The present paper deals with a computer-aided process design for tension leveling based on finite clement analysis. A FE code developed specifically for that purpose, which involves a sophisticated constitutive model of cyclic plasticity, enables the accurate performing of a numerical simulation. The very short computation time in numerical simulation by this FE code is due to a novel calculation algorithm to solve the steady elasto-plasticity problem based on the incremental deformation theory of plasticity. From the results of numerical simulation for some tension leveling processes, it has been concluded that a series of work rolls should be set in the final stage of the leveling process such that the roll-intermesh gradually decreases along the stream line and approaches zero at the final roll. (C) 1999 Elsevier Science S.A. All rights reserved.