Photo Realistic Rendering

        DESIGN AND MODELING OF AMERICAN CHOPPER IN SOLIDWORK

AIM & OBJECTIVE
❖ To learn interface and commands of solidworks.
❖ To design American chopper, design its part individually, applying materials, applying decals and assemble all the parts in soliworks assembly.
❖ How to do setting lighting, background, camera, in photoview 360 to get the realistic view.
❖ Rendering in soliworks visualize to in the background images to get the realistic view of the American chopper.

INTRODUCTION
In this project we learn the interface of the solidwoks like tools, commands and features at same time we designed American chopper. At first we designed the parts of the American chopper
individually give them appearances, applied some decals and assemble them in to soliworks assembly.
Editing some lights, camera, angles and do some preview in photoview 360 to get idea of how our design is going to look in real world. After all we do the final render of the American chopper in solidworks visualize.

Here is the list of parts we designed of American chopper.
1. Transmission Belt
2. Kick Stand
3. Front Fender
4. Rear Fender
5. Chain
6. Oil Tank
7. Pedal
8. Front Tire
9. Rear Tire
10. Front Fork
11. Chassis
12. Engine
13. Gas tank

➢ FLOW CHART

➢ List of the Tools and Features used to Design of American chopper, and their uses

1. Extruded Bass/Base
    It is use to get solid body of the sketch and the sketch should be fully defined.

2. Extruded cut
    It is used to cut part from the solid body to get desired shape of the body.

3. Fillet
    It converts the sharp edges in to round and smooth shape with given radius.

4. Chamfer
    It creates a slopping symmetrical surface at the selected sharp edge.

5. Revolved bass/base
    It revolves the sketch around the selected axis and creates a solid form from the sketch.

6. Swept boss/base
    It creates a solid body b closed profile along open and closed path.

7. Shell
    It creates empty space inside a solid body with given thickness.

8. Knit
    It combines two or more slide body into one solid body.

9. Sketch
    It gives us the work base to sketch our 2d or 3d geometry.

10. Trim entities
    Using trim we can cut out all the unwanted sketch from our geometry.

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11. Smart dimensions
    Using smart dimension we give desired length to our geometry and locate the geometry at desired location.

12. Convert entities
    It brings the selected sketch from the reference sketch.

13. Offset
    It allows to create to or more same object or geometry of the selected sketch or the body in given direction.

14. Linear/circular pattern
    It creates the number of copies the selected object, feature or geometry on a selected line, path or the surface.

15. Projected curve
    It combines Two 2D curves in One 3D curve.

16. Mirror
    It allow us to mirror the geometry or the solid body from the selected reference.

17. Mates
    It allow to create a geometric relation between assembly and components.

18. Appearance
    With the help of appearance we can apply materials and colours to the solid bodies.

19. Decals
    Using decals we can apply 2d images on solid body.

                                                                      ***

           As we discussed above about features and tool used to design the American chopper. Now we explained bellow how we sketched and modeled the part of the chopper individually.

1. Transmission Belt
       Transmission belt is used to connect two or more pulley mechanically in a loop for transmit power from one pulley to another. Is typically made of rubber rubber and used in various industries.
• Procedure
       First sketch on the front plane draw one horizontal line draw 3 point arc at its end point apply tangency to line and arc apply offset and extrude it, apply fillet and apply appearance.
Tools and Features used
  Sketch tools : Line, 3 point arc, offset entities
  Feature tools : Extruded boss/base, fillet
  Appearance : Matt Rubber

2. Kick Stand
      Kick stand is mounted on the on the chassis which flip down from the chassis and allow the bike kept upright when the bike is not moving and no one is riding.
• Procedure
      First sketch on the front plane draw ellip, then sketch over top plane and draw a spline after that create a reference plane over the end of the spline and draw ellip over it give them dimension. Now exit and use lofted boss select the both ellips and select spline as path to get the desired output apply dome elliptical at ends. Use
extruded cut to remove unwanted parts aplply fillet. Apply appearance
Tools and Features used
  Sketch Tool    :   line , spline, circle ellipse
  Feature Tool   :   Lofted Bass/Base, extrude cut, Dome Fillet
  Appearance    :   Chrome steel

