Hi all,
I am currently running a 2D Explicit Dynamic simulation of a milling process in Abaqus.
Today, I started encountering the following error:
“The elements contained in element set ErrElemExcessDistortion-Step1 have distorted excessively. Print-out suppressed for subsequent distorted elements. There are a total of 28 excessively distorted elements.”
What is puzzling is that over the past several weeks I have built and run multiple similar models without this issue. However, now even small adjustments—or recreating what appears to be the same model—can trigger this error.
I would appreciate any advice on how to address this problem. In particular:
- What are the most common causes of excessive element distortion in explicit machining simulations?
- What are the recommended strategies to improve stability (e.g., mesh refinement, damage settings, contact definition, time increment control)?
- Are there specific checks I should perform to identify the root cause?
For context, this is a cutting simulation with material removal and chip formation, so large deformation is expected.
Thanks in advance for your help.
Best regards,
Samuel
