Abstract: FEM simulation was done for the deformation behavior of a dog-bone shaped workpiece during flat-spread rolling. The effects of the apical position and maximum height of the workpiece and pass reductions on its corner tensile stress in rolling process were analyzed. The results showed that the change in apical position affects greatly the corner tensile stress which can be increased by 66.7%, and the changes in maximum height and pass reduction affect the corner tensile stress rather smaller. The comer tensile stress increases with the positional distance of the workpiece. The conclusion drawn from the simulation is of significance to improving productivity especially the rate of finished products.