Photo Realistic Rendering

ASSEMBLY OF AMERICAN CHOPPER MODEL

Objectives:

1. To get introduced to the solid works user interface.

2. To fully define the 2D sketches and conversion to 3D of the same.

3. To understand the sketching features such as projected curves , offset entities ,etc.

4. To understand the surface modelling and assembly of the various components of the American chopper.

5. Rendering of models in solid works using photoview360 under Render tools and solid works visualize.

INTRODUCTION :

This report contains a detailed explanation of design and American chopper using solid works from part modelling to final rendering of the assembly.

DESIGN METHODOLOGY:

Basic structure as follows:

Fig.1 Design Methodology Flowchart

As bikes have various components, first we need to design all the components of the bike. Then in order to design the bike, we need to assemble all the parts with proper mates (relations) between them, to form the assembly. Further the assembly is given appropriate appearances and lighting effects to produce photo-realistic rendering images of the assembly.

Tools and Features:

• Chamfer: Chamfer is used to give a sloped or angled corner to otherwise sharp edge.

• Combine: Combine feature allows you to add two bodies together and keep the area that is common to both.

• Dome: As the name suggests, dome feature is used to provide dome shape to surfaces.

• Extrude: Extrude feature allows to form 3D solid body from surface or plane.

• Fillet: Fillet is used to give rounded shape to (internal or external edges) otherwise sharp edges.

• Loft: Loft feature allows you to generate complex geometry in a single feature by specifying cross sections made from faces and profiles of closed sketches.

• Mirror: As the name suggests, mirror feature allows you to create an opposite hand version of a part .

• Pattern: Pattern tool allows you to create patterns of desired parts/sketches along oper or closed curves, edges, surfaces etc.

• Projected curve: This tool allows you to create a projected curve, from 2 different curves. The resultant curve is the intersection of surfaces formed by the two curves.

• Revolve: This feature allows you to revolve a closed sketch around a selected axis of rotation to form solid body.

• Shell: Shell tool hollows out a part and creates thin-walled features on all sides, leaving the selected faces open.

• Split surface: As the name suggests, split surface feature allows you to split a surface into two separate surfaces.

• Surface knit: Surface knit feature is used to merge 2 surfaces into one surface.

• Surface loft: Surface loft feature is used to generate complex surfaces by specifying cross sections made from sketches.

• Surface sweep: As the name suggests, sweep surface command allows you to sweep a surface along a given curve, to form a complex surface geometry.

• Sweep: sweep command is used to sweep a feature along a provided curve to form a solid body.

DESCRIPTION:

Parts to be Modelled for American Chopper

The following parts of the Chopper are modelled and assembled together in the solid works

1. Transmission Belt

2. Kick Stand

3. Front Fender

4. Rear Fender

5. Oil Tank

6. Chain

7. Pedal

8. Front Wheel

9. Rear Wheel

10. Front Fork

II. Chassis

12. Engine

13. Fuel Tank

1. Transmission Belt:

the work of the Transmission Belt is to transmit power from engine to the gearbox.

features used to create Transmission Belt

• Sketch

• Offset

• Extrude

• Fillet

• Appearances

Sketch

The sketch is the basis for a 3D model. Sketch is used to draw the 2D representation of the model with respect to the plane. In solid works there are different sketch options available to create a sketch. These are known as entities. The following are the entities available in the solid works - Line, Arc, Spline, Circle, Rectangle, Ellipse, Polygon and Slot.

Offset

Offset one or more sketch entities, selected model edges, or model faces by a specified distance. For example, you can offset sketch entities such as splines or arcs, sets of model edges, loops, and so on. You can offset finite lines, arcs, and splines.

Extrude

Extrude is tool available in solid works which is used to convert the 2D sketch drawn into a 3D model.

Fillet

Fillet/Round creates a rounded internal or external face on the part. You can fillet all edges of a face, selected sets of faces, selected edges, or edge loops.

Appearances

An appearance defines the visual properties of a model including colour and texture. Appearances do not affect physical properties, which are defined by materials. Every material is assigned a default appearance that emulates the look of the material.

2. KICK STAND:

The kick stand is also known as side stand it is the only stand which is used to support the chopper from falling while it is parked .

