The dissertation investigates innovative structures through simulation and experimental methods, aiming to develop efficient and reliable procedures for designing and analyzing metallic composite structures created via plastic deformations, particularly rolling processes. It thoroughly examines two key manufacturing processes: bulk metal forming through process-integrated powder coating via radial axial rolling of rings, and sheet metal forming through the joining of dissimilar metals by roll bonding. The research distinguishes between microscale modeling, which enables process-independent investigations of physical processes, and macromechanical modeling, which considers the structural characteristics of concrete processes. Additionally, the study addresses the scale transition between micro and macro levels, supported by various experimental investigations. To demonstrate the flexibility and process independence of the developed algorithms, the research applies these techniques to different industrial processes. It includes a comprehensive characterization of the processes alongside inverse parameter identification techniques. By varying process parameters, the study examines their impact on process deterioration. The efficacy of the numerical modeling techniques is validated through multiple structural simulations and comparisons with experimental measurements.
