Bell Crank Lever is important components from safety point of view since they are subjected to large amount of stresses. Hence to study the stress pattern in bell crank lever, analytical, numerical and photoelasticity methods are used. For analysis purpose virtual model of bell crank lever is prepared by picking data from design data book. Bending stresses in lever formula is used for determination of stresses in bell crank lever analytically. For numerical analysis bell crank lever is prepared using ANSYS and this model of bell crank lever in ANSYS where stress analysis is done by FEM. Finite Element Analysis(FEA) have been performed on various models of varying fillet radius, optimization for volume and reduction of materials form bell crank lever and by using photoelasticity of bell crank lever. Also for bell crank lever stress analysis is done by using method of FEM. From the output of these analyses it is observed that results obtained are in close agreement with each other and maximum failures stress concentration occurs at maximum bending surface. Comparison between numerical, FEM and experimentally are observed that results obtained are in close agreement with each other