Features used in kickstand

• 2D sketch

• Fillet

• Smart dimensions

• Appearance

• Chamfer

• Revolve boss / base

• Extrude boss / base

• Linear pattern

• Dome

3. FRONT FENDER:

The front fender is a part mounted on the fork above the wheel to protect the rider and the choppers other part from debris and foreign particles. The front fender is also known as front mudguard.

features used to create Front Fender

• Sketch

• Offset Entities

• Trim entities

• Revolve

• . Dynamic mirror

• Split

• Appearances

Trim entities

The trim tool type is selected based on the entities you want to trim or extend. All trim types are available with 2D sketches and 2D sketches on 3D planes. You can use any trim options and most commonly used option is Power trim.

Revolve

To create a revolve feature, create a sketch that contains one or more profiles and a centerline, line or edge to use as the axis around which the feature revolves or we can turn on the temporary ads and select one of the

following revolve Tools

Dynamic mirror

Dynamic mirror is an important tool in Solid works. As you sketch the entities, they are mirrored about the pre selected sketch entity.

4. Rear Fender:

The use of the rear fender is the same as the front tender. The rear tender is mounted on the rear part of the chassis above the Rear Wheel.

features used to create Rear Fender

• Sketch

• Offset Entities

• Trim entities

• Revolve

• Appearance.

5. Oil Tank:

The Oil tank is one the part of the Chopper. Oil tank is used to store the oil required to run the Engine Oil tank is the Hollow one. The thickness of the oil tank is given as 3mm in our chopper.

features used to create Oil Tank

• Sketch

• Boss Extrude

• Combine

• Fillet

• Shell

• Appearances

• 

Combine

Combine is the type of feature available in solid works to manually combine the two bodies into a single one.

Shell

The Shell Definition Property Manager is used to define the thickness of thin and thick shell elements:

6. Chain:

Chain is a type of transmission system with the help of chain we can transmit power from the Engine to the Rear Wheel. The Sprocket is used to transmit the power to the chain. The sprocket is connected with the Shaft with the help of a key.

features used to create Chain

• Sketch

• Trim

• Fillet

• Blocks

• Extrude

• Patterns

• Appearances

Blocks

You can make, save, edit, and insert blocks for drawing items and sketch entities that you use often, such as standard notes, title blocks, label positions, and so on. You can attach blocks to geometry or to drawing views and you can insert them into sheet formats.

To make blocks:

1. Create a sketch.

2. Click Make Block (Blocks toolbar) or Tools Block Make

3. Select the sketch entities you want to make as a block for Block Entities.

4. Click

5. Repeat steps 2-4 for each of the remaining sketch entities

6. With the sketch in edit mode, add the necessary relations

7. Save the part.

Patterns

The Curve Driven Pattern tool allows you to create patterns along a planar of 3D curve. You can base your pattern on an open curve, or on a closed curve, such as a circle. In the chair part Curve Driven Pattern is used.

7. PEDAL :

Pedal is the external part attached to the chassis the pedal is used to place leg on top of that. To give comfort to the rider pedal is used.

Tools used to create Pedal

• Sketch

• Extrude

• Fillet

• Linear pattern

• Dome

• Chamfer

• Appearances

• 

Chamber

A cut on the edge or corner of something that makes it slope slightly rather than being perfectly square.

Linear pattern

Linear pattern is also more like a circular pattern. The features/bodies are patterned linearly. Pattern is a kind tool like Array available in AutoCAD.

8. Front Wheel:

A wheel is a circular block made of the Steel/Alloy material. On the top of the wheel the tyre is covered. The tyre is made of Rubber and it has thin wires within it.

Tools used to create Front Wheel

• Sketch

• Revolve

• Trim

• Fillet Entities

• Boss/Base Extrude

• Revolve Cut

• Linear pattern

• Chamfer

• Fillet Features

• Cut Extrude

• Circular Pattern

• Appearances

• 

Circular Pattern

Circular pattern is used to create a pattern of the sporks and the patterns (Grooves) available in the tyre. Also, it is used to create holes in the discs of the front wheel. The parent bodies/ features are used to create a different number of instances required to create the pattern circularly.

9.Rear Wheel:

A circular object that revolves on an axle and is fixed below a vehicle or other object to enable it to move easily over the ground. The disc and sprocket are attached with a rear wheel The chain is connected between the Engine and the Rear Wheel Chain is a positive drive. Compared to the belt it will be more efficient and losses in the chain will be less comparatively.

