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This paper aims to present the fatigue life behaviour of upper arm suspension. The main objectives are to predict the fatigue life of the component and to identify the critical location. In this analysis, three aluminium alloys were used for the suspension, and their fatigue life was compared to select the suitable material for the suspension arm.

CAD model was prepared using Solid Works software, and finite element analysis was done using ANSYS 14.0 software by importing the Parasolid file to ANSYS. The model is subjected to loading and boundary conditions; the authors consider a vertical force with constant amplitude applied at the bushing that connected to the tire, the others two bushing that connected to the body of the car are constraint. Tetrahedral elements given enhanced results as compared to other types of elements; therefore, the elements (TET 10) are used. The maximum principal stress was considered in the linear static analysis, and fatigue analysis was done using strain life approach.

Life and damage are evaluated and the critical location was considered at node 63,754. From the fatigue analysis, aluminium alloys 7175-T73 (Al 90%-Zn 5.6%-Mg 2.5% -… …) and 2014-T6 (Al 93.5%-Cu 4.4%-Mg 0.5%… …) present a similar behaviour as compared to 6061-T6 (Al 97.9%-Mg 1.0%-Si 0.6%… … .); in this case of study, these lather are considered to be the materials of choice to manufacture the suspension arms; but 7175-T73 aluminium alloys remain the material with a better resistance to fatigue.

By the finite element analysis method and assistance of ANSYS software, it is able to analyse the different car components from varied aspects such as fatigue, and consequently save time and cost. For further research, the experimental works under controlled laboratory conditions should be done to determine the validation of the result from the software analysis.

Because of non-satisfactory results obtained at the iron rods steel mill, during the last period of work and to collect relevant data to facilitate rapid and efficient decision-making, the purpose of this study is to describe a global analysis method of risks encountered by companies resulting from their own effects or by their environment to integrate prevention as soon as the conception of work place. From this point of view, it seems that it is time for companies that did learn to master direct costs to learn how to control indirect costs, which means controlling the risks and learning to face them once they are detected.

The method of work used is hazard identification and risk assessment (HIRA), which is based on Kinney evaluation. The HIRA allowed the authors to collect and analyze different dangers and risks at work posts and consider different corrective measures to prevent damages. The HIRA techniques are based on identifying the different hazardous situations and the risk related to each working station; the risks are identified and are classified and mitigated accordingly. Using unique criteria, the objective of the risk assessment part is to assign to each risk a numerical value. The criteria used for classifying and ordering the risk importance depend greatly on the selected method.

Risks are identified, classified and mitigated accordingly using Kinney method criteria depending on three factors: frequency of exposure (NE), probability of occurrence (NP) and severity level (NG). The level of risk mitigation (NM) is obtained as the product of the three factors (NP, NG and NE). Using the Pareto plot (20-80 per cent), the authors highlighted the priorities to be taken in the order of importance of the most important causes to take targeted measures.

This work is an opportunity for the steel mill complex to start a global approach in prevention of risks and improve working conditions. This can be reached by taking into consideration the technical, organizational and human solutions; It would not be a better method to search for ways and means to reach better prevention of industrial and technological risks, but it will preserve health of workers and get to a global higher level of security. Also, the steel mill complex can be engaged in a continuous improvement process. Therefore, management of risks will be a relevant way to decrease undesirable effects due to the diverse activities of the company.