Abstract. In order to study the microstructural evolution of C45 sheet in during hot-rolling, several thermo mechanical coupled finite element models (FEM) are established. The effects of different speed ratio, friction coefficient, initial thickness, initial temperature, roll diameter and roll speed on the average grain size after finishing rolling are analyzed. In this work, a multi-pass alternate asymmetric rolling (MAAR) process is intended to refine the grain structure. The values of grain size are predicted by FEM. The results show that MAAR greatly reduced the initial grain, while the final grain size is significantly reduced by ascending of the initial thickness, speed ratio and roll diameter, but is expanded in a certain range by two enlarged or accelerated work rolls. This study indicates that under the appropriate process conditions, MAAR can refine the final grain better than the traditional multi-pass hot rolling.