<p>The multipass rolling process with crossed axes of the rolling die and blank is an effective and advanced technique for forming toothed parts. Based on the forming characteristics of this process, this paper introduces evaluation indices for toothed part formation, including the fill index, blank utilisation coefficient, forming time, and energy consumption. Through theoretical derivation, mathematical expressions for each evaluation index were established. Using these indices, the effects of initial blank diameter, rolling die rotational speed, and the number of forming passes on the formation of toothed parts were analysed through finite element simulation. The simulation results indicate that the filling quality, blank utilisation, and energy consumption are primarily influenced by the initial blank diameter, while the forming time is most significantly affected by the number of forming passes. Meanwhile, rolling experiments were conducted under various process parameters, and the hardness of the formed teeth was measured. The experimental results show that as the blank diameter increases, visible defects at the tooth tips of the formed teeth disappear, which is consistent with the simulation results. Furthermore, the improvement in tooth hardness becomes more pronounced with an increasing number of forming passes. The maximum hardness of teeth formed after five passes exceeds twice that of the original blank. This study provides valuable technical guidance for the application of the multipass rolling process with crossed axes. Additionally, the established evaluation indices serve as a useful reference for research on the rolling processes of other complex-profile parts.</p>