In my experience, ALE will not help much in a cutting simulation.

What is important is to define the correct criteria for material separaton and for damage/failure. Also look at hourglass controls.

Sir,

Thank you for replying . I took johnson cook damage criteria with damage evolution in terms of displacement . Hourglass I have take enhanced . The problem of excessive distortion still persists.Can you suggest what has to be done

Difficult to say without looking at the model in detail. Try to reduce the cutting speed and check all the units (excessive distortion may be due to overestimated elastic waves) and boundary conditions.

Hi,

cutting generally changes the topology of the workpiece because it generates new surfaces. Therefore, using the same mesh topology (connectivity) throughout the calculation (almost-Lagrangian mesh) will inevitably result in excessive mesh distortion, even with ALE.

Remeshing in the context of ALE usually means relocation of nodes resp. mesh relaxation. That is to say, ALE remeshing usually does not generate a completely new mesh but uses the original mesh topology, and the above mentioned problem persists.

For the simulation of cutting your computational model should enable the generation of new surfaces. This can be achieved by generating a completely new mesh at some step in the calculation (sometimes called "rezoning"), by using XFEM, mesh-free or particle methods, or by using multi-material ALE, Eulerian, or coupled Eulerian-Lagrangian methods.

Regards

@Daniel

But it is of course possible (and standard) to have a regular mesh for the region destined to become the chip and another one for the workpiece with a sacrificial layer in between. In this case, ALE can be used - but, as I said, in my experience it does not help much.

Thank you for commenting, Martin. Perhaps my answer was a little bit too "academic" ;-)

@sasank,

Try to adjust simulation time . It is very important in Abaqus/explicit  mode. And also try to use distortion control .