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A novel flexible roll forming method is proposed for manufacturing of large curved metal plates.By adjusting the position of three rows of staggered arranged rollers, a large curved metal plate is formed in an incremental way.In this paper, FE (finite element) model is established to analyze the stress-strain distribution of the deformed plates in the forming process.Based on the numerical simulation, the influence of the relative position between upper milers and lower rollers on the dimensional accuracy of the large curved metal plate is studied.Comparison results show that roller arrangement has great influence on the dimensional accuracy of deformed plates, and process with staggered arranged rollers has the best dimensional accuracy.