Assessment of Fatigue Life Under Three-Point Bending: Comparing S-D-S-ER and D-S-ER Techniques

In this study, it has been presented a novel approach to enhancing structural fatigue performance through the development and comparison of two methodologies: The Sub-modeling-Density-Shape-Element Removal (S-D-S-ER) method and the traditional Density-Shape-Element Removal (D-S-ER) method. Using three-point bending fatigue tests, the S-D-S-ER method is shown to significantly improve fatigue life and overall structural integrity by integrating sub-modeling into the design process. This contrasts with the conventional D-S-ER method, which displayed standard mechanical behavior and a markedly shorter lifespan. Notably, the S-D-S-ER model exhibited mechanical behavior similar to viscous materials—a characteristic often observed in composites—while the D-S-ER method did not. These results highlight the potential of advanced numerical modeling, particularly the S-D-S-ER approach, to enhance fatigue resistance and durability. This advancement is particularly relevant for the design and optimization of 3D-printed components, which are becoming crucial in industrial and biomedical applications. The adoption of such innovative methods could lead to significantly more reliable, long-lasting designs, with profound implications for the future of structural engineering and additive manufacturing.