This research focuses on the finite element-based fatigue life prediction of the lower suspension arm subjected to non-uniform variable loads. The primary objectives of this research work are to predict the fatigue life of the lower suspension arm using the Strain-life approach and to discover suitable materials for the suspension arm. The lower suspension arm CAD model is developed using CAD tool - ProE (Wildfire4.0); it was subsequently moved to Ansys 12.1, where finite element analysis was performed for fatigue life analysis using the strain-life approach subject to various load cases.1. IntroductionThe suspension system is used to absorb shocks and jolts coming from the road or rough terrain. The suspension allows the wheel to move independently of the body. Suspension components, rims and brake components are known as unsprung masses, which are important for better ride quality and are intended to reduce the overall weight of the vehicle. Comfort can be achieved by isolating cyclists from road disturbances such as bumps or potholes, while control is achieved by preventing the car body from rolling and pitching and maintaining good contact between road and tyre. Recent technological research has shown that most components fail due to fatigue. Therefore our efforts have focused on fatigue analysis of automotive components. In today's competitive environment it is a crucial task to produce lighters; cheaper and more efficient automotive components. In the engineering design of any component, the analysis of structural aspects must be performed in the early stages to reduce development time and costs. Dr SS Khandare et. Al [1] explained that finite element analysis is an important tool for analyzing structural design, it helps to determine the critical region of the... center of the paper... for the representation of the boundaries of most models of solids imported from CAD systems. Figure 2 shows the lower suspension arm mesh model with 2.4 mm mesh size and a 10-node tetrahedral element (TET10) considered for the analysis. The results shown here make it clear that the side curb (kerb) limit is the highest loading condition. From the analysis of the lower suspension arm it is concluded that the Al alloy (Al 7075-T6) will provide comparatively longer fatigue life than EN19. The weight of the component made of Al alloy (Al 7075-T6) is substantially reduced; the weight percentage reduction is almost 60% by using the aluminum alloy lower suspension arm without compromising the fatigue resistance of the component. Therefore, Al alloy (Al 7075-T6) will provide greater durability with reduced weight. Further research work can be done to optimize the size and weight of a sedan car's lower suspension arm.