A 3D multi-scratch test model for characterizing material removal regimes in 5083-Al alloy

Abstract This study addresses the sensitivity of material removal regimes in 5083-aluminum alloy to interaction mechanisms generated during multi-scratch test (MST). A testing device using three conical indenters was firstly developed. Four attack angles and four normal loads ranging, respectively, from 10–60° and 10–25 N, were considered for conducting the experimental trials. The scratch velocity was kept constant to 210 mm min − 1 and the maximum scratch distance to 25 mm. The model, developed upon ABAQUS/Explicit, uses the Johnson–Cook approach for describing both material behavior and damage evolution. Single Scratch Test (SST) and MST reveal same wear regimes, namely, (i) “ploughing”, (ii) “transition”, and (iii) “cutting” whereas a significant difference was observed in the material removal maps. While ploughing domain neatly decreases to the detriment of transition domain when passing from SST to MST, cutting domains still remain quite comparable. The indenter attack angle is depicted as the most dominant factor in apparent friction coefficient. The three dominating regimes were successfully predicted, using the FE model, in close correlation with tribological parameters. The model was found very useful to highlight the significant role of the separation distance on controlling material flow and damage within the grooves' junction.