Design And Development Of A Bell Crank For Monoshock Front Suspension For Formula Varsity Race Car

Muhamad Sahail, Zainol Abidin (2011) Design And Development Of A Bell Crank For Monoshock Front Suspension For Formula Varsity Race Car. Project Report. UTeM, Melaka, Malaysia. (Submitted)

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Abstract

This Final Year Project (FYP) presents the design and development of a bell crank for monoshock front suspension for Formula Varsity 2010 race car. The development process involved conceptual design, design selection, material selection, load and analysis, and product fabrication. In the first stage, a 3D model of a bell crank was developed using CATIA V5R16 computer aided design software. Further analysis has brought the selection of aluminum alloys, Al6061-T6 as the bell crank material. Suspension load analysis was also performed to determine the maximum load for the component during cornering condition. The result later been used to determine the factor of safety of the bell crank and maximum translational displacement. The factor of safety of the bell crank is 5.51 and the maximum translational displacement is 0.0904mm. This result showed that the product was able to withstand the load as required. The development process was later been carried out by fabricating the bell crank using 5-axis Computer Numerical Control (CNC) machine and manual hand milling technique. The fabricated part then be evaluated and weighted. The bell crank final weight after fabrication was 0.405 kg

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