Abstract: Three dimensional thermal-mechanical coupled elasto-plastic FEM has been used for simulation of round to oval single pass rolling. The analysis was conducted using MARC/AUTOFORCE1. 2 code. The material is assumed to be elasto-plastic and it obey the Von Mises yield criterion and Prandtl- Reuss rule. Deformation of the workpiece is simulated in a step-by-step manner,updating the coordinates of material points and the property after each step, so that both nonsteady-state and stendy-state deformation can be simulated. The heat transfter between the workpiece, the rolls, and enviroment and the heat generation due to plastic work and friction force, are considered in the analys- is.Predicted the deformation shape of the workpiece, distributions of strains, stresses, strain rates and temperatures, roll-separating force and roll torque are presented.

Key words: bar rolling, oval pass, elasto-plastic FEM, thermal mechanical process