The paper deals with computational analysis of the process of cross roll straightening of circular bars in a nine-roll straightening machine. In the process of cross roll straightening, initially curved circular bar rotates along its axis as it progresses through laterally staggered rolls, being loaded by a fluctuating bending moment beyond its elastic limit. Resulting redistribution of residual stress is aimed at minimization of both curvature and residual stress. The principal problem is to choose optimal roll intermeshing strategy to minimize residual stress and curvature for given input parameters initial bar curvature, its diameter, yield stress and material hardening. The nonlinear finite element model was created by ANSYS program for solving this problem. The straightening process was simulated by the following testing example: circular cross section bar with diameter of 70 mm is moved through the leveling machine with subsequent intermeshing of adjustable rollers: 5.2, 8.0 and 8.4 mm and initial constant curvature of 4 mm/m.  Material is characterized by yield stress of 900 MPa and no hardening. The bar was modeled by beam or solid elements. The straightening rollers were assumed to be rigid bodies. The post-processing was done in MATLAB and the residual stress and straightness was obtained. The curvature of bar after straightening was reduced to 4.2, 1.7 and 1.4 mm/m. The developed FEM model has been verified experimentally. Other examples will be presented at the conference.