In this article, stress analysis and energy estimation during cold-roll forming of symmetrical channel sections have been discussed. Geometry of sheet strip is pre-estimated by a shape function. Then longitudinal, transversal and shear strains have been calculated. Using both the Levy-Mises and the Prandtl Reuss equations, and also considering the Bauschinger effect, stress distributions have been obtained. Preestimated geometry can be modified by minimization of deformation energy. Strains and stresses at different points have been represented and predicted strains have been satisfactorily compared with experimental data. Application of the Levy-Mises equations for reducing computational time, presentation of stress distributions including shear stresses, and consideration of the Bauschinger effect are the new concepts of this paper.

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