Abstract: To improve the cut-edge quality produced by the crescent shear in a cold-rolling electrical steel production line at a steel enterprise and to reduce the incidence of strip breakage during rolling, this study carried out a targeted investigation on the optimization of crescent-shearing process parameters. The influence mechanisms of key shearing parameters on cutting quality were systematically examined. Guided by orthogonal experimental design, a series of numerical simulation cases with different parameter combinations were established. By varying the bite-in depth, shearing clearance, shearing speed, and strip thickness, the stress distribution in different regions of the sheet and the evolution of characteristic zones were analyzed as the parameters changed. The effects of shearing parameters on the edge cutting quality of electrical steel strips were quantified. Subsequently, response surface methodology (RSM) was employed to analyze and optimize the crescent shearing parameters for the head-tail regions of adjacent coils. The results indicate that a smaller bite-in depth leads to pronounced stress concentration at the crescent-tip region. Increasing the shearing clearance enlarges the maximum-stress region; however, when the clearance is below 0.2 mm, the fracture morphology becomes flatter and the shearing quality improves. shearing speed and strip thickness jointly affect the thickness and uniformity of the sheared zone on the cut surface. When the blade speed is smaller than 2 500 mm/s, the sheared-zone thickness accounts for a relatively high proportion of the cut-surface thickness (approximately 36.5%); as the speed increases further, the sheared-zone thickness gradually decreases. Increasing the strip thickness,the sheared-zone thickness increases, while its proportion decreases, suggesting that a thicker strip may improve shearing stability under certain conditions. Based on multi-factor coupling analysis via RSM, the optimal parameter set was identified as a bite-in depth of 8 mm and a shearing speed of 862 mm/s under a shearing clearance of 0.17 mm and a strip thickness of 2.3 mm. This optimized combination significantly enhances the quality stability of crescent shearing for high-grade electrical steel, providing effective theoretical support and practical guidance for industrial production.