Material point method vs. finite element method: a comparative study of scratch test modeling

Abstract

Numerical modeling plays a critical role in understanding and predicting material behavior under mechanical loading. In the context of surface durability, scratch testing is widely used to assess the wear resistance of coatings and engineered materials. While the finite element method (FEM) is a standard tool for such simulations, it faces challenges in handling large deformations and material failure due to its reliance on fixed meshes. The material point method (MPM), a mesh-free alternative, offers improved robustness in capturing severe plastic deformation and material separation. Although MPM has shown promise for high-strain contact simulations, direct comparisons with FEM, especially those validated against experiments, remain limited. This study addresses that gap by systematically evaluating FEM and MPM in simulating scratch tests. Key aspects such as predictive accuracy, computational efficiency, and the ability to replicate experimental damage patterns are assessed. The findings highlight the trade-offs between both approaches and offer practical guidance for selecting appropriate modeling techniques in the design of wear-resistant materials and surfaces. By linking simulation outcomes to experimental observations, this work supports materials engineers in developing more reliable, performance-oriented solutions for tribological applications.