Why do I get different displacement when I tread my component as solid(1.74mm) and shell(3.99mm). I tried thick formulation as well but results are the same as thin shell formulation? Am I interpreting the results in a wrong way or have I not set up the problem correctly?
The internal formulations are entirely different. Thin plies of solid elements, especially tetrahedrons, will under-predict bending.
The behavior of solid elements in high aspect ratio shapes is explored here,
https://www.stonelakeanalytics.com/2020/11/05/mesh-density-challenge/