Finite Element-Based Multi-Objective Optimization of a New Inclined Oval Rolling Pass Geometry
Nogayev K. Kamarov A. Abishkenov M. Ashkeyev Z. Sembayev N. Kydyrbayeva S.
September 2025Multidisciplinary Digital Publishing Institute (MDPI)
Modelling
2025#6Issue 3
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.
finite element method (FEM) , knee point detection , multi-objective optimization , pareto front , rolling , severe plastic deformation (SPD) , stress–strain state
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Department of Technological Machines and Transportation, Karaganda Industrial University, Temirtau, 101400, Kazakhstan
Department of Transport Equipment and Logistics, Toraighyrov University, Pavlodar, 140008, Kazakhstan
Department of Technological Machines and Transportation
Department of Transport Equipment and Logistics
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