Orthogonal machining is one of the most complex metal forming operations involving a diversity of physical phenomena, such as large deformation, complicated contact/friction condition, thermo-mechanical coupling and chip separation mechanisms. In this study, numerical simulation of this class of problems has been performed using advanced adaptive re-meshing procedures for inelastic problems, making it possible to capture shear band localization of realistic orthogonal machining. Blanking is another complex metal forming process which needs adaptive re-meshing procedure to avoid large finite element distortion. Both orthogonal machining and blanking have been numerically simulated and discussed.