For the automobile differential housing, in order to change the current production status of low efficiency, poor housing performance, excessive material waste, and easy to have insufficient filling defects, a set of flash free die forging process was developed and studied based on Deform-3D finite element platform. Then, two different forming schemes were worked out according to the material and structure of part, and the finite element model was established by Deform-3D to conduct the thermal mechanical coupling numerical simulation. Finally, the forming feasibility of the two schemes was analyzed, and the advantages and disadvantages of the two schemes were compared. The results show that when the large-diameter billet scheme is adopted, the deformation amount distribution between each process is more appropriate, the material flow is more reasonable, the metal streamline continuity of the formed differential housing is better, the shape is complete, there are no problems such as folding, fracture, holes and other problems, and the temperature distribution after forging is better, while the differential housing forgings obtained by the small-diameter billet scheme have folding problem. At last, the forging test is carried out by using the large-diameter billet scheme, and the differential housing meeting the requirements is obtained, and the development of the new process is completed.