For a given rotation, yes, the more reality you add, the lower the stresses get, as the section softens.
A reasonable rule of thumb is that you'll only see 60% of the theoretical stiffness near the joint (say 10*a) if you use squarish tubes and butt joints. Good joint design can take that up to 90-95%.
It is almost impossible to manually estimate the stiffness of sections that are re-entrant or generally weird, such as are used in cars. A good example of that is using a light foam to stiffen a steel structure. At first sight it is ridiculous, but the foam stabilises the flat surfaces in the section and provides a measurable improvement in performance.
Cheers
Greg Locock
Please see FAQ731-376 for tips on how to make the best use of Eng-Tips.