Challenge

Photo Realistic Rendering

SShivani Raikwar12 Nov 2022

DESIGN OF AMERICAN CHOPPER

INTRODUCTION

This Report Contains brief explanation of designing of American chopper using solid works 3D modelling cad software ; from initial sketch to Final rendering including Solid Modelling, Surface Modelling tools explanation

OBJECTIVE

The main objective of this designing is to obtain sustainable knowledge in solid part modelling and surface modelling

Get clear vision of solid works interface and make custom shortcuts of tools tool bar , command manager commands
Detail designing of Each components of chopper with sketch & dimensions.
Accurate Assembly of designed parts with proper relations of all part model.
Became professional in using Decals, Lights, Appearance, Environment, Backplates
Obtain Knowledge in SOLID WORKS, PHOTOVIEW 360 tools to make realistic render of the modelled Chopper .

PART MODELING

Part modelling is the process in which modelling of a component\Object in 3D by using the 2d Sketch by using tools and sketch constraints, features of solid works .

METHODOLOGY

COMPONENTS TO DESIGN

Transmission belt
Kick stand
Front fender
Rear fender
Chain
Oil tank
Pedal
Front wheel
Rear wheel
Front fork
Chassis
Engine
Gas tank

DESCRIPTION

Features and Tools used for modelling will be explained in separate topics each component design.

TRANSMISSION BELT

Component Description : Transmission Belt is used to transmit power from one end to another end of pulley

Features

1.Boss Extrude - Used to expand the object in 3D according to sketch plane

2.Fillet - Fillet is a feature used for making round edges to avoid sharp edges

Constraints used

1.Tangent

2.Midpoint

Tools used

1.Line tool – used to draw straight and tangent arcs

Methodology

Using Lines and arc constraints making a sketch with given dimensions offset the sketch with offset entities after get defined sketch make extrude using Boss extrude. After making Extrude of belt model Make 1mm Fillet at edges of Transmission belt.

BOSS EXTRUDE FEATURE AS SHOWN BELOW

KICKSTAND

Component Description : Kick stand is a Supporting Mechanism which is used to prevent the chopper lean on ground and makes upright with out interfere with a Object .

Features

1 Extrude Boss\Base - Used to expand the object in 3D according to sketch plane

2.Fillet- Fillet is a feature used for making round edges to avoid sharp edges

3.Lofted Boss\Base - Lofted boss is a feature used to achieve Complex Shapes .Which basically extruded loft surfaces by means of two lofted profiles along with guide curves direct the path of lofting

4.Split-Split tool is used to split single solid part into two solid parts

Constraints used

1.coincident

2.Midpoint

Tools used

1.Ellipse - Used to make elliptical sketches as per dimension

2.Spline - Spline tool use to make spline curves and complex geometry shapes

3.Center point - It is used to make Rectangle based on center point Rectangle

Methodology

Create an Ellipse according to vertical and horizontal dimensions after that make a spline in perpendicular plane. With reference of spline and its end point creating another plane for draw another loft profile after sketching by

using loft boss\base feature create a loft profile spline as guide curve to make perfect loft needed after that make a dome in the side of stand which going to lean in ground and finally make a flat surface to lean in ground by using split tool.

SPLIT FEATURE AS SHOWN BELOW

LOFT /BOSS FEATURE AS SHOWN BELOW

DOME FEATURE AS SHOWN BELOW( ELLIPTICAL DOME)

FRONT FENDER

Component Description : Fender is a frame like structure which is laying over a wheel is used to prevent the mud, liquids ,slippery things will be flown into air while rotating at high speed also it prevents the small stones will be flown over a rider because of acceleration cover a tyre

Features used

1.Revolve boss\base – Revolve feature is used to make cylindrical or circular 3D extrude along with a given reference axis as per drawn sketch

2.Split - Split tool is used to split single solid part into two solid parts

3.Fillet - Fillet is a feature used for making round edges to avoid sharp edges

4.Dome -Dome is a feature used to make dome shaped extrude including elliptical dome

5.Extrude Cut - Extrude cut feature used to cut the 3d object in linear path according to sketch

Constraints used 1.Reference axis for revolve.

