SAE 52100 steel bars are extensively employed in the mining, shipping, forging, and bearing industries. During manufacturing of bars, the roll force (RF), roll torque (RT), cropping loss (CL), and drive energy (DE) are important production variables that must be monitored for high-quality output, scrap reduction, mill safety with minimum consumption of energy. Roll RPM, temperature of bloom, roll gap, bloom cross-section area, and diameter of roll are process characteristics that influence these response parameters. The impact of process variables on response variables during SAE 52100 steel rolling is investigated in this research. FORGE® NxT 1.1 was used to simulate the rolling process. Following statistical testing, the simulated findings were validated utilizing data from experiments acquired in a bar rolling plant. The results of an analysis of variance were used to find significant model terms. For minimising response parameters, the ideal rolling conditions have been identified.