The mathematical model of the stress-strain state during flux-cored wire rolling in round gauges has been developed. Simulation was based on dividing the deformation zone into elementary volumes and simultaneous solution of the plasticity condition for porous materials and power static equilibrium equation inside the elementary volume. A distinctive feature of this model is taking into account the porous medium strain in the deformation zone. The experiments have confirmed the validity of the mathematical model for predicting the powder density and the energy-power characteristics of the process. Based on the developed mathematical model, the criteria and conditions for optimization were formulated, and the algorithm was developed for the automated design of technology for flux-cored wire rolling in round gauges. As an example of the obtained solutions implementation, the calculation of sintered copper flux-cored wire rolling technology was given.