In order to solve the problems of high scrap rate and short die life in the cold heading production process of a vehicle octagonal rod bolt, the cold heading process of the bolt was simulated by software DEFORM, and the curling and folding formed during the cold heading of bolt were the key factors. Then, with the goal of eliminating the curling and folding and optimizing the process scheme, the four factors of die forming angle α, diameter reduction ratio ε, pressing speed v and friction coefficient f were selected, and L16 (44 ) orthogonal experiment was designed and carried out. Furthermore, the influence degree of each factor on the curling and folding of metal stacking was obtained, and combined with the influence trend diagram, the optimal combination of process parameters was obtained with the die forming angle of 14°, the diameter reduction ratio of 1. 1, the pressing speed of 10 mm·s-1 and the friction coefficient of 0. 08. The simulation results show that under the optimal process parameters combination, the curling and folding problems are eliminated, the metal fluidity is improved, the forming loading force is reduced by 38. 6%, and the equivalent stress in the collapse area of upper port for die is reduced by 40. 3%. The actual production proves that the scrap rate is reduced from 87. 0% to 0. 1%, and the premature damage of die is effectively solved. Thus, the research results provide a reference for the improvement of similar folding defects.