The aim of this paper is to critically assess the potential of mathematical modelling which uses finite element method software for solving operation problems in the hot rolling of flat and long products. We focused on concrete issues faced by rolling plants in the Moravian-Silesian region (Czech Republic). The investigation was always combined with field or pilot measurements or laboratory experiments.
The application of finite element simulation to the problem of roll pass design for round bar rolling is considered. Two roll pass sequences were developed by analytical methods and then optimized using 2.5D Finite Element Method (FEM). The first one is a classical oval-round roll pass design. The second one is a combination of flat rolls and round roll passes. Relying on the simulation data obtained by FEM, the roll gaps were adjusted to achieve the required bar shape and the uniform distribution of rolling force between the passes. Advantages and disadvantages of each roll pass design were considered.