm line and merge with clamps only.

Brake lever sketch:

• Create a new plane with plane as reference at an angle of 160°.
• Sketch on this plane 2 .
• Extrude the sketch midplane with dl=15mm.
• Fillet the edges appropriately.
• Create 2 sketches for cable and use projected curves.
• Mirror the whole front fork about flat face of triple clamp and combine the bodies.

Apply following appearances:

• Chrome plate to headlight buckets, forks, triple clamp and handle bar.
• Glossy rubber on handle grips and cables.
• White area lights to the headlight face with luminous intensity of IW/sm³

11 Chassis:

Chassis is the main strength component or the structural framework of any automobile. All components of the motorcycle are either directly or indirectly mounted to the chassis. The chassis has to be the strongest component of any vehicle as it is the base structure The chassis should be made up of high strength material that can withstand variable compressive tensile and shear stresses.

The chassis used in this American chopper motorcycle is a rigid hardtail frame chassis which excludes the rear suspension component.

Features & Sketch tools:

• Sketch Picture
• Lines
• Splines
• Circle
• Trim
• Extrude boss/base
• Extrude cut
• Revolve
• Dome
• Curves-Projected
• Sweep
• Split
• Reference geometry planes
• Mirror
• Combine
• Fillet
• Chamfer
• Appearance

Procedure for modelling:

• Rename Top plane and Front plane to Bottom plane chassis and Midplane chassis respectively.
• Sketch on mid plane chassis and bring in the sketch picture of the chopper.
• Place the sketch picture by applying coordinates as x-930mm and y=-805mm. Use transparency as required.
• Sketch on midplane chassis taking a reference of the sketch picture draw splines and sweep the splines with hollow tubes of 040mm and offset 4mm inwards to create concentric circles.
• Use Projected curves for chassis tubes in 30 as in sketch picture Create sketch for Chassis back plate on right plane.
• Extrude boss the sketch 22mm away from tube section and merge results.
• Extrude cut the portion on back plate as per chassis.
• Sweep the swingarms on a new reference plane and create hub, axle and dome on hub.
• Create a new reference plano and Sketch for upper tube of chassis.
• Sweep the sketch with similar tube sections as before.
• Use split and consume the bodies after the back-plate section.
• Create another reference plane for the downtube and create splines as per sketch picture and sweep the path using pierce relation.
• Use split at intersection of downtube to lower chassis and consume cut bodies.
• Create the sketch for steering system.
• Revolve about the construction line and use split to consume bodies at intersection.
• Sketch for creating the chassis base plates.
• Extrude the sketch up to next.
• Creating mounts for foot peg and kickstand.
• Use extrude boss, extrude cut and appropriate fillets for the mounts and mirror the foot peg mount about midplane chassis.
• Combine all solid bodies into one as chassis.
• Create a reference plane as bottom plane fuel tank 308mm above the bottom plane chassis.
• Apply black appearance from painted-car and save the part.

12. Engine:

Engine is the main powerhouse of any automobile, Motorcycle engines are generally Internal combustion Spark ignition type. The engine consists of piston cylinder arrangement which powers the motorcycle. The IC engine houses air intake, exhaust outlet and fuel intake ports

This American chopper motorcycle has a V-Twin type engine consisting of external air filter, spark plugs for each cylinder, transmission pulleys, air cooling fins, starter motor, front sprocket for chain drive, exhaust pipes and casing for sump and gearbox. It also consists of 4 mounting points to the chessis.

Features & Sketch tools:

• Sketch Picture
• Lines
• Splines
• Circle
• Circular sketch pattern
• Construction line
• Centre point rectangle
• 3-point centre rectangle
• Trim
• Extrude boss/base
• Extrudo cut
• Revolve
• Dome
• Curves-Projected
• Composite curves
• Sweep
• Split
• Reference geometry- planes
• Circular pattern
• Linear Pattern
• Mirror
• Combine
• Fillet
• Chamfer
• Appearance

Procedure for modelling:

• Import the sketch picture of chopper and place on front plane with x-1493mm and y=-965mm. Use appropriate transparency.
• Sketch using the picture reference on front plane the base of engine.
• Extrude the base 200mm midplane and the gearbox section 150mm midplane.
• Use fillets on sharp edges.
• Sketch the transmission belt pulleys on right plane.
• Revolve the sketch and make extruded rectangles on the pulley for grip element for belt, use circular pattern.
• Make circular pattern holes on pulley face and apply dome.
• Do similar operations for rear pulley.
• Sketch for starter motor with the picture reference and extrudo it appropriately.
• Sketch for cylinder casing using reference plane.
• Sketch a rectangle on the plane and extrude it as per sketch reference.
• Provide fins using linear pattern and fillet as required.
• Create spark plugs and provide fillets.
• Mirror across the right plane to create second cylinder casing.
• Create mounts on bottom for the chassis mounts.

