Finite Element-Based Multi-Objective Optimization of a New Inclined Oval Rolling Pass Geometry

A novel rolling scheme incorporating an inclined oval-caliber configuration is proposed to enhance plastic deformation mechanisms in the traditional oval–round rolling sequence. Finite Element Method (FEM) simulations were performed using DEFORM-3D to evaluate and optimize this new scheme across multiple objectives: maximizing average effective strain, minimizing strain non-uniformity (captured via the standard deviation of effective strain), and minimizing rolling force. Numerical modeling was conducted for calibration angles of γ = 0°, 25°, 35°, and 45°, from which Pareto-optimal solutions were identified based on classical non-dominance criteria. Pairwise 2D projections of the Pareto front enabled visualization of trade-offs and revealed γ = 35° as the Pareto knee-point, representing the most balanced compromise among high deformation intensity, increased uniformity, and reduced energy consumption. This optimal angle was further corroborated through a normalized weighted sum of the objective functions. The findings provide a validated reference for designing prototype deforming tools and support future experimental validation.