The distribution of residual stress in hot rolled large size H-beams is complex due to the uneven temperature distribution on the final rolling cross-sections. In this paper, 3D simulation analysis is conducted on the residual stress field of cooled large H-beams and the transformation of residual stress field during the flange cutting based on the calculations of thermo-mechanical coupling whole rolling process. There are tensile stress in the flange and web connection areas and compressive stress in web. During the flange cutting process, tensile stress increases suddenly when the kerf arrives at the flange and web connection area, resulting in the brittle fracture of the web. The method of controlling the residual stress of large H-beams is also simulated. Improvement in the distribution of residual stress is achieved through the forced cooling of the outside flange or reduction of the temperature differences on the final rolling cross-sections.
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