To reduce the waste of profiles during the rolling process, different rolling forming processes were studied based on the finite element method. The straight edge allowance generated by different forming processes during the rolling process was analyzed. Simulation results showed that the pre-bending/side roll lifting rolling process with the same side roll displacement produced the least straight edge allowance, reducing the straight edge allowance from 30.3981 to 2.79983 cm for the three-roll downward processing, a 90% decrease, and reducing profile waste. To improve the processing quality of profile rolling forming technology, the influence of profile thickness, rolling processing speed, and friction coefficient on profile forming curvature and forming quality were quantitatively analyzed. The grey relational analysis method was used to comprehensively analyze the influence of various factors on the profile during the rolling process, and the optimal processing conditions for the profile could be obtained through analysis, providing a new experimental method for the research of profile rolling forming.