Front Sprocket:

• Sketch 040mm at sprocket reference from the picture.
• Extrude the sketch 80mm and sketch sprocket circle and extrude further 15mm.
• Provide chamfer, chain cuts as done with rear sprocket.
• Provide chamfer to the sprocket shaft.

Exhaust pipes:

• Use spline following the sketch picture and use projected curves.
• Sketch a line to cut out the exhaust ends using split.
• Use splines and projected curves for air intake manifold.
• Sketch the air filter and revolve it and provide cuts using extrude cuts.
• Use splines and sweep it with circles for the spark plug cables.
• Provide polished Aluminium appearance to the engine and gloss black to spark plugs and the cables and save the part as engine.

13. Gas Tank:

Fuel tank is the fuel storage component of the motorcycle. It is made to store flammable fluids or gas in a cool state away from the engine heat. Safety of the petrol is the main criteria in designing the fuel tank. It is connected to a fuel pump or a fuel regulator device such as carburettor or an injection system to supply appropriate amount to the engine with proper mixture of air and fuel.

The fuel tank of this American chopper is made to house a seat and fit to the chassis centrally with the mount. It is made up of surfaces and finally these surfaces are knit together to form a complete solid body with hollow shell to store fuel.

Features & Sketch tools:

• Sketch Picture
• Lines
• Splines
• Construction line
• Trim
• Surface sweep
• Surface loft
• Surface trim
• Boundary Surface
• Surface knit
• Surface Extrude
• Curves
• Projected curve
• Split line
• Sweep cut
• Reference geometry-planes
• Mirror
• Shell
• Fillet
• Appearance

Procedure for modelling:

• Rename the Front, Top and Right planes to Mid plane FT, Bottorm plane FT and Right plane FT respectively.
• Bring in sketch picture to Mid plane FT and place it x=-2096mm y=-1096mm and use appropriate transparency
• Sketch on mid plane FT .
• Create new reference plane using front plane on the starting point of the sketch.
• Create appropriate splines on new plane using the picture reference.
• In surface tab use sweep in direction of Mid plane FT.
• Sketch splines on Bottom plane FT as in fig73 using the picture reference.
• Create projected curves, new planes and sketch as in reference picture.
• Use surface loft for the new sketches.
• Use boundary surfaces and appropriate relations to create the surface model of fuel tank.
• Create sketch for the seat on the bottom plane ft.
• Use surface extrude for the seat and provide appropriate fillets.
• Knit all surfaces and make solid Create a shell of 3mm without any selection.
• Give appearance to seat as beige cotton fabric and the fuel tank as painted car blue.
• Save the part.

Assembly

American Chopper Motorcycle Assembly:

The assembly of the chopper consists of all the parts attached in appropriate manner with proper mates. The main component chassis is first fixed and other parts are mated with respect to its position.

                                                                             Fig: Front View

                                                                                   Fig: Right View

                                                                                            Fig: Top View

                                                                                            Fig:Isomatric View

                                                                                                Fig : Camera View

Mates in assembly:

Mates in assembly environment is analogous to relations in part environment. Basically, it is the relation between two different components. Solidworks assembly mates consists of 3 main mates namely Standard mates, Advanced mates and Mechanical mates.

Standard mates consist of Coincident, Concentric, Parallel, Perpendicular, Tangent Lock, Mate alignment angles and distance mates.

Advanced mates consist of Profile centre, Symmetric, Path mate, Width mate, Linear/Linear coupler, Angle and distance mates.

Mechanical mates consist of Cam, Slot, Hinge, Gear, Rack & Pinion, Screw, Universal joint.

The analysis tab under mates is used to define motion analysis between two components.

