<p>In this study, aiming at the problem of die wear in the cold extrusion forming process of a 15CrMo motor gear, the cold extrusion process was simulated based on DEFORM-3D, so as to optimize the cold extrusion forming process and study the law of die wear. The results show that the wear mechanism during cold extrusion is more sensitive to contact pressure, and the onset of wear requires the combined influence of contact pressure and sliding velocity. Experimental findings align well with both the wear model and the finite element predictions. Reciprocating wear experiments were carried out to study the wear behavior under different contact pressures, and a modified Archard wear model was derived. A forming process was designed to forming a motor gear. Based on the comparison of the finite element analysis results of the modified Archard wear model and the traditional Archard wear model, it is found that the modified Archard wear model can better characterize the wear of the die, and its accuracy is proved by experimental verification.</p>