For an edge wave problem of electrical steel in SFR (schedule-free rolling) process, the CCT curves and the Gleeble thermal stress-stain simulator are analyzed for electrical steel. The deformation resistance decreases as temperature is lowered in the austenite-ferrite region (975-875℃). The significant roll wear contours and thermal behaviors characteristics of SFR are obtained by the measured data of industrial mills. Considering the difference of deformation resistance with double phases and the actual roll contours, a 3D elastic-plastic finite element coupling model of roll stacks and strip is established for the effect of roll force, roll bending and shifting system on the loaded roll gap profile, and the influence of friction coefficient, strip thickness and rolling speed on strip internal stress distribution. The change path of ratio crown difference by Shohet criteria are attained to explain the formation process of irregular edge wave in upstream stands of hot rolling mills with larger flatness dead zones, which provides evidences for flatness control of electrical strip in hot rolling.