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Abstract. In this paper, a hot forging die set is designed for a shaft gear. A finite element software DEFORM was employed to simulate the hot forging process. The forming parameter range was determined and the forging force was predicted. The metal flow law in hot forging processes was studied using metal flow analysis and point tracking analysis. The metal flow law was further analysed through finite element simulations and precision forging experiments. The accuracy of hot formed gears is analysed and the deviation of the tooth profile reaches the 8th grade, which meet the defined requirement. The pitch cumulative deviation of the forged part is low enough for practical applications.