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For small thin wall casing parts with a small size but a complex structure, the choice of processing methods and forming process design are main difficulies. In view of the above difficulties, the multistage cold forming method suitable for small and mediumsized parts batch processing was proposed, and two more reasonable sixstage cold forging processes was designed based on the forming theory analysis. Then, the forming process was simulated by Deform3D software, and the maximum load of the thinwalled end 5.6×104 N produced by the first antiextrusion was far less than that produced by first upsetting flange. Furthermore, the deep hole with step was formed by the cupcup compound extrusion, and the damage value of material was much smaller than that of the critical damage. Finally, the optimal program of simulation results are verified by the production test, and the microstructural distribution is reasonable without cold upsetting defects.
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