Aiming to obtain the optimal molding parameters of the straw multi-stage roll forming machine when compressing corn stalks with lower moisture content, and explore the influence of molding parameters on molding results, based on the Design-Expert Box-Behnken Design (BBD) experimental design method and principle. Taking the moisture content, crushing length and the final roller speed of the forming machine as experimental factors, and the rebound rate, density and the molding energy consumption as the test indicators, using the three-factor and three-level response surface analysis method, the mathematical models between each factor and the rebound rate, density and the molding energy consumption were established respectively. The influence of the significant interaction of various factors on the test indicators was analyzed. The results showed that when the forming machine compressed corn stalks, the contribution rate of each test factor to the rebound rate from large to small was: the final roller speed, the crushing length, and the moisture content; the contribution rate of each test factor to the density from large to small was: the crushing length, the final roller speed, and the moisture content; the contribution rate of each test factor to the molding energy consumption from large to small was: the final roller speed, the crushing length, and the moisture content. When the final roller speed was 1.07r/min, the moisture content was 21.5%~25.0%, and the crushing length was 64~108mm, the rebound rate was less than 7.0%, the density was greater than 350kg/m3, and the molding energy consumption was less than 16.0kW·h/t; the optimal molding parameters obtained by parameter optimization were: the moisture content was 24.26%, the crushing length was 73.25mm, the final roller speed was 1.07r/min, at this time, the rebound rate was 6.32%, and the density was 375.6kg/m3, the molding energy consumption was 15.89kW·h/t. This research can provide a theoretical basis and technical support for multi-stage continuous cold roll forming of straw.