Procedure for Assembly:

• Fix the chassis position on the Front plane of the assembly coincident plane chassis.
• Give relation coincident Mid plane chassis and front plane engine.
• Make the engine mounts coincident to the base plate of chassis and 20mm behind the vertical face of plate.
• Make the pedals concentric and coincident to the mounts and mirror the part appropriately.
• Use coincident, concentric and limit angle mates with kickstand and mount.
• Give relation coincident Mid plane chassis and Right plane rear wheel and make the axle hole concentric to the Hub axle on swingarm.
• Give relation parallel to right plane chassis and front plane of rear wheel.
• Make rear fender concentric to rear wheel and give relation parallel to vertical plane Rear Fender and Right plane chassis.
• Give relation coincident to mid plane chassis and mid plane rear fender.
• Give width mates, concentric and angle mates to transmission belt on pulleys.
• Make oil tank coincident on gearbox face and give relation of coincident to Midplane chassis and mid plane of oil tank.
• Back edge of oil tank coincident to the edge of gearbox.
• Make front forks concentric to the steering stem and give width mates on the chassis, limit the rotation to 30" in both directions.
• Make a central position mate and suppress it.
• Use concentric and width mates for the chain with rear wheel, make its front centre coincident to the front sprocket sketch or apply appropriate angle mates if error occurs.
• Give parallel relations between midplane chain and midplane chassis; parallel relation between Bottom plane chassis and contre plane chain.
• Make bottom plane FT coincident to plane created in chassis.
• Make Midplane FT and Midplane Chassis coincident.
• Give a distance mate of 5mm for Front plane FT from plane 1 in chassis.
• Give relation coincident to Midplane forks and right plane front wheel.
• Make the axle concentric to axle hole.
• Use coincident relations to straighten the front wheel with respect to the front forks.
• Make the front wheel, rear wheel and the kickstand tangent to the top plane of the assembly to give it a rest position.
• Save the assembly.

• Photorealistic Rendering

Rendering of the assembly is done to make a good quality 2D images for the purpose of advertising and promotion of the products before selling it to the customers. Photorealistic rendering creates high quality images or motion graphics if available so as to look appealing in various environments and backdrops.

                                                                                           Fig : Final Render

                                                                                              Fig : Chessis Render

                                                                                         Fig:Engine Render

Solidworks provides 2 rendering products:

1. Photoview 360 which is inbuilt add in for Solidworks.
2. Solidworks Visualize which is a separate Render Engine.

• Photoview 360:

                                                                                            Fig:Photoview 360

• After adding photoview 360 the render tools tab can be brought in.
• It has various options like preview window, render region, final render, edit appearance, edit scenes, and options for managing render quality, Bloom, cartoon, direct caustics, network rendering and final image type.
• Schedule render and recall last renders are also some options.
• Decals can be added using edit decals, image can be added on faces by mapping values in coordinate directions. Illumination can be set to underlying appearance for better blending of decals.
• Display states can be set for parts individually so as to provide multiple appearances to a single part and changing the appearance whenever required.
• From view dropdown- Lights and camera is for setting up camera views and lighting of the scenes.

• Solidworks Visualize:

• Solidworks Visualize provides a suite of standalone software tools that combine industry-leading rendering capabilities with visual design-oriented features and workflows, allowing easy and fast creation of visual content that communicates a design's vision, passion, and emotion.
• It is a separate render engine that is provided under solidworks professional.
• Visualize Professional adds an array of features including animations, custom lighting, VR, 360 Interactive, and much more.
• Solidworks Visualize Professional provides the highest level of detail and optimized render times.
• It helps in creating Rendered images of the solidworks models in Photorealistic environments for marketing quality images with various options to tweak on the final image required as per the user.
• It uses either of the CPU or GPU or both as hybrid to render quality images.
• Import the assembly and select part grouping as appearance, this ensures that all the parts having same appearance are grouped together in appearance tab.
• All parts having same appearance can be tweaked together using appearance options.
• Setting up of background can be done from scenes tab which includes a wide range of HDR images and backgrounds.
• Background brightness, rotation, gamma can be changes as required from the scenes tab.
• Camera views can be added or used from assembly.
• Render output image properties can be changed from output tools. Things such as image size, animation, photograph scenes, usage of CPU, GPU or both as hybrid can be selected.
• Some rendered image of chopper are attached below.

                                                                   Fig: Chopper in Salt view 2

                                                                Fig : Chopper in Showroom 2

Conclusion:

Design, Assembly and Photorealistic rendering using Solidworks was successfully completed