Present work is on the optimization of forging process parameters for wheel hub using numerical simulation. Aim of this paper is to reduce the loading conditions within the specified limit of 1600T and also to reduce the machining thickness. A Finite Element Method based numerical simulation is used to simulate from current design of die till finalized modified design. DEFORM 3D software was used to validate the modifications done in dies and process through simulation. The loading conditions were optimized in blocker and finisher operations with an improvement in yield by 13% using numerical simulation. (C) 2017 Elsevier Ltd. All rights reserved.