The forging process of the right-angle elbow was improved by changing the traditional process of one piece in one module into the process of two pieces in one module, and the type of forging arrangement, groove spacing, shape and size of blank etc. were designed and calculated. Then, for two pieces in one module, the forging process was simulated by Deform-3D software, and the load-stroke curve in the process of forming and equivalent stress distribution in the end of forming were obtained by describing the construction of model and parameter settings in the simulation. The simulation results show that the product is full of cavity during the forming process, and the forging forming process is reasonable. The parameters in the simulation are applied to the production, and the products meet requirements completely through pilot production of a small batch. The actual production proves that the production efficiency for two pieces in one module is increased by five times, and the service life of mould is enhanced nearly two times. Thus, the production costs are saved by 8230 RMB for every 3000 pieces.