Simulating shear and bending on a welded tow hook bracket

Hey, sounds like you’re running into a common FEA issue in SolidWorks. Full-penetration fillet welds often get oversimplified, especially if you’re not modeling the welds directly – which leads to underestimated stresses.
Best fix? Try explicitly modeling the weld bead. It takes a finer mesh but gives much more accurate results. If that’s too much, SolidWorks’ “welded connection” features or mesh refinement tools can help as a compromise. Also, check if you’re using the right material properties — the default base material might not reflect the weld zone properly. A more realistic material model can improve accuracy too.
So yeah, for solid stress results around welds, detailed modeling and mesh tweaks go a long way.