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This paper presents a multilevel product model that supports Simulation-Based Design (SBD) of mechanical systems, from preliminary to detailed design stages The pnmary goal of the SBD is to achieve product designs featuring better performance and greater durability and reliability through computer-based modeling, engineering analysis, and design trade-off

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In the Army mechanical fatigue subject to external and inertia transient loads in the service life of mechanical systems often leads to a structural failure due to accumulated damage. Structural durability analysis that predicts the fatigue life of mechanical components subject to dynamic stresses and strains is a compute intensive multidisciplinary simulation process, since it requires the integration of several computer-aided engineering tools and considerable data communication and computation. Uncertainties in geometric dimensions due to manufacturing tolerances cause the indeterministic nature of the fatigue life of a mechanical component. Due to the fact that uncertainty propagation to structural fatigue under transient dynamic loading is not only numerically complicated but also extremely computationally expensive, it is a challenging task to develop a structural durability-based design optimization process and reliability analysis to ascertain whether the optimal design is reliable. The objective of this paper is the demonstration of an integrated CAD-based computer-aided engineering process to effectively carry out design optimization for structural durability, yielding a durable and cost-effectively manufacturable product. This paper shows preliminary results of reliability-based durability design optimization for the Army Stryker A-Arm.