Virtual fatigue testing

A system for virtual fatigue testing comprising:

• one or more libraries operational to store a coarse-grid finite-element-model of a component;
• and
• a computer operational to:
• identify a plurality of static stress locations neighboring at least one of one or more fasteners and one or more non-fastener stress concentration regions in the component by a static analysis of a component intermediate-grid finite-element-model of the component, wherein the component intermediate-grid finite-element-model has higher fidelity than the coarse-grid finite-element-model;
• identify a plurality of hot spot locations in the component intermediate-grid finite-element-model by performing a fatigue screening on the component;
• generate a plurality of details for the component intermediate-grid finite-element-model based on the plurality of hot spot locations;
• predict a plurality of crack results by a deterministic durability-and-damage-tolerance analysis of the plurality of details for a component fine-grid finite-element-model of the component, wherein the component fine-grid finite-element-model has higher fidelity than the component intermediate-grid finite-element-model;
• calculate a plurality of crack margins for the component fine-grid finite-element-model by a probabilistic durability-and-damage-tolerance analysis of the plurality of crack results, wherein the plurality of crack margins include a final crack initiation margin and a final crack growth margin;
• and
• generate an output file that contains the final crack initiation margin and the final crack growth margin.

A non-transitory computer readable storage medium storing instructions that control data processing, the instructions, when executed by a processor cause the processor to perform a plurality of operations comprising:

• reading a coarse-grid finite-element-model of a component from one or more libraries;
• identifying a plurality of static stress locations neighboring at least one of one or more fasteners and one or more non-fastener stress concentration regions in the component by a static analysis of a component intermediate-grid finite-element-model of the component, wherein the component intermediate-grid finite-element-model has higher fidelity than the coarse-grid finite-element-model;
• identifying a plurality of hot spot locations in the component intermediate-grid finite-element-model by performing a fatigue screening on the component;
• generating a plurality of details for the component intermediate-grid finite-element-model based on the plurality of hot spot locations;
• predicting a plurality of crack results by a deterministic durability-and-damage-tolerance analysis of the plurality of details for a component fine-grid finite-element-model of the component, wherein the component fine-grid finite-element-model has higher fidelity than the component intermediate-grid finite-element-model;
• calculating a plurality of crack margins for the component fine-grid finite-element-model by a probabilistic durability-and-damage-tolerance analysis of the plurality of crack results, wherein the plurality of crack margins include a final crack initiation margin and a final crack growth margin;
• and
• generating an output file that contains the final crack initiation margin and the final crack growth margin.