I have done a static structural analysis of an assembled component that uses bolt connections and welds. I had defined two type of loads, 1.Bolt pretension 2.External load as force.
I have defined bonded contacts for all the bolt, nut interfaces and the surfaces that were mated for assembly. The results were not as expected. I got a peak von mises stress of 960MPa, near the bolt hole region, whereas the ultimate strength of my material (structural steel in ansys) is only 460MPa.
NOTE-1: I have previously defined frictional contacts for bolt head and nut head interfaces, but it resulted in DOF limit exceed error and newton raphson residual showed my elements flew off in space. So i switched all my contacts to bonded type and got this undesired result. I am sure the component wont fail (from the experiments) that is it can never develop this high stress value.
NOTE-2: I have redesigned my original component with a generic model and have used it for this post
Please direct me to find where the problem is in this analysis, i have attached with this the post my archived workbench file