In this paper, the design method for intermediate rolls has been developed to manufacture excavator idler rims in multi-stage profile ring rolling process, based on the uniform volume distribution element technique (UVDET) and the extremum rolling ratio(${lambda}_{max}$). UVDET is presented as the ratio of the volume change of ring blanks to that of undeformed rings per unit height. ${lambda}_{max}$ is defined as the ratio of the cross-sectional area of blanks to that of rolled rings. The theoretical value of intermediate roll shapes were determined by UVDET and ${lambda}_{max}$, i.e. the outer diameter and cross-sectional shape of the intermediate ring, respectively. FE simulations and profile ring rolling experiments using AISI 1035 steel alloys were performed to prove the validity of proposed design method. In order to investigate the deformation behavior in profile ring rolling of excavator idler rims, the expanding rule of plastic zone should be carried out firstly. The proposed roll design method led to the successful ring shape and the highest dimensional precision.