A comprehensive study on the comparison of hot rolling and plane strain compression testing (PSC) using the finite-element method (FEM) is reported in the present paper. The key physical variables during hot rolling and PSC testing of aluminum AA1050 are quantified and compared. The results show that the process variables, i.e., local stress, strain, strain rate, and temperature, vary from entry to exit and throughout the thickness of the work piece during hot rolling, while the evolution pattern of these parameters during PSC testing under a constant nominal strain rate is quite uniform. Therefore, for a given amount of nominal deformation (reduction), the loading history and the spatial distributions of these process variables are quite different in both cases. It is indicated that a further examination of the deformation history should be made when applying the relationships established from PSC testing to real industrial hot rolling operations.
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