This study presents the roller hemming operation of a curved edge sheet metal which is critical in terms of dimensional accuracy and deformation. The investigation is focused on the process parameters such as bending angle, sheet thickness and roller diameter to observe their influence on roll-in, deformation, undesired wrinkling formation and hemming force which are directly related to material reliability and visual quality in the operation. A set of numerical simulations was designed and through the regression analysis of the results, the magnitude of each input parameter was investigated. The verification of the numerical model was carried out using experimental results. In the light of the results, the influence of input parameters was discussed for designing proper roller hemming operations for curved edge parts. (c) 2018 Politechnika Wroclawska. Published by Elsevier B.V. All rights reserved.