Abstract
This study presents a novel approach for implementing intense shear deformation in rod rolling by modifying the traditional oval–round pass design. The proposed scheme utilizes oval passes with an inclined longitudinal axis to induce skew-symmetric rolling conditions that generate enhanced shear deformation. Analytical models were developed to determine the roll grip length for the new geometry, and numerical simulations using DEFORM 3D were carried out to assess stress–strain distribution and plastic flow behavior. Laboratory experiments were performed on 25G2S structural steel using both the classical and new rolling schemes. The results demonstrated that the inclined pass configuration not only increases the overall strain intensity and homogeneity but also improves the mechanical properties of the final product. In particular, the new scheme enhanced ductility without compromising strength, partially mitigating the well-known strength–ductility trade-off. These findings highlight the potential of the proposed rolling method for industrial application in improving metal quality. Future research will focus on metallographic studies to correlate microstructural evolution with mechanical performance.