<p>In this research, the simulation and experimental control of crown formation in the rolling process of ultra-thin silver strip is comprehensively investigated, which is crucial for the applications in high-voltage circuit protection, particularly in new energy vehicles. The objective was to identify key factors influencing crown formation and develop control strategies to ensure product quality and consistency. A finite element model was constructed to simulate the fourteen-stand rolling mill system, integrating static and dynamic analyses to evaluate the rolled crown value under various process parameters. The simulation results were validated against actual rolling data, confirming the model’s accuracy. Factors affecting crown formation were identified through simulation and analysis, including reduction per pass, friction coefficient, lateral displacement of intermediate rolls, strip entry position, input strip crown, material strength, strip width, and entry/exit tension. Empirical formulas were derived to predict crown values based on these parameters, providing a scientific basis for process optimization. Optimization recommendations included adjusting intermediate roller lateral displacement, annealing before the final rolling pass, selecting narrow strip, implementing progressive reduction per pass and controlling strip entry position. An experimental investigation validated the simulation findings, Maintaining thickness tolerance within a stringent standard of less than 1 micron, demonstrating the feasibility of ultra-high precision rolling for silver strips. In conclusion, this study significantly contributes to the understanding and control of crown formation in ultra-thin silver strip rolling, offering a scientific basis for optimizing the rolling process and improving product quality. The research outcomes are expected to influence the development of advanced rolling technologies and the manufacturing of high-performance strips for various industries.</p>