Tools

1.3point Arc - 3point arc used to draw an arc with make center point as reference point draw an arc.

2.Spline - Spline tool use to make spline curves and complex geometry shapes

3.Dynamic mirror- Dynamic mirror used to mirror the entire feature of the plane selected for mirroring

4.Extent entities - It is used to extend the end point lines to make closed sketch

5.Trim entities - Trim is used to trim\delete the additional lines in the geometry

Methodology

Creating 3 point arc as per dimension with offset and using extend entities to make complete the sketch by making a reference axis by means mid plane which by means of axis using revolve feature by two direction at specific angle After that making a spline to obtain required shape with dynamic mirror option

FILLET FEATURE AS SHOWN BELOW

REAR FENDER

Features used

1.Revolve boss\base

2.Split

3.Fillet

4.Shell

Constraints used

1.Horizontal

2.Vertical

Tools used

1.3point Arc - 3point arc used to draw a arc with make center point as reference point draw an arc.

2.Spline - Spline tool use to make spline curves and complex geometry shape

3.Extent entities - It is used to extend the end point lines to make closed sketch

4.Trim entities - Trim is used to trim\delete the additional lines in the geometry

Methodology

Creating a 3 point arc at midplane of rear fender at offset a line at a given distance at end of the arc line draw and extend using extend entities , as reference of construction line making a revolve feature at two direction and angle needed to achieve fender after that make split at end of the fender to get curvature by using 3 point arc at last by selecting face of fender to make full fillet at edges at last to make shell command to reduce the thickness of the fender at given dimension

CHAIN

Component Description : Chain is used to transmit power from engine to sprocket at rear wheel for acceleration of vehicle.

Features used

1.Extrude Boss\Base

2.Fillet 3.Curve

Constraints used

1.Concentric 2.Coincident 3.Tangent

Tools used

1.Circle – Circle is the tool used to draw a circular sketch

2.3point Arc - 3point arc used to draw a arc with make center point as reference Point draw an arc.

3.Blocks - Block are the tool which make a particular sketch as blocks that we can get sketch as block able to insert in geometry and sketch any time.

4.Trim- Trim is used to trim\delete the additional lines in the geometry

Methodology

Started with a two circles which located as construction line reference after that draw a 3 point curve which is tangent with two circles with specific radius then trim additional lines after that create a chain pin block By using that block to make coincident and concentric relation which the chain block make path with the drawn curve. After fixing block with curve make extrude the pin and chain plate at offset then make a curve driven pattern by curve as reference By following the same to create a complete chain model .

OIL TANK

Component Description : Oil tank in an Engine is used to maintain the internal temperature at cylindrical blocks because of ignition for which the oil stored in a tank is known as oil tank

Features used

1.Extrude Boss\Base - Used to expand the object in 3D according to sketch plane

Fillet - Fillet is a feature used for making round edges to avoid sharp edges
Shell - Shell feature is used to make hollow space in solid part by selecting outer wall .
Combine – Combine tool is used to make integration of two solid parts which intersect Each other as same solid parts. In this we can add two solid bodies , we can subtract solid bodies & we can make bodies common.

Constraints used

1.Tangent 2.Coincident

Tools used

1.Arc 2.Spline 3.Circle

Methodology

In oil tank start with top plane making line and make tangent arc coincident with construction line make a straight line coincident with sketching point to get fully defined sketch and make a dynamic mirror after that make a extrude Then make a line with midplane to make a oil tank and shell command without selecting body to get hollow tank inside

SHELL FEATURRE AS SHOWN BELOW

Combine feature as shown below

PEDAL

Component description : Pedal is used to make support for rider to spread his foot and make rider comfortable & prevent the foot contact with road.

