This paper presents a study on effect of roller configuration on residual stresses of case-hardened rollers. A heat conduction analysis and an elastic-plastic stress analysis during the case-hardening process of rollers were carried out for various case-hardening conditions by the finite-element method (FEM), considering changes of the thermal expansion coefficient and the yield stress with the temperature, and then residual stresses were obtained. Effects of case depth, roller width, case-hardened part and roller configuration on residual stresses were determined.