That clarifies things hugely!
The result you got there in your simulation is just what I was looking for. Although not 35MPa, 43MPa is close enough for me, as you say it's an infintesimally small point so the FEA result you got is the one I'm after.
What constrains did you use?
Also your result is the 'Stress in XZ'...maybe a stupid question but how did you know that was the right one to use?
For the constraint, I used a fixed constraint on the band of material between the two planes.
In order to know which plane to look at for the stress. I have the Origin 3D Indicator turned on. If you dont see it on your screen, you can turn it on in Tools>Application options, Display Panel. Check the "Show Origin 3D indicator" box.
All sorted now.
One last question... Although I've managed to resolve this issue, and established that the shear stress (in the XZ plane in your case) is 43MPa, because the Von Mises result is much bigger, I assume that means that it will still somehow see that stress and therefore the 43MPa shear stress isn't what I should be worrying about.
After all, what I'm trying to find out is if this bolt will fail when subjected to a 1KN load in this configuration.
I have no advice to offer, but this thread reminded me of what Dr. Jess Comer said in the SAE Bolted Joint seminar I attended: "Bolts make lousy pins."
Inventor Series 2010 SR SP4
Windows 7 64 bit - SP1
8 GB Ram