A novel rolling method based on the traditional plastic rolling principle is introduced to solve the problems in the plate-fin machining process in this paper, such as technological complexity, fin falling, high rate of rejection, high cost and so on. The finite element simulation models of the rolling tool and workpiece are established according to the plate-fin plastic rolling principle. The plate-fin rolling process is simulated with Deform-3D. The state of stress-strain and laws of metal flowing are studied. The plate-fin rolling experiments are carried out by using industrial purity aluminum AL-1100. The fin appearance and characteristic parameters are consistent with simulation results. At the same time, the experimental results verify the feasibility of plate-fin rolling forming method and the accuracy of the numerical simulation results.