Aiming at the fracture of an ultra-high-strength steel (UHSS) thin-walled component with complex section in the roll forming process, the three-dimensional finite element model was established. It is found that the stress triaxiality and equivalent plastic strain are the main factors affecting the fracture behaviour of the UHSS thin-walled component with complex section, and the influence laws of forming strategies and process parameters on the fracture behaviour were discussed. The results show that the damage value, equivalent plastic strain and stress triaxiality at the fracture position are reduced by increasing the inter-distance and roll diameter, decreasing friction coefficient and forming velocity. The mathematical model of the UDP comprehensive measure with the forming strategies and process parameters was established by the response surface method. The numerical simulation and industrial test verify the effectiveness of the UDP comprehensive measure, which provides a theoretical and practical basis for the fracture prevention control.
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