贵金属原料价高,微细拉丝工艺复杂、良品率低导致贵金属微细丝的研发成本高昂。本研究使用基于晶体塑性有限元(CPFEM)的Au-27Pd-18Ag合金微丝单道次拉拔工艺跨尺度模拟方法,结合晶体塑性理论与退火态金基合金丝的电子背散射衍射(EBSD)实验数据,构建了包含255个真实晶粒形貌的二维多晶模型。同时引入位错密度演化方程表征加工硬化行为,通过试错法参数标定实现拉伸模拟结果与拉伸实验结果的应力-应变曲线误差不超过5%。本研究揭示了拉拔过程中应力应变分布规律:表面晶粒因模具挤压和摩擦作用呈现显著应力梯度,而应变分布由芯部至表面呈“低-高-低”非均匀特征;验证了晶粒取向差异通过施密特(Schmid)因子调控滑移系统激活的机制。
The development of precious-metal microwires is associated with high research and production costs, primarily due to the elevated price of precious metal raw materials, the complexity of fine wire drawing processes, and the low manufacturing yield. This study establishes a cross-scale simulation framework for single-pass drawing of Au-27Pd-18Ag alloy microwires based on crystal plasticity finite element modeling (CPFEM). By integrating crystal plasticity theory with electron backscatter diffraction (EBSD) data obtained from annealed gold-based alloy wires, a two-dimensional polycrystalline model incorporating 255 realistic grain morphologies was constructed. A dislocation density evolution equation was introduced to characterize strain-hardening behavior, and model parameters were calibrated through a trial-and-error procedure, resulting in a deviation of less than 5% between the simulated and experimental tensile stress-strain curves. The results reveal the stress and strain distribution characteristics during the drawing process: surface grains exhibit pronounced stress gradients due to die compression and friction, while the strain distribution presents a non-uniform “low–high–low” pattern from the core to the surface. Furthermore, the findings confirm that grain orientation heterogeneity governs slip system activation through variations in the Schmid factor.