From the figure, it seems that your contact definition is wrong.

I would recommend to set up the model without ALE to keep things simple.

There are several other questions here on RG dealing with machining simulations, answers there may help.

Thanks for your help dear Martin. I'll try to modify my contact definition and Lagrangian model as you said. 

I followed comments for similar problem, but I haven't be able to solve it yet.

I also used friction coefficient for penalty interaction in the model. Do you think its value can have significant effect on the model? And what is your thought about my mesh?

Thank you very much.

Looking at your model again, I assume that you use general contact and some kind of failure criterion to remove elements. If this is the case, you also have to add all interior element surfaces as possible contacts.

Your input file should contain lines like this:

*Surface, type=ELEMENT, name=interior

allWP, interior    

where AllWp is a set containing all elements in the work piece

and

*Contact Inclusions

Tool-1.m_Surf-1, interior

See the manual "modeling surface erosion" (ch  35.4.1 in 6.12)

Thanks again dear Martin. Based on some modification, the model was improved. I have to check the results and hope they'll be reasonable.

dear mr Yazdan,

i can help you with the cae model, video tutorial etc. contact me at [email protected]

Hi Yazdan,

It will work if you make the width of the cutter bigger than the plate.

Hi Prakash, is there any book with step by step guide for machining in abaqus?

rgds,