Hello Members, I am facing an issue with chip formation in a 3D turning process simulation, and I would greatly appreciate any insights or suggestions on how to address this problem. I have attached the .inp file of the model. Problem Description: In my 3D turning simulation, I am encountering difficulties with chip formation. The chips are not forming as expected, and this is impacting the accuracy and reliability of my simulation results. Process modelled is Turning operation, Workpiece material: Ti6Al4V alloy, modelled as deformable. Tool material: Tungsten Carbide, modelled as deformable. Steps Taken So Far: Checked the tool geometry and cutting parameters to ensure they are set correctly. Verified the workpiece material properties and machining conditions. Ran simulations with different cutting speeds, feeds, and depths of cut, but the issue persists. Request for Assistance: Has anyone experienced a similar issue with chip formation in a 3D turning simulation? Are there specific parameters or settings that could be causing this problem? What strategies or approaches can I try to improve chip formation in the simulation? Any guidance, tips, or advice would be highly appreciated. Thank you in advance for your help! Best regards, SUMESH C S