{"id":461126,"date":"2026-07-09T10:46:48","date_gmt":"2026-07-09T10:46:48","guid":{"rendered":"https:\/\/innovationspace.ansys.com\/forum\/forums\/topic\/guidance-required-for-ls-dyna-end-milling-simulation-with-chip-formation-ansys\/"},"modified":"2026-07-09T10:46:48","modified_gmt":"2026-07-09T10:46:48","slug":"guidance-required-for-ls-dyna-end-milling-simulation-with-chip-formation-ansys","status":"publish","type":"topic","link":"https:\/\/innovationspace.ansys.com\/forum\/forums\/topic\/guidance-required-for-ls-dyna-end-milling-simulation-with-chip-formation-ansys\/","title":{"rendered":"Guidance Required for LS-DYNA End Milling Simulation with Chip Formation &#8211; Ansys"},"content":{"rendered":"<p>&lt;p&gt;Hello,&lt;\/p&gt;&lt;p&gt;<img decoding=\"async\" src=\"https:\/\/innovationspace.ansys.com\/forum\/wp-content\/uploads\/sites\/2\/2026\/07\/09-07-2026-1783593951-a00 (1).jpeg\" alt=\"\" \/>I am currently learning LS-DYNA and trying to simulate an end milling operation with chip formation.&lt;\/p&gt;&lt;p&gt;I have modelled the milling cutter as a rigid body and the workpiece as a deformable body. However, I am facing difficulties in defining the correct contact interaction required for material removal. The simulation also terminates with errors such as &#8220;Energy error too large&#8221; and &#8220;General solver error.&#8221;&lt;\/p&gt;&lt;p&gt;I have attached screenshots of my model setup, contact definition, and the solver errors.&lt;\/p&gt;&lt;p&gt;Could anyone please guide me on:&lt;\/p&gt;<\/p>\n<ul>\n<li>&lt;p&gt;The recommended workflow for end milling simulations in LS-DYNA.&lt;\/p&gt;<\/li>\n<li>&lt;p&gt;The correct contact definition for chip formation.&lt;\/p&gt;<\/li>\n<li>&lt;p&gt;The essential Control Cards, Database Cards, and Keywords required for this type of simulation.&lt;\/p&gt;<\/li>\n<li>&lt;p&gt;Any official tutorials or benchmark examples for metal cutting using LS-DYNA.&lt;\/p&gt;<\/li>\n<\/ul>\n<p>&lt;p&gt;Thank you for your time and guidance.&lt;\/p&gt;<\/p>\n","protected":false},"template":"","class_list":["post-461126","topic","type-topic","status-publish","hentry","topic-tag-chip","topic-tag-lsdyna","topic-tag-machining","topic-tag-milling"],"aioseo_notices":[],"acf":[],"custom_fields":[{"0":{"_bbp_forum_id":["27814"],"_bbp_topic_id":["461126"],"_bbp_subscription":["708030","13640"],"_bbp_author_ip":["165.101.246.252"],"_bbp_last_reply_id":["461159"],"_bbp_last_active_id":["461159"],"_bbp_last_active_time":["2026-07-09 20:26:12"],"_bbp_reply_count":["1"],"_bbp_reply_count_hidden":["0"],"_bbp_voice_count":["2"],"_bbp_engagement":["708030","13640"],"_btv_view_count":["50"],"_bbp_topic_status":["unanswered"]},"test":"m25mea001iitj-ac-in"}],"_links":{"self":[{"href":"https:\/\/innovationspace.ansys.com\/forum\/wp-json\/wp\/v2\/topics\/461126","targetHints":{"allow":["GET"]}}],"collection":[{"href":"https:\/\/innovationspace.ansys.com\/forum\/wp-json\/wp\/v2\/topics"}],"about":[{"href":"https:\/\/innovationspace.ansys.com\/forum\/wp-json\/wp\/v2\/types\/topic"}],"version-history":[{"count":0,"href":"https:\/\/innovationspace.ansys.com\/forum\/wp-json\/wp\/v2\/topics\/461126\/revisions"}],"wp:attachment":[{"href":"https:\/\/innovationspace.ansys.com\/forum\/wp-json\/wp\/v2\/media?parent=461126"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}