In this paper a variable cross-section roll forming machine is designed for variable cross-section parts in car body. Based on the process of the roll forming and motion analysis of sheet metal and roller, the mechanism model and kinematical equation of the variable cross-section roll forming machine are investigated. According to the mechanism model, the variable cross-section roll forming machine is designed. Then the kinematical analysis of the machine based on D-H method and the motion

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... ol algorithm are obtained. Finally, the kinematic diagram and three-dimensional mechanical model of the variable cross section roll forming machine are proposed. The research in this paper provides theoretical basis for developing the variable cross-section roll forming machine. The traditional uniform section roll forming is a gradually-forming technology. In the process of the traditional uniform section roll forming, the sheet metal moves through a certain amount of fixed shaped rollers which generate a shaped curved surface and is transformed into the final shape of the variable cross-section roll forming parts [9] [10] . The process of roll forming is shown in Figure 1. [12] H. Ona, "Cold roll forming for high tensile strength steel sheet proposition on forming of thin spring steel sheet pipe"