Objective Based on the thermal coupling mechanism the numerical simulation of the model and the evaluation mechanism of multi-parameters are applied to implement the optimization of the scheme so as to improve the design efficiency and forming quality of the closed hot forging process of gear blanks. Methods A CAE simulation based on DEFORM was conducted to analyze three closed hot forging forming process schemes for an engineering gear blank forging. The simulation analysis investigated the plastic flow pattern of the metal under the hot forging process. Based on this this paper adopted a combined evaluation method of TOPSIS a technique for order preferences by similarity to ideal solution and CRITIC criteria importance through intercriteria correlation . It constructed an evaluation model with eight evaluation indicators including strain stress load compaction wear etc. and a weight calculation method to evaluate the process scheme. Results In the simulation different pre-forging solutions had different plastic metal flow patterns which in turn led to different forming results. The simulation results of option 1 showed that gear blanks were not filled had burrs and were not uniformly loaded with a significant mold damage value. The simulation results of option 2 showed that gear blanks were uniformly loaded and filled but the mold wear depth was large and the equivalent force was high. The simulation results of option 3 showed that the gear blanks were formed with good quality but they were not uniformly loaded and the mold wore to a large depth and the equivalent force was high. Considering the forging forming quality and mold service life comprehensively the index weights were calculated by isotropic standardization of different indexes and the degrees of closeness of options 1 2 and 3 were obtained as 0. 446 0. 511 and 0. 556 respectively. The results showed that option 3 had the largest value and the best results. Process tests were conducted for option 3 and the gear blanks were obtained with full filling and no folding defects. Conclusion The combination of finite element numerical simulation and evaluation models allows for an accurate and efficient evaluation of the advantages and disadvantages of closed hot forging process solutions. This method can improve the design efficiency and forming quality of the closed hot forging process of gear blanks.