Photo Realistic Rendering

AMERICAN COPPER

Objective:

• To sketch and design every exterior part of the chopper under a part modelling environment with suitable sketches and commands using Solid works.
• To assemble the modelled parts of the chopper to form a complete chopper model in the assembly environment.
• To create a photorealistic rendering of the chopper using Photoview360 and Solid works Visualise.

Introduction

In this project, we are to learn the entire modeling of an American chopper using Solidworks for modeling and Solidworks Visualize for rendering.

The different components of the American Chopper we deal with are:

1. Transmission belt
2. Chassis
3. Engine with exhaust system
4. Front wheel and Rear wheel with rims sprockets and calipers
5. Front fork along with handlebars and grips
6. Front and Rear Fenders
7. Oil Tank
8. Chain
9. Kickstand
10. foot pedals
11. Gas Tank

Every part of the chopper is made separately with proper sketching and modeling. After designing the part components, we have worked upon the assembly and the photo rendering of the chopper which gives it a complete and realistic view.

Design methodology

PART MODELS WITH RENDERING

1. TRANSMISSION BELT:

• The transmission belt is a loop of flexible Material used to link two or more rotating shafts mechanically, it is used as a source of motion, to transmit power efficiently.

Features used to create Transmission Belt:

• Sketch
• Offset
• Extrude
• Fillet

Sketch:

• The sketch is a 2D representation of a particular model from different views such as front view, side view, top view, etc.

Offset:

• Offset is used to create a similar sketch at a required distance in the required direction parallel to the sketch.

Extrude:

• The extrude command is used to create a solid extrusion based on the selected sketch or contours. The extrusion made in either a positive or negative direction as required.

2.Chassis

Chassis is the main support structure of the vehicle which is also known as ‘Frame’. It bears all the stresses on the vehicle in both static and dynamic conditions. In a vehicle, it is analogous to the skeleton in living organisms. The origin of the word Chassis lies in the French language. Every vehicle whether it is a two-wheeler or a car or a truck has a chassis-frame. However, its form obviously varies with the vehicle type.

1. Supports or bears the load of the vehicle body.
2. Provide the space and mounting location for various aggregates of vehicles.
3. Supports the weight of various systems of the vehicle such as the engine, transmission, etc.
4. Supports a load of passengers as well as the luggage.
5. Withstands the stresses arising due to bad road conditions.
6. Withstands stresses during braking and acceleration of the vehicle.

Features used to create Chassis:

• Sketch
• Offset
• Project Curve
• Trim
• Sweep
• Split
• Revolve
• Cut Extrude
• Fillet
• Combine

• Fillet:

  The fillet is used to creating round faces in the interior or exterior corners of the part. The fillet distributes stresses uniformly along the corners.

• Project Curve:

  The project curve is used to create a 3D curve is it is created by using the reference of two 2D curves in two different planes.

3.Engine with exhaust system

• Motorcycle engines work the same way that car engines do.
• They consist of pistons, a cylinder block, and a head, which contains the valve train.
• The pistons move up and down in the cylinder block, driven by explosions of a fuel-air mixture that has been ignited by a spark.
• Valves open and close to allow the fuel-air mixture to enter the combustion chamber.
• As the pistons move up and down, they turn a crankshaft, which transforms the energy from the pistons into rotary motion. The rotational force of the crankshaft is transmitted, via the transmission, to the rear wheel of the motorcycle.

Features used to create Engine:

• Sketch
• Convert Entities
• Trim
• Revolve
• Boss Extrude
• Cut Extrude
• Offset
• Dome
• Project Curve
• Composite Curve
• Sweep
• Mirror
• Circular Pattern
• Fillet
• Split

• Revolve:

  Revolve is used to create a revolved 3D model using a sketch profile using an axis of rotation. The profile created with the revolution up to 360⁰ axis rotation.

4.Front fork along with handlebars and grips

• Motorcycle wheels are made to cope with radial and axial forces. They also provide a way of mounting other critical components such as the brakes, final drive, and suspension. Wheels, and anything directly connected to them, are considered to be unsprung mass.
• The front fork prevents excessive weight on the front wheel during drastic sudden applications the break, softens bumping when driving on rough road surfaces. The front fork maintains proper damping through traction with the road surface.

Features used create Front Fork:

• Sketch
• Extrude
• Trim
• Revolve
• Split
• Move/Copy Body
• Dome
• Sweep
• Reference Geometry
• Chamfer
• Fillet

Sweep:

• Sweep is used to create solid by sweeping a closed or open sketch profile in one plane along the closed or open path along the same or another plane.

Reference Geometry:

• Reference geometry is used to create a reference plane, axis, co-ordinate system based on one, two or three references.

5.Front and Rear Fenders

• Fenders make a tremendous difference when you are riding roads that are wet from the drizzle, recent rain, or snowmelt. In a hard rain, you may become wet with clean rain from above, but fenders will protect your body and bicycle from the mud and sand kicked up from dirty puddles and rivulets.

Features used to create fender:

• Sketch
• Offset Entities
• Trim Entities
• Revolve
• Dynamic Mirror
• Split

Trim:

Trim is used to remove unwanted sketch entities or extra portions of the sketch. It works based on some reference points, edges.

Dynamic Mirror:

A really quick tip for instantly creating symmetry within a sketch in SOLIDWORKS. As you create a sketch on one side of the centreline, the Dynamic Mirror tool will automatically create a symmetrical shape on the other side, which has the same relations as the sketch you're creating.

