<p>The present study investigates the effect of varying rolling passes on the surface integrity and wear resistance of 20CrNiMo steel following carburization and ultrasonic surface rolling process (USRP). The establishment of a USRP finite element analysis model enables the investigation of residual stress changes subsequent to the passage of the workpiece through the USRP. The acquisition of simulated data results in a 5% error margin compared to the experimental data, thereby substantiating the model’s precision. Wear experiments were conducted on workpieces processed with different rolling passes. The results show that the optimum wear resistance is obtained after 9 passes of USRP, and the wear amount is reduced by 50.6% compared with that of untreated workpiece, and the wear mechanism is changed from adhesive wear to abrasive wear. Additionally, no obvious spalling pits or microcracks were observed in the micro-morphology of the wear scars, and the depth of the wear scars was reduced.</p>