Background
FSAE Racecars generally don't use a 1:1 connection between the damper/spring and wheel. Usually, a bellcrank (or rocker arm) is installed to create a motion ratio and add availability for an Anti-Roll Bar.
Approach
Starting with a skeletal model of the bellcrank, we decided the plate spacing by optimizing for hardware loading. Then, we setup our stress simulation in Ansys to the load pathing. This allows us to get an idea of where we can optimize the design to reduce weight, but keep the part stiff where needed.
Design
After setting plate spacing and plate geometry, we modeled integrated conespacers to constrain the pushrod, shock, and ARB sphericals. The pivot hardware was chosen to be stiff and minimize friction between bushing surfaces.