I know I shouldn't respond to AC's but I'm going to anyway:
And it didn't need to be.
As far as geometry goes, it did need to be that detailed. Firstly, the pellets are round and to get the power and heat transfer correct you have to get the geometry correct. Also, pellets have small features on them (dishes on top and chamfers around the edges) that are put there on purpose and make a big difference in the overall response of the system (the dishes, in particular, reduce the axial expansion by a lot). So the detailed geometry is a very important part of this simulation. But that's not the only reason why it's large.
Your simulating a simple heat transfer and simple expansion, NOTHING MORE, no different that any other chemical process simulation in any other factory. Just with a lot more nodes.
I already explained how that is not the case. These are fully-coupled, fully-implicit multiphysics calculations. It is _not_ just heat conduction going on. Very complicated processes like fission gas creation, migration and release and fission induced and thermal creep, and fission product swelling are all involved. Plus the heat conduction and solid mechanics and thermal contact and mechanical contact and fluid flow model (on the outside of the pin) and conjugate heat transfer. All of these processes feed and are impacted by each other. These are NOT simple calculations.
It's also an arbitrary simulation serving no purpose. You said "what is that panel is broken right there' then ran a simulation with a stupid number of nodes to soak up a computer. But the pellet was made, it exists, it didn't need your simulation to be made and the simulation make zippo difference. You can run any number of similar simulations with the damage in an infinite number of places or combination of places, and it makes zip difference to the world because you don't know where each pellet is damaged. So NONE of your simulations apply to the actual pellet.
Actually, you are very wrong. Firstly, the Missing Pellet Surface problem is a huge problem in industry. What we can do with simulation is explore boundaries of how much tolerance there can be for such missing surfaces. We can vary the missing surface size and run thousands of calculations to determine the sizes that operators need to worry about. They can then adjust their QA practices to take this information into account. We can also run simulations of full reactors and stochastically sprinkle in defect pellets and show the overall response of the system which can help in understanding how to bring a reactor back up to full power in a safe way after refueling.
As for "that pellet exists"... firstly that's not true... but even if it did, doing experiments with nuclear fuel is _very_ costly and takes years (that is something else we do at INL) in order to better target our experimental money we do simulation to guide the experiments.
Their mission statement is absolutely clear. Turn cold war spending into security theatre spending and that's your job.
I don't work in security.... there are many national labs, all with different missions, but they _all_ do non-security work. They all work with US industry to solve some of the toughest problems on the planet. They are all full of extremely smart people and they are all working to add to the competitive advantage of the US. I'm sorry that you feel that way, but if you are interested in learning more about the national labs you should get a hold of me.