Design of Triaxial Impact Wear Tester: Finite Element Simulation for Performance Analysis of AA6061-T6 Alloy

Wear is a critical mechanism that directly affects the service life of engineering materials and can lead to premature system failure. To prevent wear-related losses, particularly encountered in manufacturing processes, test systems capable of simulating realistic laboratory conditions are needed. In this study, a three-dimensional wear tester was developed that can simultaneously evaluate impact effects with abrasive sliding. The system was designed to apply impact forces using a vibration motor and a spring-supported structure placed under the sample. CAD modeling was performed with SolidWorks software, and finite element analyses were performed using the ANSYS Explicit Dynamics module. Simulations were performed on AA6061-T6 alloy at speeds of 0.25, 0.50, and 1.00 m/s and loads of 10 N, 20 N and 40 N at a constant wear distance of 10 mm. The findings showed that wear depth, maximum shear stress, and elastic deformation values increased significantly with increasing load. A 50% load increase at a speed of 0.5 m/s increased wear depth by 39.8%. However, increasing speed under constant load limited these effects. It is anticipated that the developed system will contribute to the understanding of wear mechanisms and will be an important tool for evaluating material behavior under multiaxial loading.