Experimental validation and 3D finite element modelling of scratch-induced deformation in Ti-6Al-4V alloy

Scratch testing is a valuable method for understanding material deformation and wear in high-performance alloys. Finite element modelling (FEM) has proven to be a powerful tool for simulating complex processes such as scratch testing, offering insights that would otherwise require extensive experimental work. Ti-6Al-4V poses unique challenges for modelling due to its high strength, wear resistance, and sensitivity to strain rate and temperature effects. In this study, the behaviour of Ti-6Al-4V under scratch loading was investigated using both experimental scratch tests and FEM simulations. The Johnson-Cook (JC) damage model was employed to simulate plastic deformation and damage, while the Archard wear model was integrated to account for material removal. Validation against four experimental scratch tests showed strong correlation, with the FEM model demonstrating minimal deviation in plastic deformation depth. The frictional force trends also closely aligned, validating the model’s capability to predict mechanical response and progressive wear accurately.