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The rectangular macro‐segregation region in the core of hot‐rolled steel bar has a great influence on the heat treatment distortion of an automotive gear steel FAS3420H. In order to understand the distortion process of the segregation region during hot‐rolling process, a finite element (FE) analysis of the whole hot‐rolling process was carried out by software DEFORM‐3D, and a constructed constitutive model was embedded into DEFORM‐3D to describe the deformation process. The results show there is an inhomogeneous strain distribution at the cross‐section of hot‐rolled round bar, which results in uneven distortion of the segregation region in different directions. A square segregation region, which can reduce inhomogeneous distortion of gear in the subsequent heat treatment, is obtained after being rolled by simulation calculation verified through experiment.

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