3. Front Fender
    It protects you from spraying the water or mude by tire from the road while the bike is moving or riding.
  • Procedure
    Sketch on the on the front plane using 3 point arc give it relation from the origin apply offset to the arc use line to make a closed geometry, and revolve it using horizontal axis. Remove some part using split to get the desired shape and apply fillet to smoothen the edges and apply appearance
Tools and Features used
    Sketch Tool    :  Line, Spline , 3 point arc , offset, trim
    Feature Tool   :  Revolve Boss/Base, split, fillet.
    Appearance    :  Painted Siena

4. Rear Fender
      Rear fender also called as mude guard protects you form the sprays of water and mude by the rear tire from the road.
➢ Procedure
      The procedure of the rear fender is same as the procedure of the front fender, only defference is the size of the fender is bigger compare to the front fender because of the size of the rear tire, and applied shell command to inside face to give it a proper shape.
Tolls and Feature used
   Sketch Tool   : 3 point arc, line ,spline, offset entities , extend and trim entities.
   Feature Tool  : Revolve boss/base, split, fillet, shell
   Appearance   : Painted siena

5. Oil Tank
      Oil Tank it is basically hollow tank which contain oil required for the operation of the engine and gear box smoothly. It is mounted above the engine or on the engine an provide the oil to engine.
➢ Procedure
      Sketch on top plane draw line 3 pointed arc and give them relations, make the sketch enclosed and extrude it. Now sketch in top plane draw tank like geometry and extrude use midplane and through all options, then combine them to make oil tank like shape then use shell to hollow the body and apply fillet, apply appearance.
Tools and Features used
   Sketch tool   :   line, 3 point arc, circle.
   Feature tool  :   Extruded boss/base, combine, fillet.
   Appearance   :  White Colour & painted siena

6. Chain
      Chain is a connection bridge between drive gear to driven gear which transfers the power from engine to rear wheel. In chopper it connects the engine sprocket to real wheel sprocket.
➢ Procedure
      To design the sketch on front plane draw 3 point arc line, apply tangency to them apply dimension to the geometry. The exit from the sketch and again sketch on to front plane draw two circle make them apart apply equal relation to them then draw 3 point arc connect the circles using arc apply tangency, make them block, then add block and apply coincident to the sketch we drawn before use it as chain path apply appropriate relation to them, now do the extrude to make inner plate, outer plate and pine. Now using curve pattern use the first sketch as path an make to required bodies. Them mirror the plate to midplane, apply appearance.
Tools and Features used
   Sketch Tools   :   line, 3 point arc
   Feature Tools  :   Extruded boss/base, curve driven pattern, fillet ,mirror , block.
   Appearance    :   chrome steel

7. Pedal
      Pedal is a strong rigid body mounted on the chassis or frame it is used as a foot rest while riding the bike
➢ Procedure
Draw line spline from the origin of the front plane and give them appropriate dimensions, extrude it and apply fillet. Now draw over the extruded surface and extrude them to. Then sketch on front plane use convert entities to bring circle form previous sketch now extrude
them using offset from surface, apply linear pattern across the bass extruded, use chamfer distance-distance option, apply fillet, apply appearance.
Tool and Feature used
   Sketch tool   :  line, circle , spline
   Feature tool  :  Extruded boss/base, revolve, Dome , fillet , chamfer , linear pattern,
   Appearance  :  Chrome plate

8. Front Wheel
     Front wheel is group of many bodies rim, rotor . tire, caliper. Uses to movement of the motorcycle we know all that right .
➢ Procedure
     First draw the sketch on midplane draw 3 point arc line apply dimension from origin and revolve them using temporary axis make solid body apply fillet. Sketch on the front plane draw construction line from origin to upward, draw 3 point arc, spines give them appropriate dimensions and mirror about construction line, extrude it sketch on the extruded surface use convert entities, use line splines 3 point arc offset to draw spider web like design, use extruded cut the use circular pattern like that make bodies of rotor and caliper. Now convert curve from the rim portion and draw geometry for the tire give appropriate dimension and revolve it. Sketch on top plane draw geometry for the treads use extrude cut, use circular pattern, apply some fillets, apply appearance. we designed four part in this - 1) Rim , 2) Rotor , 3) Tire , 4) caliper
Tools and Feature used 
   Sketch tool  :  line , 3 point arc, circle , splines, rectangle, trim and extend entities , mirror, convert entities, offset
   Feature tool :  Revolve boss/base, Revolved cut , extruded cut ,fillet, linear pattern , circular pattern, mirror, chamfer.
   Appearance  :  Rim      -  Chrome steel
                         Rotor    -  Carbon steel
                         Caliper  -  Painted siena
                         Tire       -  Matt rubber

