Analysis of stress intensity factor for fatigue crack using bootstrap S-version finite element model Muhamad Husnain Mohd Noh and Mohd Akramin Mohd Romlay Faculty of Mechanical and Automotive Engineering Technology, Universiti Malaysia Pahang, Pekan, Malaysia Chuan Zun Liang Centre for Mathematical Sciences, Universiti Malaysia Pahang, Pekan, Malaysia Mohd Shamil Shaari Faculty of Mechanical and Automotive Engineering Technology, Universiti Malaysia Pahang, Pekan, Malaysia, and Akiyuki Takahashi Department of Mechanical Engineering, Faculty of Science and Technology, Tokyo University of Sciences, Noda, Japan Abstract Purpose – Failure of the materials occurs once the stress intensity factor (SIF) overtakes the material fracture toughness. At this level, the crack will grow rapidly resulting in unstable crack growth until a complete fracture happens. The SIF calculation of the materials can be conducted by experimental, theoretical and numerical techniques. Prediction of SIF is crucial to ensure safety life from the material failure. The aim of the simulation study is to evaluate the accuracy of SIF prediction using finite element analysis. Design/methodology/approach – The bootstrap resampling method is employed in S-version finite element model (S-FEM) to generate the random variables in this simulation analysis. The SIF analysis studies are promoted by bootstrap S-version Finite Element Model (BootstrapS-FEM). Virtual crack closure-integral method (VCCM) is an important concept to compute the energy release rate and SIF. The semielliptical crack shape is applied with different crack shape aspect ratio in this simulation analysis. The BootstrapS-FEM produces the prediction of SIFs for tension model. Findings – The mean of BootstrapS-FEM is calculated from 100 samples by the resampling method. The bounds are computed based on the lower and upper bounds of the hundred samples of BootstrapS-FEM. The prediction of SIFs is validated with Newman–Raju solution and deterministic S-FEM within 95 percent confidence bounds. All possible values of SIF estimation by BootstrapS-FEM are plotted in a graph. The mean of the BootstrapS-FEM is referred to as point estimation. The Newman–Raju solution and deterministic S-FEM values are within the 95 percent confidence bounds. Thus, the BootstrapS-FEM is considered valid for the prediction with less than 6 percent of percentage error. Originality/value – The bootstrap resampling method is employed in S-FEM to generate the random variables in this simulation analysis. Keywords Stress intensity factor, S-version finite element model, Bootstrap resampling method, Random variables, Bounds Paper type Research paper 1. Introduction Fatigue crack growth occurs in manufacturing industries in automotive, aerospace, building and engineering applications. The cracks appear because of inherent defects in the material Analysis of stress intensity factor 579 This study were funded by RDU170383 and RDU1703184 from Universiti Malaysia Pahang (UMP) and Fundamental Research Grant Scheme (FRGS/1/2017/TK03/UMP/02/24) and (FRGS/1/2018/STG06/ UMP/02/16) from Kementerian Pendidikan Malaysia (KPM) with number RDU170124 and RDU190134 respectively. The current issue and full text archive of this journal is available on Emerald Insight at: https://www.emerald.com/insight/1757-9864.htm Received 18 October 2019 Revised 1 December 2019 Accepted 13 January 2020 International Journal of Structural Integrity Vol. 11 No. 4, 2020 pp. 579-589 © Emerald Publishing Limited 1757-9864 DOI 10.1108/IJSI-10-2019-0108