Abstract: To improve the product quality of Ti6411 heavy plates, a three-dimensional thermo-mechanical coupled model was established using ABAQUS software to simulate the multi-pass rolling process of Ti6411 heavy plates based on actual rolling production conditions. The simulated rolling force data were compared with field measurements, and error analysis was conducted to verify the model′s accuracy. Through finite element simulations, the plate profile of the titanium alloy under different rolling parameters was investigated. The results demonstrate that roll diameter, rolling speed, rolling temperature, slab thickness, slab width, pass reduction rate, and friction coefficient are the primary factors affecting the head-end abnormal zone length in Ti6411 heavy plates. The causes of variations in the head-end abnormal zone length were analyzed based on heavy plate rolling theory. Furthermore, principal component analysis (PCA) was employed to investigate the influence patterns and extent of various rolling parameters on the head-end abnormal zone length. These findings were compared with the influence coefficients obtained from FEM-based analysis of each parameter′s effect on the head-end abnormal zone length. The research outcomes provide a theoretical foundation for optimizing the profile control process of Ti6411 heavy plates.