We are designing a flow check valve rated for 7500 psi and using Solidworks Simulation to analyze the check valve poppet stress distribution. Please see image-01 for the section cut of the valve assembly.
After running the static FEA with non-penetration contact set between the poppet head and the casing shoulder, I'm getting really high stresses around the two contact points shown on image-02.
We did the hand calculation based on formula: Contact Stress = Contact Force / Contact Area, and we got 64.4 KSI contact stress which is about 1/2 of the maximum number the FEA gave us.
We don't know if the high stresses are singularities or not. We have put a rounded corners around the high stress location but no luck, the stress is still very high.
My question is how to interoperate the stress result?
Does the material yield or not yield?
How to make the conclusion persuasive? I don't want to say "the red area is singularity and next to it is the green, hence ok. .."
Should I trust the result from the FEA analysis?
Are there anything else we can do to get a meaningful result?
Thanks in advance.