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The cause of accidents due to suspension failure is fatigue. The goal of this project was to design a bell crank for an FSAE prototype to withstand fatigue loads and reduce the chances of failure during its use. After finding the bellcrank forces, the dimensions of the bellcrank and the associated OEMs (bearings) are calculated and found. This was followed by CAD modelling and structural optimization using Autodesk Fusion 360 software. Finally, finite element analysis was performed and a comparative study was done between the new and old model of bellcrank assembly based on mass, fatigue life and factor of safety and the results were acknowledged.

Structural analysis of bellcrank in a pullrod suspension system in an FSAE prototype