The application of advanced high strength steel (AHSS) has an important significance in the development of the lightweight of automobile, but the parts made of AHSS usually have defects, such as fracture and large amount of springback, etc. In this paper, a model of multi-pass roll forming and springback process of AHSS is established with finite element software ABAQUS. Then a roll forming experiment is performed, and simulation and experimental results have been compared and analyzed. The model is established under complex contact conditions, including self-contact condition. The results shows that during the process of sheet bending, large Mises stresses appear at bending corners. The smaller the bending radius is, the larger the Mises stress and strain are. Thickness of sheet metal changes differently if the bending radius is different. When the bending radius exceeds a certain limit, the change tendency of the sheet thickness turns from increase to decrease.