Hi I'm a starter on simulation and I'm sorry if my question may be repeated in other posts.

I was working on an analysis for a lever, having major thickness of 4.92mm, with fillets of 0.3mm radius on all edges, and:

1 - a hinge on one end

2 - a flat support at the bottom face

3 - a roller support on the tip at the other end

4 - a 206 N load (by pressing a smaller metal cylinder against the arc) along an edge on the inner arc, with specified applying angle

So I ran the static analysis to generate the von Mises stress distribution, which gave a maximum of 8e+7 N/m2. The material was the default alloy steel from solidworks library (Elastic modulus 2.1e+11, Poisson's ratio 0.28). I was on Solidworks Premium 2015.

While a quick math done on the load 206 N, divided by an assumed contact area of 4.32mm*0.1mm, should give more than 4e+8 N/m2. What was the input going wrong to deviate the result? I am happy to provide more information if needed, thanks!

Not getting into the last paragraph and taking about expectations, I'd like to grab your attention to some other points:

1) suppress all fillets, they have minor effect on your structure and their only job is wasting your mesh.

2) How's your mesh resolution? Are these results independent of mesh resolution?

3) The stress pick is concentrated at a specific area...