Flat metal strips are deformed progressively into profiles with certain geometry sections by a series of successive rotating rolls at the room temperature, and it is called the cold roll-forming. An effective method is given for roll design to avoid major defects via finite element method （FEM） simulation using a booting model. The simulation gives reasonable fit to the actual product in the two major roll-forming defects, i.e. , edge wave and springback. The redesigned rolls using the approach of multi-stand FEM simulation can effectively control these two defects.
