In this work, a computational framework is proposed for fatigue damage estimation in structural systems by integrating operational experimental measurements in a high-fidelity, large-scale finite element model. The proposed method is applied in a linear steel substructure of a lignite grinder assembly at a Public Power Corporation power plant. A finite element model of the steel base is developed and updated to match the dynamic characteristics measured in real operating conditions. This is achieved through coupled use of numerical and experimental methods for identifying, updating, and optimizing a high-fidelity finite element model. The full stress time histories of the complex mechanical assembly are estimated, at critical locations, by imposing operational vibration measurements from a limited number of sensors in the updated finite element model. Fatigue damage and remaining lifetime is subsequently estimated via commonly adopted engineering approaches, such as Palmgren-Miner damage rule, S-N curves, and rainflow cycle counting. Incorporation of a numerical model of the structure in the response estimation procedure permits stress estimation at unmeasured locations, thereby enabling the drawing of a complete and substantially dense fatigue map consistent with the vibration measurements. Fatigue predictions via the proposed framework are highly correlated to experimental fatigue results, proving the efficiency and applicability of the framework.

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