(basically re-sharing an older query). 
Hello,
I am using Abaqus 2022 for simulating material removal behavior for an additively manufactured (AM) workpiece. 
In the attached image, I am simulating wire EDM process whereby this workpiece (AM) has been removed from the baseplate using this material removal simulation technique. (Reference => https://help.3ds.com/2023x/english/dsdoc/SIMA3DXANLRefMap/simaanl-c-amspecialpurpose-removal.htm?contextscope=cloud). During this material removal process 0.2 mm elements at the interface of workpiece and substrate has been removed during EDM simulation. This has worked nicely. 

As a subsequent step, I am removing material from this workpiece/blade which is similar to milling process or material removal in XY plane. The problem is while I apply the stress field from the end of previous simulation (EDM), to the new milling simulation where I used both models ((1) complete model without 0.2 mm removed at bottom and (2) model with 0.2 mm removed as it should be). As can be seen from the simulation resulting image that some miss-orientation occurs as stress field do not matches with the geometry of the blade during milling simulation at time = 0. Does anyone have any suggestion on how to prevent such mismatch between applied stress and geometry of workpiece?
Could meshing have some effect on it? although same mesh is used in both simulations.