Macro–Meso-Scale Simulation for Surface Roughness Evolution of Aluminum Alloy Tube Drawing Process

Surface roughening is a common defect in plastic deformation processing, directly affecting product surface quality and service performance. This study investigates the mechanisms of surface roughness evolution during plastic deformation by considering both intrinsic and extrinsic factors. A macro–meso-scale modelling framework is developed by coupling crystal plasticity finite element modelling, fluid–solid interaction modelling, and macro–meso boundary conditions. The crystal plasticity model incorporates a constitutive model based on crystal plasticity theory, a Voronoi-based geometric model, and a real rough-surface topography model to capture non-uniform grain-scale plastic deformation. Fluid–solid interaction modelling is introduced to analyze the influence of liquid lubricant on the deforming solid material. Boundary interpolation and continuous displacement theories are then used to transfer macro-scale boundary constraints to the meso scale. The proposed framework is numerically implemented and applied to the aluminum alloy tube drawing process. The effects of intrinsic factors, including grain size, grain orientation, and initial surface roughness, and extrinsic factors, including deformation path, strain rate, and lubrication condition, are systematically examined. From a practical point of view, effective strategies to improve surface quality are by reducing grain size, lowering initial surface roughness, decreasing the strain rate and using low-viscosity lubricants.