Resolving high-strain-rate scratch behavior of Ti6Al4V in experiment and meshless simulation

The outstanding strength-to-weight ratio and corrosion resistance of titanium have made it the material of choice in the aerospace industry and medicine. The alpha–beta alloy Ti6Al4V is particularly preferred for its excellent mechanical and bio-compatible properties. Despite its advantages, the low thermal conductivity and poor tribological performance of titanium pose significant challenges during manufacturing and in operation. This research offers deep insights into the high strain rate behavior of Ti6Al4V under abrasive load, such as e.g. experienced in machining, by modifying the standard scratch test setup and using optimized Johnson–Cook material parameters to perform Material Point Method (MPM) simulations. The MPM simulations provide accurate predictions of the data gathered through high strain rate scratch experiments. We found an increase in the von Mises stress distribution as well as the normal and tangential forces required to perform a scratch of the same depth as the strain rate increases. The morphology of the scratch profiles also showed an increase in the height of the ridges that form as the scratching speed increases. These findings are in line with the increase in yield strength and work hardening with growing strain rate. This study bridges the gap between simulation models and experimental observations by providing insights for improved machining strategies and surface treatments that can enhance the performance of Ti6Al4V in demanding applications.