ABSTRACT The roll forming is a process which is famous now-a-days due to its low production cost and high efficiency. In which a long sheet metal products are manufactured with various cross-section thickness. The aim is to develop the roll forming process for Ultra high strength steel (UHSS). The UHSS is considered as a material due to its vast applications in the present days, most importantly in the automobile sector. The process can be done by reducing the distance between the rolls which reduces the space for the roll forming process, we can minimise springbackness of the material, and the production cost also reduces. The values or dimensions of the roll forming process are modified as compared to the present. The values also considered on the basis of UHSS material properties. Then the design and simulation are to be done by using ANSYS software, according to the results further corrections are made. The experimental tests to be done with the UHSS for better results. From the experimental results it can be conclude that the considered roll forming process is suitable for the UHSS and also suggestions are made whether it is suitable for any other type of material. AIM and OBJECTIVES AIM: The aim is to reduce the distance between rolls to check whether the method provides better results for the UHSS while comparing to the present. OBJECTIVES: • To identify the research question from the literature review. • The question is to develop the roll forming by reducing the distance between rolls and the UHSS is selected as a material. • To simulate the roll forming design by using the information from the literature in ANSYS software. • Compare the results with literature review and to make the corrections if needed and propose the best method. • The UHSS is selected as a material in simulation, from results to decide the developed method is suitable for UHSS or any other material. CHAPTER 3 - METHODOLOGY Phase 1: From the literature review, the research gaps have been identified i.e. to improve the roll forming process by reducing the distance between rolls and compare to the present. Phase 2: Analytical development: Developing the mathematical model or equations to capture material properties and mechanical behavior. Next to conduct the case studies to verify the developed model by comparing results from the literature. Phase 3: Development of material model based on outcomes of previous tasks. Phase 4: Development of numerical modelling: Creation of models in 3-D by using ANSYS software to find the simulation of the developed design. Implementation of the design if required and validate the results by comparing with results from analytical model and data from the literature. Phase 5: Applications of developed model with the present design or model which discussed in the literature, spring back angle and the time span of the roll forming process. Phase 6: Finishing the thesis with extracting conclusions and recommendations and to prepare an oral presentation. The main aim is to reduce the distance between rolls to check whether the method gives better results for the UHSS while comparing to the present. After going through the literature review, it is known that there is a need to focus to reduce distance between rolls. First, UHSS is considered as a material and according to the properties the further assumptions are made. • The roller diameter should be considered according to the required thickness of the material after being rolled. • The feeding speed of the material is taken into considerations, which depends on how much reduction is required at each step. • The revolution speed of the rollers, reduction ratio at each step. Most importantly, how much distance should be considered to reduce between the rolls where the material gives better results are to be carefully calculate. After considering all these required values, the design and simulation is done by ANSYS software and according to the results the corrections are made. Then the experimental tests are done with the UHSS. According to the experiment results, the corrections are made if required until the better output occurs comparing to the present. After completing the tests, the suggestions are made whether this type of roll forming is suitable for other materials.