For the problem of severe upper die wear in flange fork forging, which led to unsatisfactory die life, the research and improvement were conducted by establishing a forging simulation model and a die wear model. Firstly, the simulation test results were compared with the actual forging results in multiple aspects to verify the accuracy of the prediction model. Secondly, based on the simulation results, the key process parameters that affected the die wear were determined and used as the design variables. With the aim of reducing wear, the optimal results of each process parameter were obtained by the orthogonal experimental method with fewer simulation times. Finally, a die life prediction model was established based on the optimization results, the forging test of flange fork was completed, and the wear conditions of simulation and actual forging were compared. The results show that the flange fork is well-formed  without any defects, and the developed prediction model is accurate with minimal error. The actual service life of die increases from 2760 pieces to 4750 pieces, which is significantly improved and meets the expectation of the enterprise.