In this study, the three-dimensional modeling and numerical simulation of the rolling process were carried out based on the Finite Element Method (FEM). This study analyzes von Mises stress distribution, maximum strain, and deformation patterns of the workpiece under compressive forces from two counter-rotating rollers. Three workpiece dimensions (20 × 20 × 200 mm, 25 × 25 × 200 mm, and 30 × 30 × 200 mm) were tested to evaluate the effect of cross-sectional size on load distribution and plastic deformation. The results show that von Mises stress ranged from 65.71 MPa to 460 MPa, with maximum strain from 152,000 µstrain to 723,800 µstrain. Larger cross sections provide wider contact areas, leading to more uniform stress distribution and enhanced plastic flow. These findings serve as a reference for optimizing rolling parameters in metal manufacturing to produce precise and defect-minimized products.

The 9th Mechanical Engineering, Science and Technology International Conference (MEST 2025), organized by the Department of Mechanical Engineering, Universitas Muhammadiyah Kalimantan Timur, was successfully conducted on 11–12 December 2025 in Samarinda, Indonesia

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