Features used

1.Extrude Boss\Base - Used to expand the object in 3D according to sketch plane

2.Fillet - Fillet is a feature used for making round edges to avoid sharp edges

3.Revolve boss\base – Revolve feature is used to make cylindrical or circular 3D extrude

4.Dome -Dome is a feature used to make dome shaped extrude including elliptical dome

5.Chamfer - Chamfer is used to make a edges sharp edge to make angled tapering

6.Liner Pattern -Linear pattern is to make a solid feature pattern in path as linear

Tools used

1.Fillet

2.Line tool

3.3point Arc

4.Offset

Linear pattern shown below

Dome feature

CHAMFER FEATURE

FRONT WHEEL

Component description : Wheel is used as locomotive component of every vehicle .The wheel generally rotated based on the axis fixed with the vehicle. Its built with hard rim cover with nylon tyre.

Features used

1.Extrude Boss\Base - Used to expand the object in 3D according to sketch plane

2.Fillet - Fillet is a feature used for making round edges to avoid sharp edges.

3.Revolve boss\base – Revolve feature is used to make cylindrical or circular 3D extrude along with a given reference axis as per drawn sketch .

4.Revolve cut - Revolve cut is a method to cut\reduce the extrude of cylindrical\round Surface.

5.Chamfer - Chamfer is used to make a edges sharp edge to make angled tapering.

6.Linear Pattern - Linear pattern is to make a solid feature pattern in path as linear

7.Extrude Cut - Extrude cut feature used to cut the 3d object in linear path according to sketch

8.Circular pattern – Circular pattern is a feature used to make 3d feature into circular pattern according to number of insistence

Constraints used

1.Coincident 2.Midpoint 3.Horizontal

Tools used

Fillet
Line tool
3point Arc
Spline
Trim
Extend entities.

Methodology

Front wheel consist of Tyre , Rotor, Calliper, Wheel rim

Rim The rim is made by extrude revolve in the front plane reference by making sketch and revolve to achieve the rim after making a revolve boss\base Then making a sketch to do make a spider web like forks by using circular pattern and other sketch entities according to dimensions

For Rotor rotor is extrude offset from midplane to offset at specific dimension and make a circular patterned holes for grip to callipers

For calliper Callipers is extrude along with mid plane extrude at both direction and make fillet and chamfer to achieve calliper

For Tyre Tyre is done by making revolve with front plane as per dimension to achieve pattern in tyre making a circular pattern feature

Feature as shown below

CIRCULAR PATTERN

REVOLVED BOSS / BASE FEATURE AS SHOWN

EXTRUDE CUT FEATURE AS SHOWN BELOW

REAR WHEEL

Wheel is used as locomotive component of every vehicle .The wheel generally rotated based on the axis fixed with the vehicle. Its built with hard rim cover with nylon tyre. It also include sprocket, Calliper , Rotor, Tyre.

Features used

1Extrude Boss\Base

2.Fillet

3.Revolve boss\base

4.Revolve cut Chamfer

5.Linear Pattern

6.Extrude Cut

8.Circular pattern

Constraints used

1.Coincident

2.Midpoint

3.Horizontal

Tools used

1.Line tool

2.3point Arc

3.Spline

4.Trim

5.Extrude entities

Methodology

Rear wheel consist of Tyre ,Rotor, Calliper, Wheel rim, Sprocket

For rim

The rim is made by extrude revolve in the front plane reference by making sketch and revolve to achieve rim after making a revolve boss\base

For Rotor

Rotor is extrude offset from midplane to offset at specific dimension and make a circular patterned holes for grip to callipers

For calliper

Calliper is extrude along with mid plane extrude at both direction and make fillet and chamfer to achieve calliper

For Tyre

Tyre is done by making revolve with front plane as per dimension to achieve pattern in tyre making a circular pattern feature

For Sprocket

Sprocket is made by extrude from the midplane of wheel with offset from a distance which is parallel to sprocket at engine block the sprocket is made by circular pattern to achieve the teeth at sprocket

CIRCULAR FEATURE AS SHOWN BELOW IN ROTOR

REVOLVE BOSS USED FOR MAKING TIER AS SHOWN BELOW

FRONT FORK

Components Description : Front fork is consists two narrow tube consists of two shock absorbers along with axis of front wheel and tope end fixed with handle bar to control direction of vehicle with head light