6.Oil Tank

Oil tanks are used to store engine oil which from there is pumped to the engine and other parts of an automobile for lubrication and maintenance.

Features used to create Fender:

• Sketch
• Extrude Boss
• Combine
• Fillet
• Shell

Combine:

A combine feature is used to merge two or more solids into a single solid.

7.Chain

• Chains are mainly used in chain and sprocket drives these are used to perform three basic functions: transmitting power, conveying materials, and timing purposes.
• Chain and sprocket drives are used to transmit power from one component to another. Specifically, they transfer speed and torque through the use of a linked chain and sprockets.
• In automobiles, roller chains are used in these drives to transmit power and torque.

Features used to create Chain:

• Sketch
• Trim
• Fillet
• Extrude
• Patterns
• Insert blocks

Pattern:

The pattern is used to create similar geometry or sketch profile up to user-defined instances based on some reference edges, vertex, etc.,

Insert blocks:

this command is in sketch we can save a perticular profile and repeat itagain in the sketch

8.Kickstand

• The kickstand is a swiveling metal bar for holding a bicycle, motorcycle, or another two-wheeled vehicle upright when it is not being ridden and is used for the safety of the vehicle. It is pivoted to the axle in such a way that it can be kicked down below the frame.

Features used to create Chain:

• Sketch
• Loft
• Dome
• Extrude Boss
• Extrude Cut
• Fillet
• Split

Loft:

The loft feature in SOLIDWORKS allows you to generate complex geometry in a single feature. It does this by interpolating surfaces between various cross-sections of a model. These cross-sections can be sketches, faces, or edges. In the loft interface, these cross-sections are considered “Loft Profiles”.

Dome:

Dome is an architecture, the hemispherical structure evolved from the arch, usually forming a ceiling or roof over the surface/face being selected.

Extrude Cut:

The extrude cut is used to remove unwanted material from the solid model as per the sketch defined. Based on the sketch the material is removed from the component.

Split:

Split is used to split a single surface into multiple surfaces based on the sketch, by using the desired sketch split surface can be performed.

9.foot pedals

• The pedal is used to rest feet while driving a two-wheeler. It is an extended piece from the chassis which is used for resting feet to maintain balance and comfort while riding the vehicle.

Features used to create Chain:

• Sketch
• Extrude
• Fillet
• Linear Pattern
• Dome
• Chamfer

Chamfer:

The chamfer is used to create beveled features on the selected edge face and vertex according to angle or distance specified.

Linear Pattern:

Linear Pattern is used to create a similar sketch or feature along a specified linear vector i.e., XYZ directions. The pattern is created based on the reference edge, face, etc.

10.Gas Tank

The gas tank acts as a reservoir to meet the fuel requirements of the chopper.

1. Storage of fuel: the system must contain a given quantity of fuel and must avoid leakage and limit evaporative emissions.
2. Filling: the fuel tank must be filled in a secure way, without sparks.
3. Provide a method for determining the level of fuel in the tank, gauging (the remaining quantity of fuel in the tank must be measured or evaluated).
4. Venting (if over-pressure is not allowed, the fuel vapors must be managed through valves).
5. Feeding of the engine (through a pump).
6. Anticipate potentials for damage and provide safe survival potential.

Features used to create Gas tank:

• Sketch
• Extrude Boss
• Trim
• Surface Sweep
• Loft Surface
• Curves-Split Line
• Knit Surface
• Sweep Cut
• Shell
• Fillet

Sweep Surface:

It is used to create surface features by sweeping an open or closed sketch profile along an open or closed path.

Loft Surfaced:

It is used to create a surface between two or more profiles using one guide profile.

Sweep Cut:

It is used to cut a solid geometry by sweeping a closed profile along a closed or open path.

11. Front wheel and Rear wheel with rims sprockets and calipers

• A wheel is a circular block of a hard and durable material at whose center has been bored a circular hole through which is placed a front axle bearing about which the wheel rotates when the moment is applied by gravity or torque to the wheel.

Wheel consists of

• Rim
• Brake Caliper

• Motorcycle wheels are made to cope with radial and axial forces. They also provide a way of mounting other critical components such as the brakes, final drive, and suspension. Wheels, and anything directly connected to them, are considered to be unsprung mass.

Rim:

The rim is the "outer edge of a wheel, holding the tire". It makes up the outer circular design of the wheel on which the inside edge of the tire is mounted on vehicles such as automobiles.

Brake Caliper:

A disc brake is a type of brake that uses the calipers to squeeze pairs of pads against a disc or "rotor" to create friction. This action slows the rotation of a shaft, such as a vehicle axle, either to reduce its rotational speed or to hold it stationary. The energy of motion is converted into waste heat which must be dispersed.

Features used to create Front Wheel:

• Sketch
• Revolve
• Trim
• Fillet
• Extrude Boss
• Revolve Cut
• Linear Pattern
• Circular Pattern
• Chamfer

Circular Pattern:

A circular pattern is used to create a solid feature in a circular direction with respect to the reference axis of rotation up to user-defined instances.

Revolve Cut:

Revolve cut is used to remove solid geometry by revolving the sketch profile along a reference axis from the selected solid body.

PHOTOREALISTIC RENDERING OF THE CHOPPER:

ORIENTATION OF THE ASSY CHOPPER

TREE STRUCTURE

Conclusion

• Finally part modeling, assembly, redering is completed