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The major objective of this research is to develop a 3-D FEM simulation technique in order to analyze the deformation behavior of surface defects on hot rolling. The developed technique will be applied to quantify the relationship between rolling condition and the process parameters, and the rolling pattern will be tested to verify and validate the simulation technique. This technique will allow us to quantify the shrinkage of slab width at the head and tail, width spread after the horizontal rolling, dog-bone shape, position change of the slab corner as the slab is being rolled, strain distributions. And the shape change of surface defects in hot rolling was investigated using the 3-D rolling simulation technique. The proposed prediction method of surface defect can be utilized to make defect free products in rolling.