<p>Variable cross-section profiles are commonplace in the metal forming industry. Due to its difficulty in forming, the introduction of Chain-die forming has been proposed as a viable solution. Given that web-warping is a prevalent defect in profiles with variable cross-sections, it becomes imperative to predict web-warping prior to the forming process. In this study, the deformation energy method was employed to forecast web-warping in variable width cross-section profiles formed by Chain-die forming. In addition, developable surfaces were introduced to control web-warping in variable cross-section profiles by combining variable width and depth. All results were validated through finite element simulation. The results showed that the R2 of the web-warping prediction model is 0.906, which indicate that deformation energy is closely related to the web-warping of variable cross-section profiles. In addition, compared to the variable only width profile, the peak longitudinal strain of the variable width+depth profile in the concave region decreased by 43.478% and 63.889% in the convex region, respectively. The R2 between the analytic result and simulation result of the web-warping is 0.982, which is 0.076 higher than the prediction model for web-warping. Combining variable width and depth forming to control web-warping has high research value. These provide valuable guidance for the practical production of variable cross-section profiles.</p>