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In this work, a combined finite element analysis and upper bound technique is employed to assess temperature field and thermal stress distribution within the work rolls during continuous hot strip rolling process. Two-dimensional finite element analysis is utilised to simultaneously predict temperature fields within the rolling metal and the work roll as well as thermal stresses in the work rolls. In order to calculate the velocity field and the rate of heat of deformation, an upper bound solution is coupled with the employed finite element analysis. The utilised model makes it possible to estimate the effects of different parameters such as idling revolutions and initial temperature on thermal stresses within the work rolls. The predictions are compared with the experimental data as well as the published results and reasonable agreement is observed.

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