In order to solve the problem of slow production speed and low material utilization rate for a kind of handle screw in turning process, a three-station cold heading process of necking, pre-upsetting and final forming was designed, and the finite element modeling of the whole process was completed by Deform-3D to predict the forming results and analyse the rationality of the process. Then, in order to reduce the forming load of the pre-upsetting and final forming stations and meet the forming requirements, the influence of key dimensional parameters such as upper cone angle, lower cone angle, head lower circle diameter and lower cone height of the pre-upsetting station part on the forming load was studied by the orthogonal experimental method, and the optimization was carried out by range analysis method. The results show that the optimized parameters are as follows：the upper cone angle is 10°, the lower cone angle is 8°, the head lower circle diameter is Φ14.8 mm, and the lower cone height is 5.5 mm, and the forming loads of the two stations are reduced by 22.2% and 23.5% respectively after optimization. Finally, the actual forming experiments are conducted on the handle screw, and the forming condition is good. Through the microstructure analysis, no obvious defects are detected. Thus, its size and performance meet the requirements of manufacturer, which indicating that this process can replace the turning process.