<p>Roller straightening is an important process that is usually used to improve the final quality of H-beams, sheets, or bars. By appropriate control of the plunge or descent of each roller in a roller straightener, partial elasto-plastic deformation occurs in the flange and web of the H-beam during the straightening and bending processes. Finally, the straightening of H-beams is achieved through repeated and reverse curvature changes by a multiple-roller straightener. In this study, the finite element analysis is used to investigate the effects of upper roller plunge schedules on the longitudinal gradient and right-angle deviation of SS400 low-carbon steel H-beams in a seven-roller straightening process. A commercial optimization software OASIS is also used to obtain the permissible setting ranges of the roller plunge ratio to attain the required product shape and dimension specifications. Finally, a seven-roller prototype straightener is developed. Roller straightening experiments of A6063-T5 aluminum alloy H-beams are conducted. The measured longitudinal gradients of the straightened H-beams are compared with simulated results to validate the proposed roller plunge schedule and roller design and the finite element modeling.</p>