from my experiemence I can only confirm it. I didn't do anythink on rhelogy though, but we expanded typical mech.-thermal FEM calculations by combinations with CFD using FLUENT as well as COMSOL. We were able to included the Rotation Speed of a drill during the Drilling process. we are now in the Position to calculated drill-internal fluid supply design measures and compare the effects (flow, cooling, pressure Distribution, turbulences a.s.o.) by experiments which improves the Analysis a lot because of a proces insight we wouldn't have without CFD. We were ignoring chip Formation for simplicity (easier, shorter calculation), but that is not necessary. I can imagine that it would be quite helpful in your case too. Regards, R.Rentsch
For reference: Oezkaya, E., Beer, N., Biermann, D., Experimental studies and CFD simulation of the internal cooling conditions when drilling Inconel 718, International Journal of Machine Tools & Manufacture 108 (2016) 52–65.
An optimal choice of non-Newtonian fluid model concerning accuracy vs. tractability is often far from obvious. A good starting point can be to perform a simulation for a Newtonian (constant viscosity) case first and then assess the deformation rate/stress fields to judge how far shear thinning or transient effects are likely to change the result. And, of course, compare against trustable experimental data where available.