Non-local damage models in manufacturing simulations

•Mesh independent solutions when refining below non-local damage model length scale.•Effects of various approximations in exact nonlocal consistent tangent.•Accurate results with explicit nonlocal update model for small increments.•Different parameters for non-local and local models are needed for given material.

Localisation of deformation is a problem in several manufacturing processes. Machining is an exception where it is a wanted feature. However, it is always a problem in finite element modelling of these processes due to mesh sensitivity of the computed results. The remedy is to incorporate a length scale into the numerical formulations in order to achieve convergent solutions. Different simplifications in the implementation of a non-local damage model are evaluated with respect to temporal and spatial discretisation to show the effect of different approximations on accuracy and convergence.