Numerical and experimental analysis of roll crown influence on thickness and force in hot rolling of AISI 1015 steel

One of the most common problems in flat rolling process is the control of flatness and distribution of pressure between work rolls and strips, this problem is critical considering the requirements of flatness in dimensional quality of strip. To try to control the dimensional flatness and shape of the strip, studies have been conducted for each mill individually, considering roller deflection, wear, thermal crowns, etc. However, the problem persists. This study presents a numerical and experimental investigation of the influence of roll crown geometry on the flatness of hot rolling AISI 1015 steel. Three configurations were analyzed: negative crown (–0.1 mm), flat rolls (0 mm), and positive crown (+ 0.1 mm), using finite element simulations validated with industrial data from a Steckel mill. The simulation model was developed in Simufact Forming 2022 under realistic thermal and mechanical boundary conditions. The results indicate that the positive crown configuration provides the most uniform thickness distribution (± 0.05 mm) and stable deformation behavior, while the negative crown leads to edge waviness and dimensional instability. Statistical validation using a paired t test yielded a mean thickness difference of 0.015 mm with a p value < 0.001, confirming strong agreement between the simulated and experimental results. Although rolling forces were overestimated by approximately 1.056 times due to model simplifications, the overall deformation and force trends were consistent, demonstrating the model’s suitability for industrial hot rolling process optimization.