Abstract: To address the production challenges posed by the complex structure of auxiliary box drive gear forgings, a novel precision forming die was designed. The design positions the parting surface on the lower end face of the forging to simplify the design of the lower die, and achieves precise forging forming by leveraging flash positioning and the top ejection function of the equipment. Through in-depth analysis of the original closed die forging production process and Deform-3D simulation, the root causes of the issues in the original process were verified. Simulation analysis of the new precision forming die using Deform-3D and practical applications demonstrate that it not only ensures stable filling of the forging, eliminates folding at the inner hole, and significantly improves the die life,but also drastically reduces the machining allowance of the forging and material usage for the die, thereby greatly lowering production costs. Additionally, it breaks free from the dependence of precision forming processes on high-precision equipment, providing innovative insights and practical references for related manufacturing applications.