The weight of flash resulting from traditional die forging process is up to 30% of the forging. Thus material utilization is very low. Based on analyzing the structure features of fork part, the appropriate precision die forging process was made by means of traditional plasticity theory and thermodynamic couple numerical simulation in rigid\|viscoplastic finite element method. The concrete technical procesd includes three steps: upsetting or extrusion, flattening and forging with small flash. Owning to extrusion was used to design blank in the round bar of forging and the small sin flash is only formed at ends of fork, the flash metal consumption decline from 30% to 15%. Meanwhile, material utilization and forging quality were improved efficiently, because the machining allowance of forging was reduced to 50% in comparison with traditional die forging process.