An accelerated high cycle fatigue testing approach is presented to determine the fatigue endurance limit of materials at high frequencies. Base excitation of a tapered plaque driven into a high frequency resonance mode allows the test to be completed in a significantly shorter time. This high cycle fatigue testing is performed using the tracked sine resonance search and dwell strategy. The controller monitors the structural health during the test. Any change in the dynamic response indicates crack initiation in the material. In addition, a shape optimization finite element model is conducted for the design of the tapered plaques. An integrated neural (Neural-Network) genetic (NSGA_II) optimization technique is implemented to carry out the shape optimization for this component. This process results in a significant reduction in the computational cost. A Pareto set is then produced that meets the designer’s requirements and provides the decision maker several alternatives to choose from.

An accelerated high cycle fatigue testing approach is presented to determine the fatigue endurance limit of materials at high frequencies. Base excitation of a tapered plaque driven into a high frequency resonance mode allows the test to be completed in a significantly shorter time. This high cycle fatigue testing is performed using the tracked sine resonance search and dwell strategy. The controller monitors the structural health during the test. Any change in the dynamic response indicates crack initiation in the material. In addition, a shape optimization finite element model is conducted for the design of the tapered plaques. An integrated neural (Neural-Network) genetic (NSGA_II) optimization technique is implemented to carry out the shape optimization for this component. This process results in a significant reduction in the computational cost. A Pareto set is then produced that meets the designer’s requirements and provides the decision maker several alternatives to choose from.