There are three main problems in the conventional cold forging process of spur gear: insufficient corner filling; excessive forming force; short life of dies. To avoid these disadvantages, a new forming process, which is the two steps forming technology based on rigid parallel motion, is put forward. Firstly, finite element method is used to simulate the upend forging preformation and rigid parallel motive finish forging process, and equivalent stress field and load-stroke curve are investigated. Secondly, a corresponding experiment is done with pure lead to validate the numerical simulation. Finally, the conventional forging process is also simulated to compare with the new forming process. The results show that the two steps forming process is in favor of improvement of the corner filling condition and decreases the forming force significantly.