During the cold roll forming of porous C-section cable trays, although asynchronous oblique rolling overcomes the forming blind zones inherent to conventional rolling methods, it introduces uneven residual stresses that lead to circumferential twist. This distortion critically undermines product dimensional accuracy, assembly alignment, and long-term service reliability in practical engineering applications. Revealing that phase differences during rolling create counter-directional asymmetric stress fields across the profile, generating a torsional torque that manifests as twist upon unloading. The oblique roller spacing coefficient λ is defined to quantify pass arrangement. Proposing a novel stress-compensation strategy, including Modified Alternate Forming (MAF) and Alternate First Forming (AFF) methodologies. Results demonstrate λ = 1 MAF reduces twist angles from 2.88° to 0.91° (68.4% deformation decrease). This study has important guiding significance for high-precision cold bending forming processes.
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