There are three key inputs to any finite element analysis process; the geometry representation as a mesh, the materials data and the loads. The validity of your decisions made from an analysis depends on capturing all of these accurately.
Accurate loading can be difficult to obtain. Some years ago we were involved in a project where the loads were provided by an OEM through a chain of suppliers. The stress results on the assembly indicated a catastrophic failure and no amount of tinkering with geometry and materials could go any way towards mitigating it.
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