A feasible process for combined reduction using a double-sided convex roll is proposed to manufacture H-shaped blooms in a continuous casting process, which reduces rolling by two passes and improves the production capacity. Based on the bloom requirement for rough rolling with an H-beam blank bloom mill, a reasonable convex roll structure is designed using the parameters of actual working condition on site, and a single-pass double-sided convex roll reduction model using different reductions is established. Under a large reduction, the corner of the casting blank has raised feet, which cannot connect with the rolling process. Based on the blank shape, blank reduction force, stress and strain after a single pass, a multiple-pass three-dimensional thermal mechanical coupled model of flat rolled modified feet using multiple sets of inner and outer arc double-sided convex roll reduction is established. An optimal arrangement method for the convex and flat rolls and the reduction distribution are designed. Using this process, the error between the simulated key dimensions after rolling and the required dimensions before rolling of the H-beam blank is ≤ 5 pct, reflecting a smooth connection. Focusing on the strain concentration of a large reduction, the temperature range and critical strain of the internal and corner cracks are experimentally measured. Single-pass reduction is carried out under different reductions, the risk of internal cracks is predicted by simulation, and the risk of corner cracks in the multiple-pass simulation is predicted according to the solid-phase fraction (fs).
