Abstract: To control residual stress in stranded and compacted milliken conductors, a mechanical analysis model of cable cores incorporating the entire pre-twisting and stranding processes was established. Using COMSOL software, stress distribution in a five-segment 2500 mm² cable core was simulated, with a focus on investigating the influence of the compaction angle and pre-twist pitch on stress and deformation. Results showed that the compaction angle affected stress by balancing axial tension and radial compression, while the pre-twist pitch regulated stress distribution through the competing mechanisms of geometric interference and bending deformation. When the pre-twist pitch was 1300 mm and the compression angle was 70°, maximum displacement and maximum stress of the core both reached minimum values, at 0.0623 mm and 4.85×10⁷ N·m⁻², respectively. Compared to those at a compaction angle of 68°, the maximum displacement and maximum stress decreased by 4.70% and 9.68%, respectively. The maximum stress decreased by 8.32% compared to that at a pre-twist pitch of 1200 mm. Under the combination of a 70° compaction angle and a 1300 mm pre-twist pitch, axial tension and radial compression reached an optimal balance, geometric interference stress and bending deformation stress were well coordinated, leading to a significant reduction in residual stress. In this case, the compaction angle governed the forming mechanical path, while the pre-twist pitch optimized the initial geometric shape. Their synergistic interaction provided a theoretical basis and critical process window for low-stress precision manufacturing of high-performance cable conductors.