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The present investigation deals with process analysis of oxy-acetylene flame assisted double pass line heating for varying plate thickness.Oxy-acetylene flame as the heat source for multi pass line heating to achieve 3-D bending of plates with varying thicknesses was studied.The oxy-acetylene flame was modeled as the moving heat source in the FEM analysis.The transient thermal histories were predicted taking into account the temperature dependent thermo-mechanical properties.A comparative study between single pass and double pass line heating residual deformation was also carried out.The temperature distribution and residual deformations predicted by the numerical model developed in the present work compared fairly well with those of the experimental ones.