Abstract: Aiming at the active residual stress control of H-beams during a roller straightening process,an analysis model of stress evolution during the straightening process is constructed based on the elastic-plastic theory. A numerical solution method to quickly deal with the analysis model is investigated by discrete analysis. Then,an active design method of process parameters that can realize active residual stress control is established according to the analysis model. By using this method,process parameters are designed for typical specification H-beam straightening. Calculated results using the analysis model match those by a finite element method well and the analysis model makes the computational cost saved. The analysis model can achieve the result analysis of residual stress evolution within the feasible region in limited time. The process design method can get the process parameters of active control under specific target parameters and constraint conditions.