A spiral bevel gear forging process was simulated using the intelligent remeshing function. The predictions were shown with emphasis on teeth formation. It can be seen that all teeth were formed with high accuracy even though minimized number of tetrahedral elements was used. Note that too small tetrahedral elements cause frequent remeshings which deteriorate solution accuracy, implying that the optimized mesh system can be defined as the mesh system that has a minimized number of elements for accurate description of characteristic lines and surfaces of the material.