9. Rear Wheel
      It provides acceleration to the bike, it takes power from the engine an move bike in forward direction.
➢ Procedure
      The design process of the rear wheel is same as the front wheel only change is that we design extra part over here that is sprocket, circle over the rotor face and use extrude from face feature extrude it then draw over splines circles use trim to make an desired geometry over the extruded surface an do extrude cut, apply appearances. Designed 5 parts here 1) Rim , 2) Rotor, 3) Caliper, 4) Tire, 5) Sprocket
Tools and Features used
   Sketch tool   :  line , 3 point arc, splines , circle , rectangles, , trim and extend entities , mirror, convert entities, offset.
   Feature tool  :  Revolve boss/base, Revolved cut, extruded cut ,fillet, linear pattern , circular pattern, mirror, chamfer.
   Appearance   :  Rim       -  Chrome steel
                          Rotor     -  Carbon steel
                          Caliper   -  Painted siena
                          Tire        -  Matt Rubber
                          Sprocket -  Chrome steel

10. Front Fork
      It used to handle the bike it is mounted at the front of the chassis and the front wheel is mounted on the front fork by axle and it holds plenty of parts to control the bike such as handle, front break leaver, clutch leaver, head lights, front suspension, indicators etc.
➢ Procedure
     Procedure of the front fork is little bit long so we added with some points
For Fork tube - Sketch on the Front plane, by drawing a cylindrical diagram using line and give dimensions, relations to make it fully defined, then revolve it.
     For Triple Clamps - Select Top Plane and draw a concentric circle to the fork tube and draw another circle left and upward. Connect the circles and make them fully defined by giving dimensions, then extrude them.
     For Bulb - Select Front Plane, draw a horizontal construction line, spline, and revolve it. Move the bulb in z-direction then fillet it. Handle & Brake wires Select 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. Select the Bodies Mirror and combine. Give Appearance to the fork to make it realistic
Tools and Features used
   Sketch tool   : Line, Spline & Circle, Convert Entities, Trim entities
   Feature tool  : Extruded Boss/Base, Extruded cut, Dome, revolve cut, Projected curve ,Swept boss/base, Combine, mirror                             and Fillet.
   Appearance   :  Fork - Chrome Steel
                          Handle gripe - Glose Rubber 
                          Break Wire - Glose Rubber

11. Chassis
       Chassis is the main part of the vehicle it hold the all parts and component of the vehicle, Engine , Fuel tank , oil tank , rear wheel , fork etc. it provides rigidity to the whole vehicle.
➢ Procedure
      Insert Blueprint of the chopper in the front plane, adjust the location, transparency & sketch on it. Draw two concentric circles with and offset of 4mm. Draw a horizontal &
vertical line from origin. Then a spline connects the circle center and tangent to the horizontal line and gets a projected sketch.
     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. Next Sketch on the Right plane, draw a spline from top to bottom with relation to origin and make it fully defined. Remove the unwanted area using cut extrude. Mirror the bodies, and combine. Apply fillet, Chamfer, and give the appearance to it.
Tools and Feature used
   Sketch tool    :  Line, Spline, 3 Point Arc & Circle, Convert Entities & Offset Entities.
   Feature tool   :  Extruded Boss/Base, Extruded cut, Dome, Split, Project Curve, Swept Boss/Base, Combine, Revolved,                                   Boss/Base, Chamfer, Fillet, mirror.
   Appearance   : Painted Siena

