Sampat Kumar
Ansys Employee

Hi Sachin, 

The stress, as you mentioned, exceeded the material’s yield point, but it can’t simply imply that the material may fail. As we consider the developed stress of 200 MPa obtained in the larger part of the component then we can assume the material has undergone plastic deformation, but it still depends upon you which point you consider for the design and FOS you have used. If the developed stress exceeded the yield stress at the pointed location or on a very small part, then we can’t compare this with the experimental result. The stress developed in the component depends upon various reasons, like geometric irregularities, and loading conditions, whether they are tensile, compressive, fluctuating, etc.

For strain 0.013, which is below the failure strain (0.05),  according to your data, it indicates that the material has not exceeded its maximum strain capacity and can be considered to have not failed. But again, if you have the above-mentioned geometry irregularities or loading conditions, then the strain may not develop as in the experimental, so you can’t compare this.

In summary, the developed stress has exceeded the yield point of the material but has not crossed its failure strain or is not close to that. Based on the above data, we may consider that the material may not fail, but still, it depends upon your experience and the design point that you have selected. It also depends upon the geometric irregularities, loading condition, material, and FEA numerical error.