I'm experiencing very similar results for one of my plastic parts. Solidworks is suggesting one of my parts has a 57mm deflection with a 100lb load applied, and in real world testing, that same load only causes a 12mm deflection. I have the material properties for the plastic entered exactly as found in the datasheet, and I'm certain I have my fixtures, connections, and forces entered properly. I'm not sure why the simulation has such a discrepancy with real world testing...
The bucket is meshed far too coarse to do a stress analysis. Refine the mesh in high stress area's untill the stress value converges to a steady solution. You will see a drastic change in you results.
Other aspects that can influence your solution:
- too rigid fixture
- incorrect / inaccurate material properties
- incorrect assumed force(direction)
- assuming small strains (large strain is off, so the stress area is not updated)
I am running simulation again with a smaller mesh. The result is still very different from real life test.
Do I need to use carefully between material parameter? When I select material type in material property they are a few option for non-linear plastic material. How can you select the right one for the simulation?
I would hope to be within 20% of the real life case. What would be your expectation.
I have reduce to a minimum the fixture and achieve lower stress but it is still 14 times higher than what I am experiencing.
Can you comment on the handle as well please?
Hey Richard, were you able to figure out what the issue was? I'm still struggling with this when trying to calculate displacement from plastics...