To study the integral forming process of torsion damper shell pulley with characteristic structure is of great significance for producing and developing of the rotational part such as shell pulley. A processing way was proposed by combining plate bending forming and roller structure design, to integral forming torsion damper shell pulley. A model for two-step bending forming was establishedvia finite element method. Under the radial feeding of roller, the outer edge of plate was subjected to compress thickening and secondary thickened after bending, and effective stress and metal flow in the deformation zone were analyzed by using marking point. Combining with the structural characteristics of shell pulley, a design criterion "rotating thickening, gathering thickening" of roller was proposed. The metal flow in deformation zone was effectively controlled through the characteristic structure of roller, thereby the specific region to forming multi-wedge toothwas obtained. The quantitative analysis of the instantaneous part section in the forming process, combining with the design criteria of roller structure and material flow rate, radius and arc angle of roller were determined. With the objective forming parameters, the comparison between the simulation results and the experimental are basically coincided, the ribs were fully formed and the specific regions was thickened to minimum value, which verified the feasibility of sheet-bulk metal rotary bending forming theory and the design criterion of roller structure.
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