###### Abstract  
This study investigates the effects of deep rolling parameters, pressure, speed, and offset, on the residual stress distribution and material deformation in UIC 860 Grade 900A railway rails. We will model deep rolling to simulate the process and predict the residual stress profile in railway rails. Subsequently, we will rigorously compare and analyze the FEM simulation results with experimental data to optimize deep rolling parameters for improved residual stress distribution. Using both experimental methods and finite element analysis via ANSYS 2023 R1, the study varied deep rolling parameters. Experimental deep rolling pressure was set at 150 bar, speed at 1800 mm/min, and offset at 0.1 mm, while FEA simulations predicted corresponding pressures of 157 bar and speed of 1796.52 mm/min. These parameter settings were chosen to induce significant surface compressive stresses that could enhance the material's mechanical performance. The experimental results showed an average compressive residual stress of 498.9 MPa, closely aligning with the FEA-predicted value of 502.5 MPa. A paired \(t\)-test revealed no statistically significant difference between the two results, with a T-value of \(-0.22\) and a \(p\)-value of 0.833, validating the reliability of the FEA model. The consistent deformation observed in both experimental and FEA simulations, especially with a 0.1 mm offset, confirmed that the rolling parameters were effective in producing uniform stress distribution, albeit with a slightly extended processing time due to the small offset. Overall, the findings confirm that optimizing the deep rolling parameters of pressure, speed, and offset leads to favorable residual stress distributions and improved material properties. The results indicate that FEA is a reliable tool for predicting the outcomes of deep rolling, and this study provides a strong foundation for further refinement of the process to enhance performance in practical applications, such as railway railway rail to treatments.  
deep rolling; residual stresses; finite element analysis; UIC 860 grade 900A; railway infrastructure 202 In recent years, finite element analysis (FEA) has become a critical tool in simulating and predicting the effects of deep rolling. Finite element analysis has been used by numerous researchers to simulate and predict residual stress in various types of joints and materials [2]. FEA models allow researchers to investigate the influence of process parameters without the need for extensive physical experimentation, thus saving time and resources [3]. Previous studies have highlighted the importance of deep rolling pressure, speed, and offset in determining the depth and magnitude of compressive residual stresses [4; 5; 6]. However, there remain gaps in understanding how these parameters interact to achieve optimal results, particularly in high-strength steels like UIC 860 Grade 900A [7]. This study uses ANSYS software to simulate the deep rolling process and compares the results with experimental data to validate the accuracy of the simulations [8; 9].  
This flowchart outlines the research framework in Figure 1 for evaluating the effects of deep rolling parameters on residual stress and material deformation in railway rails. It begins with a literature review, followed by the parallel steps of FEA setup and experimental design. The FEA setup includes defining meshing, material properties, and boundary conditions, leading to post-processing for residual stress analysis. Concurrently, experimental parameters such as rolling pressure, speed, and offset are defined, and a residual stress experiment is conducted. The validation and comparison phase ensures alignment between experimental and FEA results. If validated, the process proceeds to Railway Rail FEA for final analysis; otherwise, the parameters are revised, and the analysis is repeated, ensuring an iterative refinement of the model and accuracy of the results.