Those are some interesting things to think about.
I ran a few more scenarios, loading the hole from a rigid (in the case of the study) pin and a contact set. With 0.5mm of slop in the hole the FOS was 0.95, when you bring that down to 0.05mm FOS goes to 1.43. This is with an 8mm plate instead...
The plate shown in the attachment has a bearing load of 12500N on the bottom larger hole, the top two holes have fixed hinge geometry.
The min FOS result is 1.34, just at the bearing load point. All around this point there is material where the FOS is over 5.
Would you consider the FOS on this...