Features used

1.Revolve boss\base

2.Dome

3.Extrude Boss\Base

4.Split

5.Combine

6 Move\copy body

7.Mirror

8.Sweep

Constraints used

1.Midpoint

2.Coincident

3.Horizontal

Tools used

1.Projected curve – Projected curve is a special tool to make work easier projected used to combine a curves from different plane in to single plane sketch means of integration

2.Convert Entities

3.Line tool

4.3point Arc

5.Spline

Methodology

Starting with the long barrel which where suspension located make a revolve feature as per sketch sketched at front plane From top plane extrude the centre part of fork where head light and speedo meter located offset from some distance , After extrude making right plane make a revolve of head light using move\copy feature move a head light towards z direction to make head light centre

Make a fillet at the end of the head light to get soft round edges ,

Make a mirror as plan as right side of solid part which mounted upside of fork make a mirror feature to get complete fork , making revolve of handle bar make a composite curve to get break wire connected with fork at last make a new for front fork used to assembly.

PROJECTIVE CURVE FEATURE AS SHOWN BELOW

SWEPT FEATURE AS SHOWN BELOW

MOVE /COPY FEATURRE AS SHOWN BELOW

MIRROR FEATURE AS SHOWN BELOW

FILLET FEATURE SHOWN BELOW

CHASSIS

Components description : Chassis is a skeleton of bike which is main frame that is used to hold everything like Engine, gas tank , pedal.. each and every parts .

Features used

1.Mirror

2.Sweep

3.Revolve boss\base

4.Dome

5.Extrude Boss\Base

6.Split

7.Combine

8.Chamfer

9.Fillet

Constraints used

1.Midpoint 2.concentric 3.coincident

Tools

1.Projected curve

2.Convert Entities

Line tool

4.Spline

5.Circle

Methodology

Need blue print as reference for making chassis by importing chopper blue print using image sketch feature after importing image make sketch with reference of imported image by using splines to make projected curve of bottom part of chassis make sweep along with curve.

ENGINE

Components description

Engine is the power house of the vehicle it transmit the power to rear wheel through chain and sprocket

Features used

1.Mirror

2.Sweep

3.Revolve boss\base

4.Dome

5.Extrude Boss\Base

6.Split

7.Combine 8.Chamfer 9.Fillet

10.Extrude Cut

11.Circular pattern

12.Linear Pattern

Constraints used

1.Coincident

2.concentric

3.Horizontal

4.Vertical

COMPOSITE CURVE FEATURE FOR CREATING SWEPT

GAS TANK

Component description

Gas tank is used to store the fuel which is need for making power engine in combustion process .

Features used

1.Swept Surface – Its used to make a surface along with a path curve is driven

2.Boundary Surface

3.Loft Surface

4.Knit surface- knit surface is used to make knit\zipped two surface

5.Sweep cut

6.Combine

7.Shell

8.Fillet - Fillet is a feature used for making round edges to avoid sharp edges.

Constraints used

1.Tangent

2.Coincident

Tools used

1 . Line tool – used to draw straight , construction line and tangent arcs

2.3point Arc

3.Projected curve

4.Convert Entities

5.Mirror

METHODOLOGY

In gas tank to make a surface extrude along with blue print by making sweep surface extrude making a tangential spline curve along with sweep path to make an outer tank wall

After that to make projected curve to extrude loft surface using guided curve and make complete gas tank finally make a shell for gas tank to make hollow object fully modelled

SURFACE SWEEP FEATURE USED FOR MAKING SURFACE

SURFACE TRIM FOR TRIMING EXTRA PART

SURFACE LOFT FEATURE AS SHOWN BELOW

BOUNDARY FEATURE AS SHOWN BELOW

SURFACE KNIT FEATURE AS SHOWN BELOW

ASSEMBLY OF CHOPPER

Assembly of chopper which is made up of assembly of components.

Constraints used

Constraints play a major role for assembly which is used to assemble parts

1.concentirc

2.coincident with planes

3.tangent with planes

4.parallel

5.perpendicular

Mates

Mates is a feature used to make mate with each other components properly used to make accurate assembly of a components. There is a type of Components.

1.Advanced mate

2.Mechanical Matte

Finally apply decals for all the components.