The carcass layer is the innermost structure of the marine flexible pipeline, which can resist the external hydrostatic pressure. The carcass layer is manufactured by multi-pass roll bending. Due to the complex cross section characteristics of the carcass layer, there are many bending angles and large bending angles, which brings great challenges to the forming process of the carcass layer. Therefore, in this paper, the roll profile in the forming process of carcass layer is designed, the distribution of processing stress and residual stress in the process of forming of carcass layer is analyzed by numerical software, and the influences of strip thickness and the roller clearance are analyzed. The relevant conclusions in this paper can provide reference for forming and manufacturing process of the carcass layer.