12. Engine
       Engine Is the heart of the vehicle. it converts the chemical energy into mechanical energy to move forward the vehicle. It contain cylinders, pistons, crank shaft etc.
➢ Procedure
     Insert the blue print adjust it to get the desired location. Select the front Plane to draw a diagram of the base of the engine by using line and 3 point arc, extrude it. Again extrude it on the large 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. Select a top plane, draw the pulley by line and then turn on a temporary axis to revolve it.Sketch on Pulley by selecting on edge then
    Draw a rectangle and extrude towards outside to next surface then select sketch and make a circular pattern.
Select the outer face of the pulley and sketch on it, draw a circle inward then draw a small circle vertically to the origin, use the circular pattern feature, select the center point respectively, and coincident. Then use the cut extrude feature to remove the material. Select the front plane to create the cylindrical part of the engine. Draw a line from origin again draw a line which will be collinear to the line.
   Generate the new plane by selecting the line and endpoint of the line. Sketch in a new plane, draw a rectangle, and extrude it upward. Use fillet as well. Create an angled rectangle to the new plane and use cut extrude. Draw a curve, sketch 2D Diagram in two different planes by ensuring the endpoint should be the same, use features like convert entities, Construction line, Spline after getting projected curve, draw two concentric circles, make use of Pierce relation to curve then sweep it.
Tools and Feature used
   Sketch tool  :  line, Spline, 3 point arc, circle, Convert Entities, offset entities.
   Feature tool :  Extruded boss/base, extruded cut, dome, Split, Projected curve, Composite curve, Swept boss/base,                                    Combine, circular pattern, Revolve boss/base, Fillet, Mirror, Chamfer
   Appearance : Chrome Steel

13. Gas Tank / Fuel Tank
       Fuel tank used to carry the fuel required to run the engine. It is a hollow body contain petrol in it. It is mounted at the upper portion of the chassis over the engine.
➢ Procedure
     Insert Blueprint in the front plane and give proper dimensions for locating and renaming it. Sketch on a front plane by drawing construction lines, Spline roughly as per sketch picture & give dimension to make it fully defined. Create a plane at the endpoint of the spline and sketch on it, by drawing another spline & making a pierce relation with sketch 1, then sweep the surface.
    Sketch on Top Plane by drawing a spline & lines. Trim the outside portion using a trim surface. Create one more plane using the front plane & endpoint of surface 2 as reference. Sketch on it, by drawing a spline and a vertical construction line to dimension it. Draw two sketches on Front Plane & Midplane, using spline and line, then project curve and use lofted surface along the projected curve.
   Repeat the procedure for sketching the remaining surface, mirror it & apply a knit surface. For Seat - Select the outer edges and offset it and then extrude, apply fillet. Remove the unwanted surface using a swept cut & apply the shell to the body. Give appearance to tank as well as driver seat, After all apply decals.
Tools and Feature used
   Sketch tool     :   line, splines, Circle, Convert entities, Offset entities.
   Feature used  :  Swept Surface, Loft surface, Boundary surface, Projective curves, Knit surface, Sweep cut, Mirror, Fillet,                               Shell.
   Appearance    :  Gas Tank - Painted Siena
                           Seat - Grey Cotton

                                                
Assembly of all the Designed Parts
    Insert all the parts designed in solidworks assembly one by as required. Add chassis firs and apply mates to fix the position of the chassis. Now insert the remaining parts and apply mates conditions and relation with respect to chassis. At the end apply coincident mate to Front wheel, Rear wheel and Kick stand with top plane so the chopper looks like its standing on the ground and little bit leaned towards the ground.

ASSEMBLY

                                                                                    ****

➢ Some images from the PHOTOVIEW 360

Camera View

                                                          --

➢ Here is the Final Rendering in Solidworks Visulize

Conclusion

              At the end of the project we designed the part induvidually in parts file, we asseble the chopper in the assembly. we learned the tools and features of the soliworks, how to apply appearances according to the part of the chpper, we learned to apply decals, after we used the photoview 360 to learn lighting , camera setings, scean settings. After all we used Solidwork visulize for the rendering and place over design in 3d environmented backgrouds to know how our design is going to look in real world.