Abstract: Aiming at the cracking problem of 1.4462 duplex stainless steel drum shaft seat during forging, this paper analyzes the defect mechanisms of the original drawing process and loose tooling forging process, and proposes a new process scheme of "pre-upsetting → small-end extrusion → loose tooling forging". Finite element simulation was used to analyze the metal flow, temperature field and stress-strain field of the three steps, and experimental verification was carried out using a 6300T hydraulic press. The results show that the original drawing process induces crack initiation and propagation due to the axial tensile stress in the center of the deformation zone; in the loose tooling forging process, the large height-to-diameter ratio and severe deformation of the billet generate circumferential tensile stress at the bulge, and the temperature difference between the surface layer and the core aggravates the deformation in homogeneity, leading to tearing of the outer diameter. The new process reduces the height-to-diameter ratio of the billet and the circumferential tensile stress at the bulge through pre-upsetting, and replaces drawing with small-end extrusion to avoid axial tensile stress. Simulation results show no metal folding in each step, confirming the rationality of the die structure. Experimental verification shows that no crack occurs after small-end extrusion, with a maximum tonnage of 4000T; no tearing at the bulge occurs during loose tooling forging, with a maximum tonnage of 5000T, which is in good agreement with the simulation results.