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A certain type of automobile hexagon lock nut is formed by six-station cold heading, but its thin-walled feature needs to be formed by subsequent turning, which not only reduces the production efficiency, increases cost, but also has a certain influence on the nut performance. Therefore, in order to solve this problem, a new six-station cold heading process for hexagon lock nut was proposed, and the thin-walled feature during the cold heading process was formed simultaneously. Then, the forming process of part at each station in the improved scheme was analyzed by finite element numerical simulation software Deform-3D, and the constitutive model and the fracture model of 45 steel were established. Furthermore, the forming quality of part was analyzed from the aspects of forming appearance, internal grid streamline diagram and damage value distribution condition, and the difference of mold life for each station was analyzed by the load condition of each station. The results show that the improved scheme can form the hexagonal lock nut with a full shape which meets the size requirement and has no internal defects, and at the same time, the mold life of each station is close which is beneficial to the overall mold replacement. The quality of hexagon lock nut obtained by the multi-station cold heading test is good, and the size meets the requirement, which verifies the feasibility of the new process and plays a certain guiding role in the process development of similar parts.
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