To realize the roller forming process of curved edges of aluminium alloy auto-body closure panels, a numerical simulation method is proposed for the roller forming of aluminium alloy sheet with adhesive in flat variable curvature. Firstly, the motion of the roller is calculated by the discrete variable curvature curve method. Secondly, a numerical method of FEM-SPH coupling is established to simulate the interaction between the adhesive layer and the sheet. Subsequently, a numerical simulation model for the roller forming of aluminium alloy sheet with adhesive in flat variable curvature was constructed and finite element calculations were carried out. The simulation results show that the motion posture of the roller matches that of the actual roller, and the adhesive layer can adequately fill the inner and outer panel areas during the rolling process, which proves the effectiveness of the method.