Taguchi design of experiment is a powerful analysis tool for modeling and analyzing the influence of control
factors on performance output. The most important stage in this method lies in the selection of control factors. An
exhaustive literature review reveals that the die life and quality of the forged part are largely influenced by flash
thickness, billet temperature, die temperature and friction coefficient. These parameters each at three levels and their
interactions are considered for the present study. The FEM simulations were conducted to study the effect of process
parameters over the output response characteristics namely forging load and billet temperature loss.