Abstract: Roll tensioning is a prestressing procedure commonly usedto increase the stability of circular saws. This paper describes how thefinite element method can be used to analyze the residual stresses inducedby roll tensioning. As the results measured by X-ray disagree withthe calculations on the basis of three-region theoretical model, this paperintroduces a new model, in which the main parameters affecting rolltensioning include plastic constitutive relationship of the material, structure androtational speed of roller, applied pressure, tensioning radius, times oftensioning. The results of residual stresses agree with experimental measurements.