Numerous FEM calculation models for load introduction onto rolling mill rolls have been developed. The stress that can arise during heat treatment as well as during roller use was calculated. This has made it possible to optimize roll use conditions and to develop new roll qualities. The following results are described: stress in the heat treatment of rolls, the calculation of large work rolls of a heavy plate mill, the counter-bending of rolls whose body length is greater than 6,000 mm, von Mises stress in roll necks, contact stress at the edge region of working and back-up rolls, stress distribution in pre-stressed composite profile rolls in use

A stress analysis for cast compound rolls is presented. Stress is divided into components as residual stress, stress implied by load, stress implied by torque, Hertz’ian contact stress and thermal stress. Furthermore, heat transfer is considered. Residual stress is measured and a 3D representation is given. All further stress components are calculated by FEM calculations. The data allow a complete description of the roll behavior in operation.

The causes of a composite roll fracture were investigated. The result of an FEM analysis showed that the occurrent stress could not have led to this fracture. Metallographic investigations in the area of the crack start site clearly showed non-metallic inclusions. These affect structural weak points and activate malfunctions. They significantly accelerated the cracking process due to the local notch effect which significantly reduced the performance of the material and thus the service life of the roll shaft.