With the arrival of the industry 4.0 era,intelligent manufacturing technology is leading the trans-formation and upgrading of the manufacturing industry.This paper proposes a new process solution based on intelligent manufacturing for the problems of low efficiency and unstable quality in the manufacturing process of traditional mechanical gear forgings.The study introduces digital simulation design,intelligent forging forming and automated finishing technologies to fully optimize the traditional process.Through experimental verification,the new process has achieved significant improvements in productivity,product quality,yield and energy consumption.This study provides feasible solutions and practical references for the intelligent upgrad-ing of gear forgings manufacturing process,which is of great significance for promoting the digital transfor-mation of related industries.