In recent years, finite element analysis of hot rolling processes along with modeling of microstructural evolution is increasingly being applied in the design and analysis of roll pass sequences. These applications have used a non integrated approach which typically leads to an over prediction of rolling loads and under prediction of material spread. This paper presents an integrated approach to modeling metal flow and microstructural evolution that has resulted in improved predictions of rolling loads and material spread the accurate prediction of which are important from the point of view of designing roll pass sequences.
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