Press forging forming of thick sheet metal is a combined extrusion process, which is put forward in the presently study. A new technological scheme for a two-step press forging of stepped holes in a thick metal sheet was proposed. Finite element analysis on the two-step process is carried out by using DEF0RM-3D. Distributions of effective strain and effective stress were obtained. The study showed that the process not only can form the stepped holes, but also can increase the surface quality and strength of stepped holes in sheet metal parts, According to the numerical simulation's process parameter, an experimental die was designed, the simulation results were in good agreement with the experimental data.
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