Tools used to create Rear Wheel

• Sketch

• Revolve

• Trim

• Fillet Entities

• Boss/Base Extrude

• Planes

• Revolve Cut

• Linear pattern

• Chamfer

• Fillet Features

• Cut Extrude

• Circular Pattern:

• Appearances

10. Front Fork:

Most motorcycles today use telescopic forks for the front suspension. The forks can be most easily understood as simply large hydraulic shock absorbers with internal coil springs. They allow the front wheel to react to imperfections in the road while isolating the rest of the motorcycle from that motion.

Tools used to create Front Fork

• Sketch

• Extrude

• Trim

• Revolve

• . Split

• Plane

• Convert entities

• Move/copy Body

• Dome

• Mirror

• Combine

• Curve (Project Curve)

• Sweep

• Appearance

• Move/copy Body

• Move/ Copy body is used to move/copy the body from one place to other places in the fork

• 

Mirror

By using mirror faces with a mid-plane selected only the chosen faces within the revolve will be mirrored. Mirroring bodies can be used whether in a single or multi body part and allows you to select solid geometry instead of the features and faces in a body. In the fork part the one part of the fork is created and the other part is mirrored. Then the parts are manually combined.

Project Curve

Project curve is the kind of 3D curve which is projected on the basis of the two different 20 sketches,

Sweep

With the Sweep feature we can create a shape by moving a 2D sketch Profile along a 2D or 3D sketch Path.

II. Chassis:

A chassis or frame forms its skeleton. All the components of a motorcycle, like the suspension, wheels, fuel tank, seats, handlebars etc, are attached to this base structure which lends a motorcycle its strength and ability to handle well.

Tools used to create Chassis

• Sketch

• Offset

• Convert entities:

• Project Curve

• Trim

• Plane

• Sweep

• Split

• Revolve

• Cut Extrude

• Fillet

• Combine

• Appearance

• 

12. Engine:

Engine is the prime mover for the Bike. The engine converts a Chemical energy into the Heat energy and then the heat energy is converted into mechanical work.

The mechanical work in the engine is rotational motion. This rotation is converted to the wheel with the use of the chain and sprocket through the gearbox and clutch.

Tools used to create Engine

• Sketch

• Convert entities

• Trim

• Revolve

• Boss extrude

• Cut extrude

• Offset

• Dome

• Fillet

• Project curve

• Composite curve

• Sweep

• Mirror

• Circular Pattern

• Split

• 

13. Fuel Tank:

Fuel tanks are used to store the fuel. To give the Fuel to the engine whenever it's required.

Tools used to create Fuel Tank

• Sketch

• Trim

• Project curve

• Convert entities

• Sweep Surface

• Loft Surface

• Fill surface

• Surface trim

• Surface knit

• Sweep cut

• Fillet

• Appearances

Loft Surface

Loft Surfaces are surfaces generated by multiple 3D Curves or existing edges creating a smooth tangency between the selected curves.

Sweep Surfaces

Sweep Surfaces are surfaces that are generated from a section curve positioned along a path.

Filled Surface

The Filled Surface feature constructs a surface patch with any number of sides, within a boundary defined by existing model edges, sketches, or curves, including composite curves.

Surface trim

Primarily used to cut away material from a surface, and provides two modes: Standard and Mutual

Surface knit

Surface knit is used to knit the two free edges/open edges of the surfaces together. Also it reduces the gap between the two edges of the surface.

Assembly of Chopper:

Initially, the Chassis part is inserted in the assembly by using insert parts in the option. After that the part is inserted in the assembly environment and clicked ok to fix the chassis.

After that the other parts of the chopper are inserted into the assembly and given possible mate conditions.

Tools used to assemble Chopper

• Mates

• Insert part

• 

Mates

Mates create geometric relationships between assembly components. As we add mates, we define the allowable directions of linear or rotational motion of the components, we can move a component within its degrees of freedom, visualizing the assembly's behaviour.

Rendering:

Rendering is the process of creating realistic images of the Photorealistic model with the environment.

Rendering has been done in two ways in solid works. The following are the two ways

• Photo view 360

• 

• Solid works Visualize Render

• 

In the photorealistic model some of the mate conditions and positions are changed to render realistic models.

Then the photorealistic model is rendered into realistic images with different views.

FrontView:

sideview

topview

camera

isometric

photorealistic render

Conclusion:

• The parts of the chopper are modelled.

• The parts are inserted into the assembly environment and the chopper is assembled.

• The realistic image was rendered with the use of the Photo view 360 & Solid works visualize.