Rolling is one of the most important forming processes and roughly 80-90% of steel are produced using rolling. In rolling numerous process parameters can influence the final dimension e.g. draft, roll diameter, rolling speed, temperature, material property and mill elasticity. In structural rolling roll pass design is one the most important parameter which decides the final shape of the product. Development of any new profile is difficult as industrial trials are expensive and stoppage in

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... tion leads to lower mill utilisation thereby increasing cost of production. Simulation and modeling gives insight of the rolling that can be used for optimization of process. Modification in roll pass, drafting schedule and its effect on final dimension, mill load can be obtained which results in saving in time and investment prior to actual production process. Modeling can also provide information that is not available on the shop floor. In the present paper, several examples of process modelling applications on different types of rolling process are discussed. It was found from the simulation results that Process modelling can be an effective tool to improve process design, such as modification of rolling defect, reduction in mill load, stress on the rolls and dimensional change during the rolling process.